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.

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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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