Doosan A2300, D15S-5, G18S-5, G20SC-5, GC15S-5 Service Manual

...

SB4106E01

Service Manual

A2300 Diesel Engine D15S-5, D18S-5, D20SC-5 G15S-5, G18S-5, G20SC-5 GC15S-5, GC18S-5, GC20SC-5

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current information available.

A Series Diesel Engine Index

Index

Introduction

About the Manual ...................................................... 5

How to Use the Manual .............................................5

Generic Symbols....................................................... 6

Definition of Terms.....................................................7

Illustrations................................................................ 8

General Engine Information

External Engine Components ....................................9

Engine Specifications...............................................11

Troubleshooting Logic

Engine Diagrams .................................................... 12

Problem Isolation and Correction ........................... 12

Troubleshooting Logic(List of Symptoms)............... 13

Coolant System

Cooling System Components and Flow...................53

Pressure Caps .........................................................56

Water(Coolant) Pump...............................................57

Thermostat...............................................................60

Gauges, Overfueling and Laoding...........................61

Cooling System Replacement Procedures..............62

Belt Tensioner Replacement................................... 62

Fan Pulley Replacement ......................................... 62

Fan Hub Replacement............................................ 63

Water Pump Replacement.......................................64

Cup Plug Replacement............................................67

Fuel System

Fuel System Components and Flow........................68

Fuel System Malfunction Diagnosis .........................69

Air in the Fuel System..............................................70

Fuel Water Separator/Filter Unit..............................71

Injection Pump .........................................................72

Governor Malfunctions.............................................72

Fuel Control Lever TRavel and Adjustment.............73

VE Pump Adjustment Screws..................................73

Manual Shut Down Levers .......................................74

Advance Timing Mechanism....................................74

Electrical Shut off Valves .........................................75

Injection Pump Timing..............................................77

High Pressure Fuel Line ..........................................78

Injectors....................................................................79

Fuel Drain Manifold..................................................81

Air System

Air System Flow.......................................................98

Diagnosing Air System Malfunctions........................99

Air Flow Restriction..................................................99

Damage from Non-Filtered Air...............................100

Pressure Side Air Leaks.........................................100

Exhaust Leaks........................................................101

Malfunctioning Turbocharger..................................101

Oil Consumption and Leaks ...................................102

Turbocharger Noise ...............................................103

Rotor Assembly Clearance Measure.....................104

Lubricating System

Lubricating System Flow........................................113

Lubricating Oil Pump..............................................113

Pressure Regulating Valve.....................................113

Oil Coolers..............................................................114

Oil Filters................................................................114

Oil Filters Bypass Valve..........................................114

Low Oil Pressure....................................................116

Oil Level .................................................................116

Oil Filter..................................................................117

Oil Gauge...............................................................117

Oil Suction Tube.....................................................117

Bearings and Oil Pump..........................................117

Incorrect Oil Pump..................................................118

Oil Dilution..............................................................118

Coolant Diluted Oil .................................................118

Fuel Diluted Oil.......................................................119

Oil Leaks................................................................123

Electrical System

Electrical System Description/Operation................134

Electrical System Spec. .........................................136

Starting Motor.........................................................137

Engine Cranking Speed Too Slow.........................139

Alternator................................................................140

Fuel Shut Off Valve Check.....................................143

Oil Pressure Switch................................................143

A Series Diesel Engine Index

Base Engine Components

Operation and Description .....................................148

Cylinder Head and Valve Train..............................149

Front Gear Housing and Gear Train......................150

Front Crankshaft Seal............................................150

Camshaft, Tappets and Push Rods.......................150

Flywheel Housing and Flywheel ............................151

Piston and Rod Assemblies...................................152

Crankshaft and Main Bearings...............................154

Oil Pan ...................................................................156

Base Engine Component.......................................156

Air and Fuel System...............................................157

Compression Check ...............................................158

Piston Ring Seal ....................................................158

Valce Sealing .........................................................158

Valve Seal Wear.....................................................160

Front Gear Housing and Gear TRain.....................161

Rocker Levers........................................................162

Piston and Rod Assembly ......................................163

Crankshaft and Main Bearings...............................165

Cylinder Block........................................................166

Flywheel Housing and Flywheel ............................166

Base Engine Componen Specifications .................168

Gear Train..............................................................169

Camshaft................................................................169

Tappets...................................................................169

Pistons ...................................................................170

Connecting Rod .....................................................171

Crankshaft..............................................................171

Cylinder Block........................................................171

Cylinder Bore .........................................................172

Base Engine Components .....................................173

Rocker Levers........................................................174

Rocker Levers Assembly .......................................179

Valve Clearance.....................................................179

Four Cylinder Engine .............................................179

Camshaft and Tappet .............................................180

Camshaft Inspection ..............................................181

Camshaft Bushing Inspection ................................182

Tappet Inspection ...................................................183

Gear Housing or Gasket........................................186

Flywheel Ring Gear and Rear Sel.........................187

Brass Drift Pin........................................................187

Flywheel.................................................................188

In Chassis Overhaul...............................................189

Cylinder Head Removal.........................................190

Main Bearing Preliminary Inspection .....................191

Main Bearing..........................................................194

Piston and Rod ......................................................196

Piston, Pin and Connecting Rod............................197

Piston Ring Gap.....................................................202

Piston Rings...........................................................202

Piston and Rod Assembly ......................................204

Cylinder Head and Gasket .....................................207

Cylinder Head.........................................................211

Valves.....................................................................214

Valve Seats............................................................216

Cylinder Head ........................................................220

Hydraulic Pump Drive Gear and Shaft...................221

Balancer-Remove ..................................................221

Balancer-Install ......................................................222

Engine Replacement and Testing

Engine Replacement ..............................................223

Engine Removal .....................................................224

Engine Installation ..................................................225

Engine Testing........................................................227

Specifications

General Engine......................................................228

Fuel System...........................................................228

Lubricating Oil System...........................................228

Cooling System......................................................229

Air Intake System...................................................229

Exhaust System.....................................................229

Electrical System....................................................229

Drive Belt Tension..................................................229

Capscrew Markings and Torque Values.................230

Fraction, Decimal, Millimeter Conversions.............233

Newton-Meter to Foot-Pound Conversions............234

Pipe Plug Torque Values........................................234

Weights and Measures-Conversion Factors ..........235

Special Tools

Special Tool List.....................................................237

Introduction

About the Manual

The procedures in this manual were developed for an in-chassis environment. The information has been grouped by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each section subdivides the instructions for the various components of the system. Wrench sizes and special tools are identified in the procedures as needed.

How to Use the Manual

The organization of this manual is based on the troubleshooting logic presented in Section 2. To fix a problem, find the logic chart for the particular symptom. Follow the steps specified until the problem is corrected.

The left column of the charts indicates a probable cause. The right column provides a brief description of the corrective action with a reference to the repair procedure or diagnostic discussion when appropriate.

The logic charts reflect three basic considerations:

1. Assumes the engine has provided satisfactory service prior to the problem.

2. Performing the easiest things first.

3. Most logical cause in descending order.

If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major system will provide guidance for sorting out the cause of the problem.

A Series Diesel Engine Introduction

Generic Symbols

The following group of symbols has been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below.

Warning – Serious personal injury or extensive property damage can result if the warning instructions are not followed.

Causion – Minor personal injury can result or a part, an assembly or the engine can be damaged if the caution instructions are not followed.

The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque

PERFORM an electrical MEASUREMENT.

A Series Diesel Engine Introduction

Refer to another location in this manual or another publication for additional information.

Definition of Terms

The following is a list of guidelines for each procedure in the “repair Sections” of the Troubleshooting and Repair Manual. The procedure will be given first; followed by a definition o the step or steps involved.

Check

Inspect

Test

Adjust

Visually Inspect

Remove

Clean

Disassemble

Repair

Note

Replace

Install

Star Pattern Torque Sequence

Examine a component or system for damage, excessive wear, accuracy, safety, or performance.

Examine a component or dimension to make sure it meets the required specifications.

Check or compare the performance of a component or system to established specifications.

Complete the necessary steps to set or adjust the component, assemblies, or system in the required setting or position.

Look for any obvious damage or problem.

Take off a component or assembly

Remove dirt, grease or other contamination.

Take the component or assembly apart.

Restore a component or assembly to a serviceable condition within the established specifications.

Only the easiest and simplest repairs will be made to a component or assembly. If a component or assembly must be rebuilt; it must be replaced with a new or Cummins Diesel Recon, Inc. replacement or be rebuilt at a Cummins authorized repair location.

Install a new, properly rebuilt, or Cummins Diesel Recon, Inc. component or assembly in place of one which is removed.

Place a component or assembly in the correct position.

A Series Diesel Engine Introduction

Illustrations

The illustrations used in the Diagnosis Sections of this manual are intended to give an example of a problem, show what to look for and where to look for the problem. Most of the illustrations are generic and might not look exactly like the engine or parts used in your application. Some illustrations contain symbols to indicate an action required and an acceptable or unacceptable condition.

Unacceptable

Acceptable

Direction of Movement

(Action)

The illustrations used in the Replacement Sections are intended to show replacement procedures when the engine is installed in a chassis. The illustration may differ from your application, but the procedure given will be the same.

A Series Diesel Engine Introduction

General Engine Information

External Engine Components

The pictures which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. Note: The pictures are only a reference to show a typical engine.

Exhaust Side [Naturally Aspirated] Intake Side [Naturally Aspirated]

1. Exhaust Manifold

2. Oil Fill Cap

3. Fan

4. Fuel Injection Pump

5. Crankshaft Pulley

6. Dip Stick

7. Oil Filter

1. Intake Manifold

2. Alternator

3. Thermostat housing

4. Starting Motor

A Series Diesel Engine General Engine Information

Exhaust Side [Turbocharged] Intake Side [Turbocharged]

1. Fuel Filter

2. Crankshaft Pulley

3. Cooling Fan

4. Exhaust Manifold

5. Dipstick

6. Oil Cooler

7. Fuel Injection Pump

8. Turbocharger Oil Drain Tube

1. Turbocharger

2. Alternator

3. Thermostat Housing

4. Intake Manifold

5. Starting Motor

6. Turbocharger Oil Tube

7. Oil Fill Cup

8. Air Crossover Tube

A Series Diesel Engine General Engine Information

Engine Specifications

Engine Model A2300

General Engine Data Naturally Aspirated

Engine Weight(Dry) Less Flywheel and Electronics 169 kg [373 lb]

Compression Ratio 21:1

Bore [mm/inch] 88 [3.46]

Stroke [mm/inch] 94 [3.7]

Displacement [ℓ/in3] 2.29 [139]

Firing Order 1-3-4-2

Valve Clearance

Rotation Viewed from the Front of the Engine Clockwise

Lubrication System Naturally Aspirated

Regulating Valve Opening Pressure 290 – 390kPa [42-56 psi]

Lubricating Oil Capacity [ℓ/gal]

Lubricating Oil Pressure at Idle(Max. Allowable) 69 kPa [10 psi]

Lubricating Oil Pressure at Rated(Min. Allowable) 245 kPa [35 psi]

Oil Filter Differential Pressure to Open Bypass Valve 98 kPa [14 psi]

Number of liters [qt] from Low to High 2.0 ℓ [0.53 gal]

Lubrication System Forced Lubrication with Pump

Intake 0.3 mm [0.012 in] Exhaust 0.3 mm [0.012 in]

Total System 7.0 [1.85] Standard Oil Pan Only

6.5 [1.72]

Cooling System Naturally Aspirated

Coolant Capacity (Engine Only) [ℓ/gal] 3.0 [0.7]

Start 71 [160] Standard Modulating Thermostat

Range [℃/F]

Cooling System Forced Lubrication with Pump

Air Induction System Naturally Aspirated

Maximum Allowable Intake Restriction at Rated Speed and Load with Dirty Filter Element

Exhaust System Naturally Aspirated

Maximum Allowable Exhaust Restriction at Rated Speed and Load with Dirty Filter Element

Fuel System Naturally Aspirated

Injection Pressure 150 kPa [22 psi]

Starting System

A Series Diesel Engine General Engine Information

Pulley Open 8 [185]

6.23 kPa [635 mmAq]

5.88 kPa [600 mmAq]

Electric starting with Starter Motor (12 V –2.0 kW)

Troubleshooting Logic

Engine Diagrams

A schematic of each of the major engine systems is provided at the beginning of the section of the manual devoted to troubleshooting and repairing that particular system. The diagrams depict flow through the various engine systems. The information and configuration of the components illustrated in the drawings are of a general nature. Some items for specific applications and installations may be different. Each Section also contains a discussion regarding diagnosing malfunctions for that specific system. Knowledge of the systems can help you troubleshoot and repair the engine.

Problem Isolation and Correction

The following Troubleshooting Logic is designed to help you organize your study of a problem and to plan a procedure to correct it. The series of fault/logic charts given do not provide all the answers, but they should stimulate a train of thought that will lead you to the source of the trouble.

Be sure to consider any maintenance or repair action that could have caused the problem. If the engine surges or runs rough initially after not being used for 2 months or more, do not assume that the engine has a malfunction. Varnish can form on the internal parts of the injection pump and the oil film can drain from the piston rings. Operate the engine for at least 5 minutes before troubleshooting.

The basic procedure is as follows:

z Study the problem thoroughly. z Relate the symptoms to your knowledge of the engine components and systems. z Double-check before beginning the disassembly. z Solve the problem by deduction starting with the easiest things. z Determine the cause of the problem and make a thorough repair. z After making corrections, operate the engine in normal conditions to verify the cause of the problem was

corrected.

A Series Diesel Engine Troubleshooting Logic 12

Troubleshooting Logic

Page List of Symptoms

52 Alternator Not Charging or Insufficient Charging

36 Coolant Loss

32 Coolant Temperature Above Normal

35 Coolant Temperature Below Normal

46 Compression Knocks

43 Contaminated Coolant

44 Contaminated Lube Oil

15 Engine Cranks But Will Not Start – No Smoke From Exhaust

16 Engine Hard to Start Or Will Not Start – Smoke From Exhaust

24 Engine RPM Will Not Reach Rated Speed

22 Engine Runs Rough or Misfiring

18 Engine Starts But Will Not Keep Running

14 Engine Will Not Crank Or Cranks Slowly

48 Engine Will Not Shut Off

51 Excessive Engine Noises

30 Excessive Engine Smoke

47 Excessive Fuel Consumption

49 Excessive Vibration

45 Fuel or Oil Leaking From Exhaust Manifold

26 Low Power

41 Lube Oil Loss

38 Lubricating Oil Pressure Low

40 Lubricating Oil Pressure Too High

20 Rough Idle (Irregularly Firing Or Engine Shaking)

19 Surging (Engine Speed Change)

A Series Diesel Engine Troubleshooting Logic 13

Engine Will Not Crank or Cranks Slowly

Cause Correction

Starting Motor Operating But Not Cranking the Engine

Crankshaft Rotation Restricted

Starting Circuit Connections Loose Or Corroded

Battery Charge Low

Remove the Starting Motor and Check for Broken Teeth on the Flywheel or Broken Starting Motor Spring. Refer to Page 138

Bar the Engine to Check for Rotational Resistance. Refer to Page 138

Clean and Tighten Connections. Refer to Page 137

Check Battery Voltage. Refer to Page 137

No Voltage to Starter Solenoid

Solenoid or Starting Motor Malfunction

Check Voltage to Solenoid. Refer to Page 137

Replace Starting Motor. Refer to Page 144

A Series Diesel Engine Troubleshooting Logic 14

Engine Cranks But Not Start – No Smoke From Exhaust

Cause

No Fuel in Supply Tank

Electrical or Manual Fuel Shutdown Not Open

Air Intake or Exhaust Plugged

Fuel Filter Plugged With Water or Other Contamination

Check/Replenish Fuel Supply

Check for Loose Wires and Verify that the Valve is Functioning. Check to be sure Manual Shut Off Lever is in the Run Position. Refer to Page 74

Visually Check: Remove the Obstruction.

Drain Fuel/Water Separator or Replace Fuel Filter. Refer to Page 71, 83

Correction

Injection Pump Not Getting Fuel or Fuel is Aerated

Worn or Malfunctioning Injection Pump

Internal Pump Timing Incorrect

Camshaft Out of Time

Check Fuel Flow/Bleed Fuel System. Refer to Page 83

Visually Check Fuel Delivery with an Externally Connected Injector to One of the Pump Outlets. Replace the Pump if Fuel is Not Being Delivered. Refer to Page 94

Verify/Time the Pump. Refer to Page 77

Check/Correct Gear Train Timing Alignment. Refer to Page 77, 185

A Series Diesel Engine Troubleshooting Logic 15

Engine Hard To Start Or Will Not Start – Smoke From Exhaust

Cause

Incorrect Starting Procedure

Cranking Speed Too Slow

The Fuel Control Lever on the Bosch VE Pump Must be Moved to One-Half Travel. The Fuel Shut Off Control Must Be in the Run Position. Refer to O&M Manual.

Verify that the Driven Units are not Engaged.

Check the Battery, Starting Motor, and Look for Loose or Corroded Wiring Connections. Refer to Page 137

Bar the Engine to Check for Internal Rotational Resistance.

Correction

Cold Starting Aids Not Working or Are Needed

Insufficient Intake Air

Air in the Fuel System or the Fuel Supply is Inadequate

(Continued)

Verify the Aids are Operating. Refer To O&M Manual.

Inspect or Replace Filter and Check for Obstructions to the Air Supply Tube. Refer to Page 98, 112

Check the Flow through the Filter and Bleed the System. Locate and Correct the Air Source. Refer to Page 83

A Series Diesel Engine Troubleshooting Logic 16

Engine Hard To Start Or Will Not Start – Smoke From Exhaust (Continued)

Cause Correction

Contaminated Fuel

Worn or Malfunctioning Injection Pump

Injection Pump Out of Time

Valves Incorrectly Adjusted

One or More Injectors Worn or Malfunctioning

Engine Compression Low

Verify by Operating the Engine with Clean Fuel from a Temporary Tank. Drain and Flush Fuel Supply Tanks.

Visually Check Fuel Delivery With an Externally Connected Injector to one of the Pump Outlets. Replace the Pump if Fuel is Not Being Delivered. Refer to 94

Check/Time the Pump. Refer to Page 77, 96

Adjust Valves. Refer to Page 179

Check/Replace Injectors. Refer to Page 88

Perform a Compression Check to Identify the Problem. Refer to Page 158

A Series Diesel Engine Troubleshooting Logic 17

Engine Starts But Will Not Keep Running

Cause

Engine Starting Under Load

Idle Speed Too Low For Accessories

Intake Air or Exhaust System Restricted

Air in the Fuel System or the Fuel Supply is Inadequate

Disengage Driven Units.

Adjust the Idle Speed. Refer to Page 73

Visually Check for Exhaust Restriction and Inspect the Air Intake. Refer to Page 99, 101

Check the Flow Through the Filter and Bleed the System. Locate and Correct the Air Source. Refer to Page 83

Correction

Fuel Waxing Due to Extremely Cold Weather

Contaminated Fuel

Restricted Fuel Drain Manifold or Return Line

Verify by Inspecting the Fuel Filter. Clean the System and Use Climatized Fuel or Fuel Heaters.

Verify by Operating the Engine With Clean Fuel from a Temporary Supply Tank. Drain and Flush the Fuel Supply Tank.

Check/Correct the Restriction. Refer to Page 81

A Series Diesel Engine Troubleshooting Logic 18

Surging (Speed Change)

Cause

If the Condition Occurs at Idle, the Idle Speed is Set Too Low for Accessories

High Pressure Fuel Leak

One or More Injectors Worn or Malfunctioning

Malfunctioning Delivery Valve

Adjust the Idle. Refer to Page 73

Inspect/Correct Leaks in the Pressure Lines. Fittings, Injector Sealing Washers or Delivery valves. Refer to Page 78

Check/Replace the Injectors. Refer to Page 88

Replace Delivery Valves. Refer to Page 84

Correction

Malfunctioning Injection Pump

Replace the Pump. Refer to Page 94

A Series Diesel Engine Troubleshooting Logic 19

Rough Idle (Irregularly Firing Or Engine Shaking)

Cause Correction

Cold Engine

Idle Speed Too Low for the Accessories

Engine Mounts Over-Tightened, Damaged or Loose

High Pressure Fuel Leak

Air in the Fuel System

Sticking Needle Valve in an Injector

Malfunctioning Delivery Valve

Refer to Troubleshooting Logic for Engine Running Too Cold. Refer to 35

Check/Adjust Low Idle Screw. Refer to Page 73

Verify Condition of Mounts. Refer to Equip. Manufactures Service Instructions.

Inspect/Correct Leaks in the High Pressure Lines, Fittings Injection Sealing Washers or Delivery Valve Seals. Refer to Page 78

Bleed the Fuel System and Correct the Source of the Air. Refer to Page 83

Replace the Injector. Refer to Page 88

Replace Delivery Valves. Refer to Page 92

(Continued)

A Series Diesel Engine Troubleshooting Logic 20

Rough Idle (Irregularly Firing Or Engine Shaking)(Continued)

Cause

Valves Not Sealing

One or More Cylinders Losing Compression

Adjust Valves. Refer to Page 179

Perform a Compression Check and Repair as Required. Refer to Page 160

Correction

A Series Diesel Engine Troubleshooting Logic 21

Engine Runs Rough Or Misfiring

Cause Correction

Fuel Injection Lines Leaking

Air in the Fuel or the Fuel Supply is Inadequate

Contaminated Fuel

Incorrect Valve Adjustment

Injection Pump Timing Incorrect

Inspect/Correct Leaks in the High Pressure Lines, Fittings Injector Sealing Washers, or Delivery Valve. Refer to Page 78

Check the Flow Through the Filter and Bleed the System. Locate and Correct the Air Source. Refer to Page 83

Verify by Operating the Engine with Clean Fuel from a Temporary Tank.

Check for a Bent Push Rod and Adjust Valves. Refer to Page 179

Check/Time Pump. Refer to Page 77

One or More Cylinders Has Low Compression

(Continued)

A Series Diesel Engine Troubleshooting Logic 22

Perform a Compression Check to Isolate the Cause of Low Compression (Piston Rings, Head Gasket or Valves). Refer to Page 158

Engine Runs Rough Or Misfiring (Continued)

Cause Correction

Malfunctioning Injectors

Defective Injection Pump (Delivery Valves)

Camshaft Out of Time

Damaged Camshaft or Tappets

Replace Injectors. Refer to Page 88

Replace Injection Pump. Refer to Page 94

Check/Correct Gear Train Timing Alignment. Refer to Page 185

Inspect Camshaft. Refer to Page 182

A Series Diesel Engine Troubleshooting Logic 23

Engine RPM will Not Reach Rated Speed

Cause Correction

Engine Overloaded

Malfunctioning Tachometer

Throttle Linkage Worn or Incorrectly Adjusted

If the Problem Occurs After Replacing the Fuel Control Lever or Pump, Incorrectly Indexed Lever (Robert Bosch VE Only)

Verify High Idle Speed Without Load. Investigate Operation to be Sure Correct Gear is Being Used.

Verify Engine Speed with Hand Tachometer - Correct as Required.

Adjust Linkage for Stop-to-Stop Fuel Control Lever Travel. Refer to Page 73, 225

Check/Correct Fuel Control Lever Indexing. Refer to Page 74

High Speed Stop Screw Incorrectly Adjusted

Partially Engaged Mechanical Shutdown Lever

Inadequate Fuel Supply

(Continued)

Check/Set High Speed Stop Screw. Refer to Page 74, 225

Check/Place Shutdown Lever in Run Position. Refer to Page 74, 225

Check the Flow Through and Filter to Locate the Source of the Restriction. Refer to Page 68

A Series Diesel Engine Troubleshooting Logic 24

Engine RPM will Not Reach Rated Speed (Continued)

Cause Correction

If the Condition is Intermittent, Restricted Manifold Drain Line

Malfunctioning Injection Pump

Check/Remove Restriction. Refer to Page 81

Replace Pump. Refer to Page 94

A Series Diesel Engine Troubleshooting Logic 25

Low Power

Cause Correction

If the Condition is Slow Throttle Response, Leaking Air Fuel Control Tube or Malfunction Control in the Pump (Automotive Only)

Fuel Control Lever Not Moving to Full Speed.

Mechanical/Shutdown Lever Partially Engaged

High Oil Level

Tighten the Fittings. Replace the Pump if the Controls are Not Functioning. Refer to Page 87

Check/Correct for Stop-to-Stop Travel. Refer to Page 73, 225

Check/Replace Shutdown Lever in Run Position. Refer to Page 74, 225

Check/Correct Oil Level

Engine Overloaded

Incorrect External Injection Pump Timing

(Continued)

Check for Added Loading from Malfunctioning Accessories or Driven Units, Brakes Dragging and Other Changes in Vehicle Loading

Verify Pump Timing Marks are Aligned. Refer to Page 77, 96

A Series Diesel Engine Troubleshooting Logic 26

Low Power (Continued)

Cause

Inadequate, or High or Low Temperature Intake Air

High Pressure Fuel Leak

Inspect/Replace Air Cleaner Element. Look for Other Restrictions. Refer to Page 112

If the vehicle is equipped with a Valve to Switch the Intake Source from Under the Hood to Outside, Position the Valve for the Season.

Coolant Passage in the After Cooler Plugged.

Inspect/Correct Leaks in the High Pressure Lines, Fittings Injector Sealing Washers or Delivery Valve Seals. Refer to Page 78

Correction

Inadequate Fuel Supply

High Fuel Temperature

If Low Power is Intermittent, Restricted Fuel Drain Manifold

Poor Quality Fuel

(Continued)

Check the Flow Through the Filter to Locate the Source of the Restriction. Refer to Page 68

Check for a Restricted Fuel Drain Manifold (Robert Bosch VE)

Check/Correct Restriction. Refer to Page 81

Verify by Operating From a Temporary Tank With Good Fuel.

A Series Diesel Engine Troubleshooting Logic 27

Low Power (Continued)

Cause Correction

Air Leak Between the Turbocharger and the Intake Manifold.

Exhaust Leak at the Manifold or Turbocharger

Malfunctioning Turbocharger

Valve Clearances Incorrect

Injection Pump Internal Malfunctioning

Check/Correct Leaks in the Air Crossover Tube, Hoses, or Through Holes in the Manifold Cover. Refer to Page 100, 101

Check/Correct Leaks in the Manifold or Turbocharger Gaskets. Look for a cracked Manifold. Refer to Page 101

Inspect/Replace Turbocharger. Refer to Page 101, 105, 109

Check/Adjust Valves. Refer to Page 179

Check/Time Pump. Refer to Page 77

Low Engine Compression

Worn or Malfunctioning Injectors

(Continued)

Perform Compression Check to Identify Malfunction. Correct as Required. Refer to Page 158

Check Injectors. Refer to Page 79

A Series Diesel Engine Troubleshooting Logic 28

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Doosan A2300, D15S-5, G18S-5, G20SC-5, GC15S-5 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual