Doosan D18NAP Electronically Controlled Industrial Diesel Engine Operation and Maintenance Manual

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This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the D18NAP Daewoo Doosan Electronically Controlled Industrial Diesel Engine. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


TABLE OF CONTENTS :

    1.General Preface
    2.Operation and Management
    3.Performance and Specifications
    4.Regular Inspection
    5.Failure Diagnosis
    6.About the engine
    7.Cooling System
    8.Lubrication System
    9.Fuel System
    10.Intake/Exhaust System
    11.Cylinder block/head
    12.Electric System
    13.Others/Driving System


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 950106-01257(C)
Total Pages : 397


This Operation and Maintenance Manual provides the most efficient methods for engine maintenance as well as quick, efficient methods to determine the cause of engine faults to ensure that any actions taken by professionally certified maintenance technicians are done in the most efficient and efficient way possible.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

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    1.General Preface
        General Information
        Danger, Warning, Caution, and Note
        Engine Management
        
    2.Operation and Management
        Starting and Stopping of the Engine
            Preparing for Start
            Starting the Engine
            After Starting the Engine
            During Operation
            Stopping the Engine
        Break-in Period of the Engine
            General Information
            Break-in Period of a New Engine
            Check Points
            Operation after Break-in
            Inspection after Starting the Engine
            Engine Oil Pressure
            Coolant Temperature
            Revolutions per Minute (rpm)
        Operation in Winter
            Cold Start
            Preventing Coolant from Freezing.
            Preventing Overcooling of the Engine
            Engine Oil
        Inspection and Repair of the Engine
            Checking Engine Parts after Prolonged Operation
            Inspection and Repair of Supercharger
            Intake Unit
            Exhaust Unit
            Lubrication Unit
            
    3.Performance and Specifications
        Engine Specifications and Performance
            Engine Specifications
            Engine output
            Engine performance curve (DL01-LEE00)
            Engine performance curve (DL01-LEL00)
        Outside Drawing of the Engine (DL01-LEE00)
            Isometric assembly drawings
            Assembly drawings (Front/Rear)
            Assembly drawings (Left/Right)
            Assembly drawings (Top/Bottom)
        Outside Drawing of the Engine (DL01-LEL00)
            Isometric assembly drawings
            Assembly drawings (Front/Rear)
            Assembly drawings (Left/Right)
            Assembly drawings (Top/Bottom)
        Engine Identification Number
            Engine number engraving
            Cylinder block number engraving
            Engraving of piston bore level of cylinder block
            Engraving of main bearing bore level of cylinder block
            Crankshaft main journal engraving
            Connecting rod engraving
            Piston engraving
            Cylinder head gasket engraving
            
    4.Regular Inspection
        General Information
            General Information
            Routine Inspection
        Regular Inspection Table
            General Conditions
        Engine oil
            General Information
            Engine oil standards
            Engine Oil Capacity
            Checking the Engine Oil
            Replenishment of Engine Oil
            Replacement of Engine Oil
        Coolant
            General Information
            Coolant standards
            Capacity of coolant
            Checking the Coolant
            Measurement of Coolant Concentration
            Replenishment of Coolant
            Replacement of Coolant
        Fuel
            General Information
            Fuel Standards
        Air filter
            General Information
            Cleaning of Air Filter
            Cleaning of the Air Filter Element
            Replacement of Air Filter Element
            
    5.Failure Diagnosis
        General Information
            Failure Diagnosis Unit
        Failure Code
            Fault Code Items
        Failure Code Diagnosis
            P0402 EGR control fault (airflow error too high)
            P0401 EGR control fault (airflow error too low)
            P0406 EGR actuator position feedback signal high fault
            P0407 EGR actuator position feedback signal low fault
            P046D EGR actuator position feedback signal noisy fault
            P0C17 EGR position learning fault (drifted)
            P0C18 EGR position learning fault (wrong range)
            U0140 J1939 CAN pedal fault
            P0088 Rail pressure control fault
            P2267 Water in Fuel sensor electrical fault (OC/SCVBATT)
            P2266 Water in Fuel sensor electrical fault (SCGND)
            P2269 Water in Fuel Detected
            P0524 Oil pressure remains low at engine run
            P0523 Oil pressure sensor high fault
            P0522 Oil pressure sensor low fault
            P0111 Intake Manifold Temperature plausibility fault
            P0113 Intake Manifold Temperature sensor high fault
            P0112 Intake Manifold Temperature sensor low fault
            P0114 Intake Manifold Temperature sensor noisy fault
            P0108 Manifold Pressure sensor electrical high fault
            P0107 Manifold Pressure sensor electrical low fault
            P2229 Barometric pressure sensor electrical high fault
            P2228 Barometric pressure sensor electrical low fault
            P0116 Coolant temperature plausibility fault
            P0118 Coolant temperature sensor high fault
            P0117 Coolant temperature sensor low fault
            P00BD MAF plausibility high fault
            P00BC MAF plausibility low fault
            P0103 MAF sensor electrical high fault
            P0102 MAF sensor electrical low fault
            P0190 Rail Pressure Sensor gradient fault
            P0193 Rail Pressure Sensor high fault
            P0192 Rail Pressure Sensor low fault
            P0087 Rail Pressure Sensor fault (pressure build up during cranking too slow)
            P0191 Rail Pressure Sensor fault (Sensor drift at key-on)
            P0002 Rail Pressure Control fault (RPC using IMV only)
            P0089 Rail Pressure Control fault (RPC using Rail Discharge)
            P0563 Battery voltage high fault
            P0562 Battery voltage low fault
            P0074 Inlet Air Temperature sensor gradient fault
            P0073 Inlet Air Temperature sensor high fault
            P0072 Inlet Air Temperature sensor low fault
            P2428 Exhaust over temperature fault
            P0181 Fuel temperature plausibility fault
            P0183 Fuel temperature sensor high fault
            P0182 Fuel temperature sensor low fault
            P0196 Oil temperature plausibility fault
            P0195 Oil temperature sensor signal fault
            P060B ADC circuit fault
            P0602 C2I data not programmed
            P0603 ECU memory integrity fault (data / cal integrity)
            P0604 ECU memory integrity fault (RAM integrity)
            P0605 ECU memory integrity fault (code integrity)
            P062F ECU non volatile memory fault
            P0371 Crank signal is too close to the previous one
            P0339 CRANK signal fault (gap lost)
            P0372 Elapsed time between CPS events is too high
            P0374 Crank signal lost(no CPS signal seen in 1 cam rotation)
            P0335 Crank signal over speed fault
            P0344 CAM signal fault (missing event within the expected window)
            P0342 Cam signal lost (no cam signal seen in 2 crank rotations)
            P0341 Cam signal drift higher than threshold
            P0340 Cam signal last learnt value is outside of limits
            U0100 CAN communication error: CAN bus confirmed off
            P0201 Injector Open Circuit fault (Cylinder #1)
            P02EE Injector Short Circuit fault (Cylinder #1)
            P0262 Wiring harness resistance high fault (Cylinder #1)
            P0261 Wiring harness resistance low fault (Cylinder #1)
            P029B Injector Minimum drive pulse drift (Cylinder #1)
            P0202 Injector Open Circuit fault (Cylinder #2)
            P02EF Injector Short Circuit fault (Cylinder #2)
            P0265 Wiring harness resistance high fault (Cylinder #2)
            P0264 Wiring harness resistance low fault (Cylinder #2)
            P029F Injector Minimum drive pulse drift (Cylinder #2)
            P0203 Injector Open Circuit fault (Cylinder #3)
            P02F0 Injector Short Circuit fault (Cylinder #3)
            P0268 Wiring harness resistance high fault (Cylinder #3)
            P0267 Wiring harness resistance low fault (Cylinder #3)
            P02A3 Injector Minimum drive pulse drift (Cylinder #3)
            P0384 Glow plug relay electrical fault (SCVBAT)
            P0383 Glow plug relay electrical fault (SCGND)
            P0380 Glow plug relay electrical fault (OC)
            P0325 Fault on the accelerometer 0 sensor decode circuit
            P0007 Rail pressure control error (IMV resistance trim value is too high)
            P0006 Rail pressure control error (IMV resistance trim value is too low)
            P0004 Rail pressure control feedback high fault
            P0003 Rail pressure control feedback low fault
            P0259 RPC error (IMV current trim drift high/high)
            P0254 RPC error (IMV current trim drift high/low)
            P0253 RPC error (IMV current trim drift low/high)
            P0258 RPC error (IMV current trim drift low/low)
            P0252 RPC PWM error
            P0251 IMV control fault
            P2080 Turbo in temperature plausibility fault
            P0546 Turbo in temperature sensor high fault
            P0545 Turbo in temperature sensor low fault
            P2081 Turbo in temperature sensor noisy fault
            P0685 Main relay stuck fault
            P068A Main relay unexpected low state
            P062D Injector Bank 1 electric or SPI fault
            P062E Injector Bank 2 electric or SPI fault
            P2145 EGR H-Bridge driver short circuit to battery voltage
            P2144 EGR H-Bridge driver short circuit to ground
            P2143 EGR H-Bridge driver open circuit
            P0404 EGR position control fault
            P0641 5V Supply #1 fault
            P0651 5V Supply #2 fault
            P0697 5V Aux supply #2 fault
            P025D IMV drive electrical fault (SCVBATT)
            P025C IMV drive electrical fault (SCGND)
            P025A IMV drive electrical fault (OC)
            P037F Glow plug feedback fault (SCVBAT)
            P037E Glow plug feedback fault (OC / SCGND)
            P0606, P0607, P060A, P060C ECU safety monitoring fault
            
    6.About the engine
        Marking system of Units
            Unit Conversion Methods
        Tightening Torque
            Tightening Torque of Main Parts
            Tightening Torque of General Bolts
            Tightening torque of plug screw
            Hollow Screw (4-Hole) Tightening Torque
        Engine Disassembly
            Special Tools
            Procedure of Disassembling an Engine
        Engine Assembly
            Special Tools
            Procedure of Assembling Engine
            
    7.Cooling System
        General Information
            General Information
            Specifications
            Failure Diagnosis
        Water pump
            General Information
            Water pump Disassembly
            Water pump Assembly
        Thermostat
            General Information
            Thermostat Disassembly
            Check of Thermostat
            Thermostat Assembly
            
    8.Lubrication System
        General Information
            General Information
            Specifications
            Failure Diagnosis
        Oil pump
            General Information
            Oil Pump Disassembly
            Oil Pump Assembly
            Disassembly of Oil Suction Pipe and Oil Delivery Pipe
            Assembly of Oil Suction Pipe and Oil Delivery Pipe
        Oil Filter Assembly
            General Information
            Disassembly of Oil Filter Assembly
            Check of Oil Cooler
            Assembly of Oil Filter Assembly
            
    9.Fuel System
        General Information
            General Information
            Specifications
        Fuel return hose
            General Information
            Disconnection of fuel return hose
            Check of fuel return hose
            Connection of fuel return hose
        Injector
            General Information
            How to Operate an Injector
            Injector Disassembly
            Injector Check
            Injector Assembly
        Common Rail
            General Information
            Injection Pipe
            Common Rail Disassembly
            Common Rail Check
            Common rail assembly
        Fuel injection pump
            General Information
            Disassembly of Fuel Injection Pump
            Assembly of Fuel Injection Pump
            
    10.Intake/Exhaust System
        General Information
            General Information
        Specifications
        Intake Manifold
            Disassembly of Intake Manifold
            Assembly of Intake Manifold
        Turbocharger
            General Information
            Failure Diagnosis
            How to Maintain Turbocharger
            Turbocharger Disassembly
            Turbocharger Check
            Turbocharger Assembly
            Disassembly of Exhaust Manifold
            Assembly of Exhaust Manifold
        Exhaust Gas Recirculation (EGR) System
            General Information
            Disassembly of EGR Cooler
            Assembly of EGR Cooler
            Disassembly of EGR Valve
            Assembly of EGR Valve
            Diesel Oxidation Catalyst (DOC)
            
    11.Cylinder block/head
        General Information
            General Information
            Specifications
        Cylinder Block
            Disassembly of cylinder block
            Check of Cylinder Block
            Measurement of Inside Diameter of Main Bearing Bore of Cylinder Block
            Measurement of Inside Diameter of Piston Bore of Cylinder Block
            Measurement of Inside Diameter of Camshaft Bearing of Cylinder Block
            Assembly of Cylinder Block
        Timing gear case
            Detaching timing gear case
            Assembly of Timing Gear Case
        Breather
            Disconnection of Breather Hose
            Connection of Breather Hose
        Cylinder head
            Disassembly of Cylinder Head
            Check of Cylinder Head
            Assembly of Cylinder Head
        Cylinder Head Cover
            Disassembly of Cylinder Head Cover
            Assembly of Cylinder Head Cover
        Oil Pan
            Disassembly of Oil Pan
            Assembly of Oil Pan
            Disassembly of Engine Oil Level Gauge and Guide Tube
            Assembly of Engine Oil Level Gauge and Guide Tube
        Valve
            Disassembly of Valve
            Measurement of Inside Diameter of Valve Guide
            Measurement of Valve Stem End
            Measurement of Valve Step Height
            Measurement of Gap between Piston and Valve
            Check of Valve Spring
            Assembly of Valve
        Rocker Arm
            Disassembly of Rocker Arm
            Adjustment of Valve Gap
            Check of Rocker Arm Shaft
            Check of Rocker Arm
            Assembly of Rocker Arm
        Valve Tappet and Push Rod
            Disassembly of Valve Tappet
            Check of Valve Tappet
            Assembly of Valve Tappet
            Disassembly of Push Rod
            Check of Warpage of Push Rod
            Assembly of Push Rod
        Camshaft
            Disassembly of Camshaft
            Measurement of Camshaft Journal Outside Diameter
            Measurement of Camshaft
            Assembly of Camshaft
        Idle gear
            Disassembly of Idle Gear
            Measurement of Outside Diameter of Idle Gear Shaft
            Measurement of Inside Diameter of Idle Gear
            Assembly of Idle Gear
        Lifting Hook
            Disassembly of Lifting Hook
            Assembly of Lifting Hook
            
    12.Electric System
        Electric Parts
            Electric Parts
        Circuit Diagram
            General Information
            Engine Connector
            Engine Connector of Engine Control Unit (ECU)
        Air Heater
            Disconnection of Glow Plug
            Connection of Glow Plug
        Switches and Sensors
            Mass Air Flow Sensor (MAF)
            Boost Temperature Sensor (BTS)
            Boost Pressure Sensor (BPS)
            Exhaust Gas Temperature Sensor (EGTS)
            Oil Pressure and Temperature Sensor (OPTS)
            Water Temperature Sensor (WTS)
            Fuel temperature sensor (FTS)
            Rail pressure sensor (RPS)
            Injector #1(INJ)
            Injector #2 (INJ)
            Injector #3 (INJ)
            Injector #4 (INJ)
            Crank Shaft Position Sensor (CRK)
            CAM Shaft Position Sensor (CAM)
            Knock Sensor1(KNOCK1)
            Knock Sensor2(KNOCK2)
            Exhaust Gas Recirculation Valve Position Sensor (EGR)
            Inlet Metering Valve (IMV)
            Water In Fuel Sensor (WIFS)
        Wire harness
            Disassembly of Wire Harness
            Assembly of Wire Harness
        Electronic Control Unit (ECU)
            General Information
            Electronic Control Unit (ECU) Connectors
            I/O of Electronic Control Unit (ECU)
            Operational Conditions of Electronic Control Unit (ECU)
            
    13.Others/Driving System
        General Information
            General Information
        Crankshaft
            Disassembly of Timing Wheel
            Assembly of Timing Wheel
            Disassembly of Crankshaft
            Measurement of Crankshaft Main Journal Diameter
            Measurement of Crankshaft Bearing Gap
            Measurement of Crankshaft Warpage
            Assembly of Crankshaft
        Connecting Rod
            Disconnection of Connecting Rod
            Measurement of Inside Diameter of Connecting Rod Small-end
            Measurement of Connecting rod large-end bore
            Measurement of Gap of Connecting Rod Big-end
            Assembly of Connecting Rod
        Piston
            Disassembly of Piston
            Measurement of Outside Diameter of Piston Pin
            Measurement of Inside Diameter of Piston Pin Bore
            Measurement of Gap of Piston Ring End
            Measurement of Step Height of Piston Top Side
            Assembly of Piston
        Crankshaft Pulley
            Disassembly of Crankshaft Pulley
            Assembly of Crankshaft Pulley
        Others
            Engine Timing
            Adjustment of Engine Timing
            Check of Gear Backlash
            Check of Gear Axial Offset

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