Doosan D18NAP Industrial Diesel Engine Service Manual PDF Download (EN)

Preface

Preface T his Operation and Maintenance Manual provides information on engine management and maintenance techniques to customers and technicians of Doosan Infracore's D18NAP electronically controlled industrial diesel engine. To provide the best engine to our customers, the D18NAP electronically controlled industrial diesel engine is designed to satisfy all requirements for low noise, economic fuel consumption, high speed and durability with the latest technology and quality. Exact operation and proper maintenance are essential for operating engines for an extended time with optimum conditions and best performance.

This Operation and Maintenance Manual provides detailed descriptions of specifications, specified values, defect diagnosis, component diagrams, and drawings for easier and more precise understanding of the product and for proper maintenance and troubleshooting. With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety of workers can be ensured. Please read and understand this manual before working with our engines. To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's best to continuously develop and invest.

The design of our product may be changed without prior notice and Doosan shall not be held liable for the failure of this manual to contain all the design changes made to improve the product. We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the requirements of our customers. If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate to contact us. Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you. 2014.01 950106-01257(C) Doosan Infracore The contents included in the Operation and Maintenance Manual are property of Doosan Infracore.

It is forbidden to copy, print or distribute this manual without prior permission.

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Table of contents

Table of contents 1. General Introduction General Information............................................................................................................................... 1-3 Danger, Warning, Caution, and Comment ..........................................................................................1-4 Engine Management ............................................................................................................................. 1-7 2. Operation and Management Starting and Stopping an Engine ........................................................................................................

2-3 Break-in Period of an Engine .............................................................................................................. 2-4 Operation in Winter............................................................................................................................... 2-6 Inspecting and Repairing an Engine ................................................................................................... 2-7 3. Performance and Specifications Engine Specifications and Performance ..............................................................................................

3-3 Outside Drawing of the Engine (DL01-LEE00)................................................................................. 3-10 Outside Drawing of the Engine (DL01-LEL00))................................................................................ 3-14 Engine Identification Number)............................................................................................................. 3-18 4. Regular Inspection Regular Inspection Table......................................................................................................................

4-4 General Information............................................................................................................................... 4-3 Engine Oil .............................................................................................................................................. 4-5 Coolant ................................................................................................................................................. 4-10 Fuel ......................................................................................................................................................

4-14 Air Filter ............................................................................................................................................... 4-15 5. Failure Diagnosis General Information............................................................................................................................... 5-5 Failure Code .......................................................................................................................................... 5-6 Failure Code Diagnosis....................................................................................................................... 5-10 6.

About the engine Marking System of Units ...................................................................................................................... 6-3 Tightening Torque ................................................................................................................................. 6-4 Engine Disassembly .............................................................................................................................. 6-7 Engine Assembly................................................................................................................................. 6-20

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Table of contents

7. Cooling System General Information............................................................................................................................. 7-3 water Pump ......................................................................................................................................... 7-6 Thermostat ........................................................................................................................................... 7-8 8. Lubrication System General Information.............................................................................................................................

8-3 Oil Pump.............................................................................................................................................. 8-6 Oil Filter Assembly.............................................................................................................................. 8-12 9. Fuel System General Information............................................................................................................................. 9-3 Fuel return hose..................................................................................................................................

9-5 Injector.................................................................................................................................................. 9-6 Common Rail....................................................................................................................................... 9-12 Fuel injection pump............................................................................................................................. 9-17 10. Intake/Exhaust System General Information.............................................................................................................................

10-3 Specifications ....................................................................................................................................... 10-4 Intake manifold .................................................................................................................................... 10-5 Turbocharger........................................................................................................................................ 10-8 Exhaust Gas Recirculation (EGR) System...................................................................................... 10-22 11.

Cylinder block/head Cylinder Block...................................................................................................................................... 11-5 General Information............................................................................................................................. 11-3 Timing Gear Case............................................................................................................................... 11-7 Breather................................................................................................................................................

11-9 Cylinder Head.................................................................................................................................... 11-10 Cylinder Head Cover......................................................................................................................... 11-11 Oil Pan............................................................................................................................................... 11-16 Valve ..................................................................................................................................................

11-18 Rocker Arm........................................................................................................................................ 11-21 Valve Tappet and Push Rod ........................................................................................................... 11-28 Camshaft ............................................................................................................................................ 11-35 Idle Gear............................................................................................................................................

11-37 Lifting Hook........................................................................................................................................ 11-42

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Table of contents

12. Electric System Electric Parts ....................................................................................................................................... 12-3 Circuit Diagram.................................................................................................................................... 12-5 Air Heater ............................................................................................................................................ 12-9 Switches and Sensors ......................................................................................................................

12-11 Wire harness ..................................................................................................................................... 12-17 Electronic Control Unit (ECU) .......................................................................................................... 12-18 13. Others/Driving System......................................................................................................13-3 General Information.............................................................................................................................

13-3 Crankshaft ............................................................................................................................................ 13-5 Connecting Rod................................................................................................................................... 13-9 Piston ................................................................................................................................................. 13-11 Crankshaft Pulley ..............................................................................................................................

13-13 Others................................................................................................................................................. 13-14

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