Doosan D24 DIPP Diesel Engine Service Manual 7270395enUS (02-15) (0)

Doosan D24 DIPP Diesel Engine Service Manual 7270395enUS (02-15)

Technical service manual based strictly on the Table of Contents, providing in-depth diagnostic procedures, testing standards, disassembly and assembly instructions, component specifications and calibration data for the Doosan D24 DIPP industrial diesel engine used in compressor applications. Includes full system coverage for fuel injection, lubrication, cooling, air intake, electrical controls, timing geartrain, and major internal engine components.

Model Covers:

Doosan D24 DIPP Diesel Engine
Engine used in P185 Compressor

File Format: PDF

Size: 19.71 MB

No. of pages: 302

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Table of Contents Overview:

Safety, Engine Identification and General Specifications

• Engine safety instructions, hazard markings and workshop precautions
• Engine serial number location and model identification data plate
• Technical specifications: power rating, torque curve, firing order, displacement and compression ratio
• Tightening torques, wear limits, service tolerances and standard clearances

Scheduled Maintenance and Service Intervals

• Maintenance chart with operating-hour based service schedule
• Oil and filter change intervals, coolant renewal, belt replacement cycles
• Fuel pre-filter, main filter and water separator maintenance
• Inspection standards for air intake restriction, crankcase pressure and vibration

Engine Disassembly, Inspection and Reassembly

• Engine removal from mounting base, lifting points and hoisting procedure
• Step-by-step teardown with sub-assembly grouping and component layout
• Block cleaning, crack detection, liner measurement and deck flatness checks
• Crankshaft inspection, journal polishing specs, thrust bearing limits and end-play adjustment
• Connecting rod alignment check, piston ring end gap and side clearance measurement
• Camshaft lobe wear test, bushing press-fit tolerance and timing gear backlash

Fuel Injection System – Diagnosis and Calibration

• DIPP common-rail layout, high-pressure pump function and spill control
• Injector removal, nozzle leak test, pilot injection verification and back-leak inspection
• Fuel rail pressure sensor test values and relief valve thresholds
• Pump drive timing alignment and torque reference
• Low-pressure circuit priming, filter head air bleed and fuel heater checks

Lubrication System

• Oil pump disassembly, clearance limits and pressure regulating valve service
• Oil cooler core flushing, bypass valve inspection and gasket sealing points
• Pressure test data at cold/hot idle and governed speed

Cooling System

• Thermostat opening temperature test and housing service
• Water pump bearing and seal overhaul
• Coolant flow path, air pocket bleeding and corrosion inhibitor specification

Air Intake and Turbocharging

• Turbocharger shaft play limits, compressor housing inspection and boost pressure test
• Charge-air piping leak check, intake restriction monitoring and filter element service

Electrical, Sensors and Starting System

• Engine harness schematic, ground points and connector pin-outs
• ECM sensor signal values: MAP, ECT, crank and cam position, rail pressure
• Starter motor current draw test, solenoid replacement and alternator output check

Engine Timing, Gear Train and Calibration Data

• Timing mark alignment for crank, cam, pump drive and auxiliary gears
• Backlash measurement and selective shim adjustment
• Valve clearance specifications, cold and hot setting procedure
• Run-in checks, break-in oil usage and post-overhaul verification steps

Specifications, Tooling and Reference Charts

• Fluids and capacities, torque table, thread types and bolt grades
• Metric-inch conversion, lifting weights and service tool list
• Revision index and manual update references

This manual provides the full technical depth required for complete overhaul, troubleshooting and field maintenance of the Doosan D24 DIPP diesel engine.