User Manuals: Doosan DV11 Diesel Engine

User Manuals: Doosan DV11 Diesel Engine

Manuals and User Guides for Doosan DV11 Diesel Engine. We have 1 Doosan DV11 Diesel Engine manual available for free PDF download: Operation And Maintenance Manual

Doosan DV11 Operation And Maintenance Manual

Doosan DV11 Operation And Maintenance Manual (221 pages)

Brand: Doosan | Category: Engine | Size: 11 MB

Table of Contents

Foreword
2
Table of Contents
3
1 Safety Regulations & Engine Specifications

4
2 Technical Information

21
- Engine Model and Serial Number
  21
- Diagnostic Tool (SCAN-200)
  21
  - Engine Character
    22
  - Cylinder Block
    23
  - Piston/ Connecting Rod/ Crank Assembly
    23
  - Electric Control Unit : ECU
    23
  - Common Rail System
    24
  - Engine Timing
    25
  - Valves
    25
  - Lubrication System
    26
  - Engine Oil
    27
  - Oil Filter
    28
  - Fan Belt
    28
  - Air Cleaner
    29
  - Pre Fuel Filter
    29
  - Fuel Filter
    29
  - Fuel Requirements
    30
  - How to Select Fuel Oil
    30
  - Fuel Oil Selection Chart
    31
  - Fuel Injection System
    32
  - Bleeding the Fuel System
    32
  - Injector and High Pressure Connector
    33
  - Inter Cooler
    33
  - Turbo Charger
    34
  - Cooling System
    35
  - Coolant Pressure Cap
    36
  - Cooling Water
    36
  - Valve Clearance Adjust Procedure
    38
  - Amount of Anti-Freeze in Winter
    38
  - Adjusting of Valves
    40
  - Adjusting of Engine Brake
    40
  - Battery
    41
  - Alternator
    42
  - Regulator Connector
    43
  - Wiring Diagram
    43
  - Starting Motor
    44
- Diagnosis and Remedy
  45
  - Engine Starting Impossible
    45
  - Engine Overheated
    46
  - Output Insufficient
    47
  - Oil Pressure Lowered
    48
  - Fuel Consumption Excessive
    49
  - Oil Consumption Excessive
    50
  - Battery Discharge
    51
- Engine Inspection
  55
  - Stopping Engine
    55
  - General Engine Inspection Cycle
    55
3 Maintenance

55
- Use of Original Parts for Repair and Replacement
  56
- Disassembly and Reassembly of Major Components
  57
- Engine Disassembly
  57
  - General Precautions
    57
  - Oil Level Gauge
    58
  - Air Pipe and Air Heater
    59
  - Cooling Fan and Fan Clutch
    59
  - V-Belt
    59
  - Turbocharger
    60
  - Air Compressor
    61
  - Power Steering Pump
    61
  - Exhaust Manifold
    62
  - Intake Manifold
    62
  - Common Rail and High Pressure Pipe
    63
  - Fuel High Pressure Pump
    63
  - Water Pump
    64
  - Fuel Pump Housing Cover
    65
  - Oil Cooler
    65
  - Vibration Damper
    65
  - Cylinder Head Cover
    66
  - Electric Control Unit
    66
  - Engine Brake
    66
  - Injector
    67
  - Rocker Arm
    67
  - Cylinder Head
    68
  - Oil Pan
    68
  - Oil Pump
    68
  - Fly Wheel
    69
  - Front Oil Seal Cover
    69
  - Piston
    69
  - Crank Shaft
    70
  - Flywheel Housing
    70
  - Cam Shaft & Tappet
    71
  - Cylinder Liner
    71
  - Oil Spray Nozzle
    71
  - Cleaning and Inspection of Cylinder Block
    72
  - Cylinder Head Disassembly
    72
  - Cylinder Liner Measurement
    72
  - Measurement and Inspection of Major Parts
    72
  - Damage Check
    73
  - Distortion of Lower Surface
    73
  - Inspection and Measurement of Cylinder Head
    73
  - Lower Face Warpage and Thickness
    73
  - Inspection and Measurement of Valve and Valve Guide
    74
  - Valve Head Thickness
    74
  - Valve Stem Outer Diameter
    74
  - Valve Guide
    75
  - Valve Seat
    75
  - Valve Stem End Play
    75
  - Valve Seat Angle
    76
  - Valve Seat Thickness
    76
  - Valve Spring
    77
  - Cylinder Head Assembling
    78
  - Inspection and Measurement
    79
  - Rocker Arm Ass`y
    79
  - Rocker Arm Disassembling
    79
  - Rocker Arm Specification
    79
  - Clearance of Block and Tappet
    80
  - Rocker Arm Reassembling
    80
  - Run-Out
    80
  - Tappet and Push Rod
    80
  - Axial End Play
    81
  - Cam Shaft
    81
  - Inspection and Measurement of Camshaft
    81
  - Cam Bearing Inside Diameter
    82
  - Clearance
    82
  - Camshaft Run-Out
    83
  - Journal and Pin Diameter
    83
  - "R” Part Standard Value
    84
  - Journal and Pin Outside Diameter
    84
  - Kinds of Bearings for Undersize
    84
  - Crankshaft Bearing and Connecting Rod Bearing
    85
  - Oil Clearance of Crankshaft and Bearing
    85
  - Run out of Crankshaft
    85
  - Bearing Oil Clearance
    86
  - Journal and Connecting Bearing Inspection
    86
  - Connecting Rod Bearing Clearance
    87
  - Cylinder Block and Bearing Clearance
    87
  - Crank Shaft End Play
    88
  - Piston Disassembling
    88
  - Check and Measurement
    89
  - Cylinder Bore Diameter
    89
  - Piston and Cylinder Clearance
    89
  - Piston Ring and Ring Groove
    90
  - Piston Ring Cut Part Clearance
    90
  - Piston Side Clearance
    90
  - Connecting Rod
    91
  - Piston Pin
    91
  - Piston Pin and Connecting Rod Bush Clearance
    91
  - Injector Projection
    92
  - Engine Reassembly
    93
  - Preparation and Precaution before and after Engine Reassembly
    93
  - Bearing Cap Bolt’s Tightening Order
    95
  - Tappet
    96
  - Front Oil Seal Holder
    99
  - Connecting Rod Bolt Tightening Order
    101
  - Oil Pump
    101
  - Standard Length of Bolt and Use Limit
    101
  - Intake and Exhaust Valve
    103
  - Cylinder Head Bolts Tightening Order
    104
  - Injector and High Pressure Connector Assembly Procedure
    105
  - Fuel High Pressure Pump Housing Cover
    108
  - Camshaft Speed Sensor
    112
  - Crankshaft Speed Sensor
    112
- Reassembly
  113
  - Starter
    113
  - Power Take off (P.T.O)
    114
  - Intake Stake and Air Heater
    116
  - Thermostat
    116
  - Alternator and Belt
    117
  - Cooling Fan
    118
  - Others
    119
  - Common Rail Fuel-Injection System
    120
  - Injection Characteristics with Common Rail
    121
  - Major Components of the Common Rail System
    121
  - Fuel Delivery Pump
    123
  - Fuel System
    123
  - Fuel Tank
    123
  - High Pressure Fuel Delivery
    124
  - High Pressure System Components
    124
  - Construction of the Fuel High Pressure Pump
    125
  - Fuel High Pressure Pipe
    125
  - Function
    125
  - Fuel Delivery Rate
    126
  - Method of Operation
    126
  - Common Rail
    127
  - Fuel Metering Shut off Valve
    127
  - Common Rail Pressure Sensor
    128
  - Pressure Limiter Valve
    129
  - Ethod of Operation
    130
  - Injector Closed (at Rest Status)
    131
  - Injector Closes (End of Injection)
    131
  - Injector Opens (Start of Injection)
    131
  - Cam Shaft Speed Sensor
    132
  - Crank Shaft Speed Sensor
    132
  - Accelerator Pedal Sensor
    133
  - Boost Pressure and Temperature Sensor
    133
  - Engine Coolant Temperature Sensor
    133
  - Engine Oil Pressure and Temperature Sensor
    133
  - Electrical Parts – Truck
    134
- Electrical System
  134
  - Electrical Parts - Bus
    135
  - Harness of Electrical Control Unit
    136
  - Electrical Control Unit
    139
  - Engine Harness
    142
  - Harness of Injector and Engine Brake
    143
  - Engine Brake Construction
    147
  - Theory of Operation
    148
  - Engine Brake Disassemble and Valve Adjustment
    149
  - Engine Brake Operation Check
    150
  - Solenoid Valve
    150
  - Control Valve
    151
  - Master Piston
    151
  - Slave Piston
    152
  - Troubleshooting
    154
  - General Problem
    155
  - Engine Diagnostic
    158
  - Method by SCAN-200
    158
  - Method of Confirmation for the Fault Code
    158
- Engine Diagnostic
  159
  - Engine Fault Code and Occurring Condition
    159
  - Input and Output of the ECU
    162
  - Engine Idle Adjusting
    163
  - Engine Starting
    163
  - Operating Condition of the ECU
    163
  - Vehicle Running
    163
  - Cruise Control
    164
  - Engine Brake Control
    164
  - Maximum Speed Limit Function
    165
  - Engine Stop During Long Time of Idling
    166
  - Safety Function When Door Is Opened
    166
  - Diagnostic
    167
  - Limp Home Function
    167
  - Power Take off (PTO)
    168
  - Vehicle Operating Record
    168
4 Commissioning and Operation

169
- Preparations
  169
- Breaking-In
  169
- Operation of a New Engine (Break-In)
  169
- Check Points for Break-In
  170
- Inspections after Starting
  171
  - Operating after Break-In
    171
  - Pressure of Lubricating Oil
    172
  - Temperature of Cooling Water
    172
  - Over-Speed Control
    172
- Operation in Winter Time
  173
- Maintenance and Care
  176
  - Periodical Inspection and Maintenance
    176
  - Exchanging of Lubrication Oil
    176
  - Oil Exchange Procedure
    177
  - Replacement of Oil Filter Cartridge
    177
  - Coolant Draining
    179
- Cooling System
  179
- Cleaning of the Cooling Inside System Circuit
  180
- Adjustment of Valve Clearance
  181
- General Information
  181
- Tightening the Cylinder Head Bolts
  183
  - Cylinder Head Bolts
    184
  - Cylinder Head Bolt’s Tightening Order
    184
  - Cooling System
    185
    
    General Descriptions and Main Data
    185
    
    Specification
    186
    
    Inspecting
    187
    
    Replacing Thermostat and Precautions for Handling
    187
    
    Diagnostics and Troubleshooting
    188
    
    Disassemble the Drive Gear and Driven Gear
    189
    
    Disassembly of Oil Pump Drive Gear
    189
  - Lubrication System
    189
    
    Remove the Oil Pump Cover
    189
    
    Inspection and Correction
    190
    
    Reassembly
    190
    
    With a Feeler Gauge, Measure
    190
    
    With Steel Rule and Feeler
    190
    
    Construction
    192
    
    Main Data and Specification
    192
    
    Operating Principle
    192
    
    Specification and Construction
    192
  - Turbo Charger
    192
    
    Components of Turbocharger
    193
    
    Bearing
    194
    
    Compressor
    194
    
    Turbine
    194
    
    How to Handle the Engine
    195
    
    Precautions for Operation of the Engine
    195
    
    Sealing at Compressor Shaft
    195
    
    Air Intake System
    196
    
    Exhaust System
    196
    
    Routine Inspection and Maintenance
    196
    
    Guide for Checking Rotor End Play
    197
    
    Guide for Checking the Rotor for Rotating Condition
    197
    
    Lubricating System
    197
    
    Periodical Servicing
    197
    
    Guide for Disassembling/Cleaning and Checking the Turbocharger
    198
    
    Precautions for Reassembling the Turbocharger Onto the Engine
    198
    
    Rotor Axial Direction End Play
    198
    
    Rotor Radial Direction End Play
    198
    
    Changing Air Cleaner Element
    201
    
    Maintenance of Air Cleaner
    201
    
    Cleaning Air Cleaner Elements
    202
  - Belt
    203
    
    Checking the Air Cleaner Cartridge
    203
    
    Knocking out Dirt by Hand
    203
    
    Measuring Tension
    204
    
    Reading of Tension
    205
5 Maintenance of Major Components

185
6 Special Tool List

206
Appendix

209

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