Daewoo Doosan QSM11 Cummins Engine manual – PDF DOWNLOAD

Description

Daewoo Doosan QSM11 Cummins Engine manual – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan QSM11 Cummins Engine manual – PDF DOWNLOAD

• DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold.
• It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment. This documentation may include attachments and optional equipment not available in your machine’s package.
• Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item

SAFETY PRECAUTIONS

• Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order.
• Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.

INTRODUCTION

• To the Owner and Operator Preventive maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommendations outlined in “Maintenance Guidelines” on page 52 Keep records of regularly scheduled maintenance.
• Use the correct fuel, lubricating oil, and coolant in your engine as specified in “Maintenance Specifications” on page 223 Cummins Inc. uses the latest technology and the highest quality components to produce its engines. Cummins Inc.
• recommends using genuine Cummins new parts and ReCon® exchange parts. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support.
• If you have a problem that cannot be resolved by a Cummins Authorized Repair Location, follow the steps outlined in the “Service Assistance” on page 135

About the Manual

• This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Inc. For additional service literature and ordering locations, refer to “Service Literature” on page 127.
• This manual does not cover vehicle, vessel, or equipment maintenance procedures. Consult the original vehicle, vessel, or equipment manufacturer for specific maintenance recommendations. Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets.
• Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to Symbols in this section for a complete listing of symbols and their definitions. Each section of the manual is preceded by a Section Contents to aid in locating information

How to Use the Manual

• This manual is organized according to intervals at which maintenance on your engine is to be performed. A maintenance schedule, that states the required intervals and maintenance checks, is located in “Maintenance Guidelines” on page 52. Locate the interval at which you are performing maintenance; then follow the steps given in that section for all the procedures to be performed.
• Keep a record of all the checks and inspections made. A maintenance record form is located in “Maintenance Guidelines” on page 52. Engine troubleshooting procedures for your engine are located in “Troubleshooting Symptoms” on page 183. Specifications for your engine are located in “Maintenance Specifications” on page 223

Illustrations

Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ

General Safety Instructions

Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death

Read and understand all the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply.

Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.

• Always wear protective glasses and protective shoes when working.

• Rotating parts can cause cuts, mutilation or strangulation.

• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.

• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.

Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator’s cabin or on the controls.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure.

• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the fill cap to relieve the pressure from the cooling system.

• Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported ONLY by lifting jacks or a hoist. WARNING! Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death.

QSM11CUMMINSENG Page 13 QSM11 Cummins Engine

• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High-pressure oil or fuel can cause personal injury.

• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant

. • To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.

• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.

• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments.

• Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Use ONLY genuine Cummins or Cummins ReConTM replacement parts.

• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary.

• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.

• Liquefied petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low lying areas

. • Natural gas is lighter than air and can accumulate under hood and awnings.

• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas and liquefied petroleum gas lines in a well ventilated area.

• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations. • The catalyst reagent contains urea. Do not get the substance in your eyes.

In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is ingested, contact a physician immediately

. • The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly. Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water.

• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local regulations.
TABLE OF CONTENTS:

Daewoo Doosan QSM11 Cummins Engine manual – PDF DOWNLOAD

QSM11 Cummins Engine QSM11CUMMINSENG..........................................  3
	Safety Precautions........................................................  9
	Applicable Models.........................................................  9
	QSM11 Engine.............................................................. 10
		Important Reference Numbers........................................... 11
	Introduction.............................................................. 12
		To the Owner and Operator............................................. 12
		About the Manual...................................................... 12
		How to Use the Manual................................................. 13
		Illustrations......................................................... 13
		General Safety Instructions........................................... 14
			Important Safety Notice........................................... 14
		General Repair Instructions........................................... 17
			General Information............................................... 17
			Welding on a Vehicle with an Electronic Controlled Fuel System.... 18
		General Cleaning Instructions......................................... 19
			Definition of Clean............................................... 19
			Abrasive Pads and Abrasive Paper.................................. 20
			Gasket Surfaces................................................... 22
			Solvent and Acid Cleaning......................................... 22
			Steam Cleaning.................................................... 23
			Plastic Bead Cleaning............................................. 24
		Acronyms and Abbreviations............................................ 27
	Engine Identification..................................................... 28
		Engine Data Plate..................................................... 28
		ECM Data Plate........................................................ 29
			With CM570........................................................ 29
		Cummins Engine Nomenclature........................................... 29
			Automotive, Industrial, and Generator Drive....................... 29
		Fuel Injection Pump Data Plate........................................ 29
		Engine Diagrams....................................................... 30
			Engine Views...................................................... 30
			Industrial Drive.................................................. 30
		Engine Specification.................................................. 32
	Operating Instructions.................................................... 34
		Operating Instructions - Overview..................................... 34
		Normal Starting Procedure............................................. 35
		Cold Weather Starting................................................. 37
			General Information............................................... 37
			Using Starting Aids............................................... 37
		Starting Procedure After Extended Shutdown or Oil Change.............. 38
		Operating the Engine.................................................. 38
			Normal............................................................ 38
			Cold Weather...................................................... 39
			Ambient Temperature............................................... 39
			0° - -32°C (32° - -25°F).......................................... 39
			-32° - -54°C (-25° - -65°F)....................................... 39
		Engine Operating Range................................................ 40
		Engine Shutdown....................................................... 41
		Electronic Controlled Fuel System..................................... 41
			General Information............................................... 41
			Diagnostic Fault Codes............................................ 42
			Stop Engine Light................................................. 42
			Warning Engine Light.............................................. 42
			Engine Maintenance Light.......................................... 43
			Engine Diagnostics................................................ 43
		Fuel System Description............................................... 46
		Programmable Features................................................. 47
			General Information............................................... 47
			Alternative Low Idle Speed........................................ 47
			Switchable (Alternate) Torque..................................... 48
			Duty Cycle Monitor................................................ 48
			Fuel Consumption Rate Logger...................................... 49
			Maintenance Monitor............................................... 50
		Electromagnetic Interference (EMI).................................... 52
			General Information............................................... 52
			System EMI Susceptibility......................................... 52
			System EMI Radiation Levels....................................... 52
	Maintenance Guidelines.................................................... 54
		Maintenance Guidelines - Overview..................................... 54
		Tool Requirements..................................................... 54
		Maintenance Schedule.................................................. 55
			Daily or Refueling - Maintenance Check............................ 55
			Oil Drain Intervals............................................... 56
	Maintenance Procedures at Daily Interval.................................. 57
		Daily Maintenance Procedures - Overview............................... 57
			General Information............................................... 57
			Engine Operation Report........................................... 57
			Unusual Engine Noise.............................................. 58
		Fuel-Water Separator.................................................. 58
			Drain............................................................. 58
		Lubricating Oil Level................................................. 59
			Maintenance Check................................................. 59
		Coolant Level......................................................... 59
			Maintenance Check................................................. 59
		Cooling System Hoses.................................................. 60
			Maintenance Check................................................. 60
		Fan, Cooling.......................................................... 61
			Inspect for Reuse................................................. 61
		Drive Belts........................................................... 62
			Maintenance Check................................................. 62
		Crankcase Breather Tube............................................... 63
			Maintenance Check................................................. 63
		Charge-Air Piping..................................................... 63
			Maintenance Check................................................. 63
		Air Cleaner Restriction............................................... 64
			Maintenance Check................................................. 64
	Maintenance Procedures at 500 Hours or 6 Months........................... 65
		Maintenance Procedures - Overview..................................... 65
			General Information............................................... 65
		Fuel Filter (Spin-on Type)............................................ 65
			Remove............................................................ 65
			Install........................................................... 66
		Lubricating Oil and Filters........................................... 67
			Drain............................................................. 67
			Fill.............................................................. 68
		Lubricating Oil Filter (Spin-on)...................................... 69
			Remove............................................................ 69
			Install........................................................... 69
		Coolant Filter........................................................ 70
			General Information............................................... 70
			Remove............................................................ 71
			Install........................................................... 72
		Supplemental Coolant Additive (SCA) and Antifreeze Concentration...... 73
			Maintenance Check................................................. 73
		Engine Wiring Harness................................................. 74
			Maintenance Check................................................. 74
	Maintenance Procedures at 1,500 Hours..................................... 75
		Maintenance Procedures - Overview..................................... 75
			General Information............................................... 75
		Overhead Set.......................................................... 75
			Injectors......................................................... 78
			Valves............................................................ 79
		Maintenance Procedures at 2,000 Hours or 1 Year....................... 82
		Maintenance Procedures - Overview..................................... 82
			General Information............................................... 82
		Air Cleaner Restriction............................................... 82
			Maintenance Check................................................. 82
		Air Leaks, Air Intake and Exhaust Systems............................. 83
			Maintenance Check................................................. 83
		Batteries............................................................. 85
			Inspect........................................................... 85
		Engine Mounts......................................................... 86
			Inspect........................................................... 86
		Engine Steam Cleaning................................................. 86
			Clean............................................................. 86
		Turbocharger.......................................................... 87
			Maintenance Check................................................. 87
		Water Pump............................................................ 88
			Maintenance Check................................................. 88
		Vibration Damper, Viscous............................................. 89
			Inspect........................................................... 89
		Fan Drive Idler Pulley Assembly....................................... 90
			Inspect........................................................... 90
		Turbocharger.......................................................... 90
			Maintenance Check................................................. 90
		Cooling System........................................................ 91
			General Information............................................... 91
			Clean............................................................. 91
			Flush............................................................. 93
			Fill.............................................................. 95
	Adjustment, Repair and Replacement........................................ 98
		Fuel Shutoff Valve.................................................... 98
			Voltage Check..................................................... 98
			Install........................................................... 99
			Adjust............................................................100
		Belt Tensioner, Automatic (Alternator)................................102
			General Information...............................................102
			Remove............................................................102
			Install...........................................................103
		Water Pump............................................................104
			Remove............................................................104
			Install...........................................................108
		Coolant Thermostat....................................................113
			Remove............................................................113
			Install...........................................................114
		Turbocharger..........................................................116
			Remove............................................................116
			Install...........................................................116
		Check for Correct Component...........................................117
		Refrigerant Compressor Drive..........................................117
			General Information...............................................117
			Remove............................................................117
			Install...........................................................118
		Starting Motor........................................................119
			Remove............................................................119
			Install...........................................................120
		Engine Storage - Long Term............................................120
			General Information...............................................120
	System Diagrams...........................................................121
		System Diagrams - Overview............................................121
			General Information...............................................121
		Fuel System...........................................................122
			Industrial Drive..................................................122
		Lubricating Oil System................................................123
			Flow Diagram......................................................123
		Cooling System........................................................124
		Flow Diagram, Air Intake System.......................................126
			Industrial Drive..................................................126
			Industrial Drive..................................................128
	Service Literature........................................................129
		Additional Service Literature.........................................129
			General Information...............................................129
		Service Literature Ordering Location..................................129
			Contact Information...............................................129
		Cummins Customized Parts Catalog......................................130
			General Information...............................................130
			Ordering the Customized Parts Catalog.............................130
	Component Manufacturers...................................................132
	Service Assistance........................................................137
		Routine Service and Parts.............................................137
		Emergency and Technical Service.......................................137
		Problem Solving.......................................................137
		Division and Regional Offices - Locations.............................139
		Distributors and Branches - United States.............................140
		Distributors and Branches - Canada....................................155
		Distributors and Branches - Australia.................................158
		Distributors and Branches - New Zealand...............................161
		Regional Offices - International - Locations..........................162
		Distributors - International - Locations..............................169
	Troubleshooting Symptoms..................................................185
		Troubleshooting Procedures and Techniques.............................185
		Troubleshooting Symptoms Charts.......................................185
			General Information...............................................185
			Alternator Not Charging or Insufficient Charging..................186
			Coolant Loss......................................................186
			Coolant Temperature Above Normal - Gradual Overheat...............187
			Coolant Temperature Above Normal - Sudden Overheat................189
			Coolant Temperature Below Normal..................................190
			Crankcase Gases (Blowby) Excessive................................190
			Engine Acceleration or Response Poor..............................191
			Engine Decelerates Slowly.........................................192
			Engine Difficult to Start or Will Not Start (Exhaust Smoke).......193
			Engine Difficult to Start or Will Not Start (No Exhaust Smoke)....195
			Engine Noise Excessive............................................196
			Engine Noise Excessive - Combustion Knocks........................198
			Engine Power Output Low...........................................199
			Engine Runs Rough at Idle.........................................201
			Engine Runs Rough or Misfires.....................................202
			Engine Shuts Off Unexpectedly or Dies During Deceleration.........203
			Engine Speed Surges at Low or High Idle...........................204
			Engine Speed Surges Under Load or in Operating Range..............205
			Engine Starts But Will Not Keep Running...........................205
			Engine Vibration Excessive........................................207
			Engine Will Not Crank or Cranks Slowly (Air Starter)..............208
			Engine Will Not Crank or Cranks Slowly (Electric Starter).........209
			Engine Will Not Reach Rated Speed (RPM)...........................210
			Engine Will Not Shut Off..........................................211
			Fuel Consumption Excessive........................................212
			Fuel in Coolant...................................................213
			Fuel in the Lubricating Oil.......................................213
			Intake Manifold Air Temperature Above Specification...............214
			Intake Manifold Pressure (Boost) is Below Normal..................215
			Lubricating Oil Consumption Excessive.............................216
			Lubricating Oil Contaminated......................................217
			Lubricating Oil Pressure High.....................................217
			Lubricating Oil Pressure Low......................................218
			Lubricating Oil Sludge in the Crankcase Excessive.................219
			Lubricating Oil Temperature Above Specification...................220
			Lubricating or Transmission Oil in the Coolant....................220
			PTO or Cruise Control Does Not Operate............................221
			Smoke, Black - Excessive..........................................222
			Smoke, White - Excessive..........................................223
			Turbocharger Leaks Engine Oil or Fuel.............................224
	Maintenance Specifications................................................225
		General Engine........................................................225
		Fuel System...........................................................225
		Lubricating Oil System................................................226
		Cooling System........................................................226
		Air Intake System.....................................................227
		Exhaust System........................................................227
		Electrical System.....................................................227
		Cummins/Fleetguard® Filter Specifications.............................228
			Specifications....................................................228
		Fuel Recommendations and Specifications...............................229
			Fuel Recommendations..............................................229
		Lubricating Oil Recommendations and Specifications....................230
			General Information...............................................230
		After Market Oil Additive Usage.......................................232
		Coolant Recommendations and Specifications............................232
			Fully Formulated Coolant/Antifreeze...............................232
		Cooling System Sealing Additives......................................234
		Cooling System Soluble Oils...........................................234
		Supplemental Coolant Additive (SCA)...................................234
		Testing SCA Concentration Level CC-2602 Test Kit......................235
			Precautions and Instructions for Proper Kit Use...................235
		Test Intervals........................................................236
		Coolant Replacement Requirements......................................236
		Drive Belt Tension....................................................237
			Tension Chart.....................................................237
		Engine Component Torque Values........................................237
			Torque Table......................................................237
		Cap Screw Markings and Torque Values..................................238
			General Information...............................................238
			Cap Screw Markings and Torque Values - Metric.....................239
			Cap Screw Markings and Torque Values - U.S. Customary.............240

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