Develon DM03VA, DM03PA Diesel Industrial Engine Operation and Maintenance Manual (950106-116013EN)

Format: PDF (Printable Document)

File Language: English

File Pages: 398

File Size: 194.40 MB (Speed Download Link)

Brand: Develon

Model: DM03VA, DM03PA Diesel Industrial Engine

Book No: 950106-116013EN

Type of Document: Operation and Maintenance Manual

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Categories: Doosan & Develon, PDF

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Develon DM03VA, DM03PA Diesel Industrial Engine Operation and Maintenance Manual (950106-116013EN)

These Develon DM03VA/DM03PA engines usually live in the ugly stuff—dusty plants, rental gear, pumps, compressors, maybe a generator sitting in a muddy yard. This operation and maintenance manual helps you set a steady rhythm: what to trace every day, what to inspect weekly, what to service before the busy season so the engine doesn’t quit when you’re buried in work. Say it starts hunting at idle right before a big pour; with this book you can systematically check fuel supply, verify filters, bleed air, and decide if it’s something you can handle or it’s shop time.

Applications & Use Cases

Set up a daily walk‑around so you trace leaks, check fluids, and spot loose mounts before they turn into downtime.
Plan seasonal services—filters, valve checks, belt tension—so you align the work with your slow periods.
Use the troubleshooting flows to isolate hard‑start or smoke issues and test the simple stuff first.
Verify correct fluid types and routing of hoses after a repair, so you don’t cook the engine under load.
Train new operators on how to warm up, load, and shut down properly, so the engine wears evenly and predictably.

FAQ

Q: Is this manual searchable on a laptop or tablet, or just a scan?

A: It’s generally a searchable PDF, so you can jump to sections and use find, though some diagrams are just images.

Q: Can I print pages and keep them in the service truck?

A: Yes, most folks print the key maintenance and service-interval pages, slip them in plastic, and keep the full file on a tablet.

Safety Note

Always disable the start circuit and verify the engine can’t crank before you put hands near belts, fans, or the flywheel.

Develon DM03VA, DM03PA Diesel Industrial Engine Index:

DM03VA, DM03PA
- Preface
- Table of Contents
- 1. General Introduction
  - General Information
    - General Information
  - Danger, Warning, Caution and Note
    - General Information
    - General Instructions
    - Cautions for Starting the Engine
    - Cautions for Inspection and Repair
    - General Repair
    - Other Safety Instructions and Environmental Pollution
    - Use of Genuine Parts
  - Emission Information
    - REGULATION (EU) 2017/654 ANNEX XV (Applies to customers using equipment in EU only.)
  - Engine Maintenance
    - Prevention of Damage and Abrasion
    - Prevention of Pollution
    - Handling of Engine Oil
    - Biodiesel Blend Fuel
    - HVO (Hydro treated Vegetable Oil)
    - GTL (Gas To Liquids)
- 2. Operation and Maintenance
  - Starting and Stopping of the Engine
    - Preparing for Start
    - Starting the Engine
    - After Starting the Engine
    - During Operation
    - Stopping the Engine
    - ECU Learning after Engine Key Off
  - Break-in Period of the Engine
    - General Information
    - Break-in Period of a New Engine
    - Check Points
    - Inspection after Starting the Engine
  - Operation in Winter
    - Cold Start
    - Preventing Coolant from Freezing.
    - Preventing Overcooling of the Engine
    - Engine Oil
  - Inspection and Repair of the Engine
    - Checking Engine Parts after Prolonged Operation
    - Inspection and Repair of Turbocharger
    - Intake Unit
    - Exhaust Unit
    - Lubrication System
  - Injection Nozzle Maintenance
    - Tips for Preventing Internal Clogging of the Injector!
- 3. Performance and Specifications
  - Engine Specifications and Performance
    - Engine Specifications
    - Engine Performance Curve (MFE00/MFE04)
    - Engine Performance Curve (MFE08)
    - Engine Performance Curve (MFE01/LEE00/LEE01)
    - Engine Performance Curve (MFE02/MFE06/LEE06)
    - Engine Performance Curve (LEE07/LEE09)
    - Engine Performance Curve (LED00/LED01/MFD00)
  - Outside Drawing of the Engine (MFE00/MFE04/MFE08)
    - Structural Diagram
    - Front View/Rear View
    - Left/Right Sectional View
    - Top/Bottom Sectional View
  - Outside Drawing of the Engine (MFE01/MFE02/LEE00/LEE01)
    - Structural Diagram
    - Front View/Rear View
    - Left/Right Sectional View
    - Top/Bottom Sectional View
  - Outside Drawing of the Engine (MFE06/LEE06)
    - Structural Diagram
    - Front View/Rear View
    - Left/Right Sectional View
    - Top/Bottom Sectional View
  - Outside Drawing of the Engine (LEE07/LEE09)
    - Structural Diagram
    - Front View/Rear View
    - Left/Right Sectional View
    - Top/Bottom Sectional View
  - Outside Drawing of the Engine (LED00/LED01/MFD00)
    - Structural Diagram
    - Front View/Rear View
    - Left/Right Sectional View
    - Top/Bottom Sectional View
  - Engine Serial Number
    - Number Engraved on Engine
    - Number Engraved on Cylinder Block
    - Piston Bore Class Engraved on Cylinder Block
    - Main Bearing Bore Class Engraved on Cylinder Block
    - Crankshaft Main Journal Engraving
    - Connecting Rod Engraving
    - Piston Engraving
    - Cylinder Head Gasket Engraving
- 4. Regular Inspections
  - General Information
    - General Information
    - Daily Inspections
  - Regular inspection Table
    - General Conditions
  - Cooling System
    - General Information
    - Amount of Antifreeze in Winter
    - Coolant Capacity
    - Checking the Coolant
    - Measuring the Coolant Concentration
    - Adding Coolant
    - Replacing Coolant
  - Lubrication System
    - General Information
    - Engine Oil Specifications
    - Engine Oil Capacity
    - Checking the Engine Oil
    - Adding Engine Oil
    - Replacing Engine Oil
  - Fuel System
    - General Information
    - Fuel Specifications
    - Injector & Fuel Return Hose
    - Fuel Filter
    - Replacing the Fuel Filter
    - Bleeding Air From the Fuel Delivery Line
    - Draining Water From the Fuel Filter
  - Intake/Exhaust System
    - General Information
    - Cleaning the Air Filter
    - Cleaning the Air Filter Element
    - Replacing the Air Filter Element
  - Other/Driving System
    - Belt Tension
- 5. General Engine Information
  - Indicating Units
    - Unit Conversion Method
  - Tightening Torque
    - Tightening Torque of Main Parts
    - Tightening Torque of General Bolts
  - Disassembling the Engine
    - Engine Disassembly Order
  - Assembling the Engine
    - Order of Engine Assembly
- 6. Cooling System
  - General Information
    - Troubleshooting
  - Coolant Pump
    - General Information
    - Removing the Coolant Pulley
    - Assembling the Coolant Pump
  - Thermostat
    - General Information
    - Removing the Thermostat
    - Assembling the Thermostat
    - Checking the Thermostat
  - Cooling Fan
    - Removing the Fan Mounting Bracket
    - Assembling the Fan Mounting Bracket
- 7. Lubrication System
  - General Information
    - General Information
    - Troubleshooting
  - Oil Pump
    - General Information
    - Disassembling the Oil Pump
    - Assembling the Oil Pump
    - Checking the Oil Pump
    - Removing the Oil Suction Pipe
    - Assembling the Oil Suction Pipe
  - Oil Cooler
    - General Information
    - Removing the Oil Filter Assembly
    - Assembling the Oil Filter Assembly
    - Checking the Oil Filter Assembly
  - Oil Pan
    - Removing the Oil Pan
    - Assembling the Oil Pan
- 8. Fuel System
  - General Information
    - General Information
  - Fuel Return Hose
    - General Information
    - Disconnecting the Fuel Return Hose
    - Assembling the Fuel Return Hose
  - Injector
    - General Information
    - Injector Operating Principles
    - Removing the Injector
    - Assembling the Injector
    - Checking the Injector
  - Common Rail
    - General Information
    - Pressure Limit Valve & Rail Pressure Sensor
    - Injection Pipe
    - Removing the Common Rail
    - Assembling the Common Rail
    - Checking the Common Rail
  - Fuel Injection Pump
    - General Information
    - Removing the Fuel Injection Pump
    - Assembling the Fuel Injection Pump
    - Removing the Fuel Injection Pump Drive Gear
    - Assembling the Fuel Injection Pump Drive Gear
- 9. Intake/Exhaust System
  - Turbocharger
    - General Information
    - Troubleshooting
    - Handling the Turbocharger
    - Removing the Turbocharger
    - Assembling the Turbocharger
    - Checking the Turbocharger
  - Intake Manifold
    - Removing the Intake Manifold
    - Assembling the Intake Manifold
  - Exhaust Manifold
    - Removing the Exhaust Manifold
    - Assembling the Exhaust Manifold
  - Throttle & the Intake Stake
    - Removing the Throttle & the Intake Stake
    - Assembling the Throttle & the Intake Stake
- 10. Cylinder Block/Head
  - General Information
    - General Information
  - Cylinder Block
    - Disassembling the Cylinder Block
    - Assembly of Cylinder Block
    - General Inspection of Cylinder Block
    - Measurement of Inside Diameter of Main Bearing Bore of Cylinder Block
    - Measurement of Inside Diameter of Piston Bore of Cylinder Block
    - Measurement of Inside Diameter of Camshaft Bearing of Cylinder Block
  - Cylinder Head
    - Disassembling the Cylinder Head
    - Assembly of Cylinder Head
    - Checking the Cylinder Head
  - Valves
    - Removing Valves
    - Assembling Valves
    - Measurement of Inside Diameter of Valve Guide
    - Measurement of Valve Stem End
    - Measurement of Valve Step Height
    - Measurement of Gap between Piston and Valve
    - Checking the Valve Spring
  - Rocker Arms
    - Disassembling the Rocker Arms
    - Assembling the Rocker Arms
    - Checking the Rocker Arms
    - Checking the Rocker Arm Shaft
  - Tappet and Push rod
    - Removing the Valve Tappet
    - Assembling the Valve Tappet
    - Checking the Valve Tappet
    - Disassembling the Push rod
    - Assembling the Push rod
    - Checking the Deflection of the Push rod
  - Camshaft
    - Removing the Camshaft
    - Assembling the Camshaft
    - Measuring the Camshaft Journal O.D.
    - Measuring the Camshaft
  - Flywheel Housing
    - Detaching the Flywheel Housing
    - Assembling the Flywheel Housing
  - Breather
    - Disconnecting the Breather Hose
    - Assembling the Breather Hose
  - Cylinder Head Cover
    - Disassembling the Cylinder Head Cover
    - Assembling the Cylinder Head Cover
  - Idle Gear
    - Removing the Idle Gear
    - Assembling the Idle Gear
    - Measuring the Outside Diameter of the Idle Gear Shaft
    - Measuring the Inside Diameter of the Idle Gear
  - Lifting Hook
    - Removing the Lifting Hooks
    - Assembling the Lifting Hook
  - Oil Seal
    - Removing the Front Oil Seal Holder
    - Assembling the Front Oil Seal Holder
- 11. Electrical System
  - Electric Parts
    - Electric Parts (MFE00/MFE04/MFE08)
    - Electric Parts (MFE01/LEE00)
    - Electric Parts (MFE02/LEE01)
    - Electric Parts (MFE06/LEE06)
    - Electric Parts (LEE07/LEE09)
    - Electric Parts (LED00/LED01/MFD00)
  - Circuit Diagram
    - General Information
    - Engine Connector
    - Engine Connector for Engine Control Unit (ECU)
  - Switches and Sensors (MFE00/MFE04/MFE08)
    - Injector#1
    - Injector#2
    - Injector#3
    - Injector#4
    - Coolant Temperature Sensor (COOLANT TEMP)
    - Crank Shaft Position Sensor (CRANK)
    - CAM Shaft Position Sensor (CAM)
    - Temperature Manifold Absolute Pressure Sensor (TMAP)
    - Oil Pressure Sensor (OIL PRES)
    - Rail Pressure Sensor (RPS)
    - Fuel Metering Unit (METERING UNIT)
    - Exhaust Gas Temperature Sensor (EGT)
    - Throttle Valve Actuator/Position Sensor
    - Glow Plug Power (GLOW PLUG)
    - Compressor
    - Fan Clutch
    - Starter Signal (START S)
    - Alternator Indicator (ALT I)
    - Inlet Air Temperature Sensor (IAT)
    - Fuel Temperature Sensor (FTS)
    - Dosing Module
  - Switches and Sensors (MFE01/MFE02/LEE00/LEE01)
    - Injector#1
    - Injector#2
    - Injector#3
    - Injector#4
    - Coolant Temperature Sensor (COOLANT TEMP)
    - Crank Shaft Position Sensor (CRANK)
    - CAM Shaft Position Sensor (CAM)
    - Temperature Manifold Absolute Pressure Sensor (TMAP)
    - Oil Pressure Sensor (OIL PRES)
    - Rail Pressure Sensor (RPS)
    - Fuel Metering Unit (METERING UNIT)
    - Exhaust Gas Temperature Sensor (EGT)
    - Throttle Valve Actuator/Position Sensor
    - Glow Plug Power (GLOW PLUG)
    - Compressor
    - Fan Clutch
    - Starter Signal (START S)
    - Alternator Indicator (ALT I)
    - Alternator B+ (ALT B)
    - Alternator Ground (ALT GND)
    - Earth
  - Switches and Sensors (MFE06/LEE06/LEE07/LEE09/LED00/LED01/MFD00)
    - Injector#1
    - Injector#2
    - Injector#3
    - Injector#4
    - Coolant Temperature Sensor (COOLANT TEMP)
    - Crank Shaft Position Sensor (CRANK)
    - CAM Shaft Position Sensor (CAM)
    - Temperature Manifold Absolute Pressure Sensor (TMAP)
    - Oil Pressure Sensor (OIL PRES)
    - Rail Pressure Sensor (RPS)
    - Fuel Metering Unit (METERING UNIT)
    - Exhaust Gas Temperature Sensor (EGT)
    - Throttle Valve Actuator/Position Sensor
    - Glow Plug Power (GLOW PLUG)
    - Compressor
    - Starter Signal (START S)
    - Alternator Indicator (ALT I)
    - Engine Earth
    - Fan Clutch
  - Wire Harness
    - Removing the Wire Harness
    - Assembling the Wire Harness
  - Engine Control Unit (ECU)
    - General Information
    - Engine Control Unit (ECU) Connector
    - Engine Control Unit (ECU) Input/Output
    - Engine Control Unit (ECU) Operating Conditions
  - Starter
    - General Information
    - Specifications
    - Circuit Diagram
    - Starter Motor Performance Curve
    - Removing the Starter Motor
    - Assembling the Starter Motor
  - Alternator (MFE00/MFE04/MFE08)
    - General Information
    - Wiring Diagram
    - Disassembly of Alternator
    - Assembly of Alternator
- 12. Other/Driving System
  - General Information
    - General Information
    - Specifications
  - Crankshaft
    - Removing the Crankshaft
    - Assembling the Crankshaft
    - Measuring the Diameter of the Crankshaft Main Journal
    - Measuring the Crankshaft Bearing Clearance
    - Measuring the Deflection of the Crankshaft
    - Disassembling the Timing Wheel
    - Assembling the Timing Wheel
  - Piston
    - Disassembling the Pistons
    - Assembling the Pistons
    - Measuring the Inside Diameter of the Piston Pin Bore in Pistons
    - Measuring the Step Height of the Piston Top Side
    - Measuring the Piston Ring End Gap
    - Measuring the Outside Diameter of the Piston Pin
  - Connecting Rod
    - Disconnecting the Connecting Rod
    - Assembling the Connecting Rod
    - Measuring the Inside Diameter of the Connecting Rod Small End
    - Measuring the Inside Diameter of the Connecting Rod Big End
    - Measuring the Connecting Rod Big End Clearance
  - Crankshaft Pulley
    - Removing the Crankshaft Pulley
    - Assembling the Crankshaft Pulley
  - Others
    - Engine Timing
    - Adjusting the Engine Timing
    - Checking the Gear Backlash
    - Checking the Axial Play of Gears
- 13. Aftertreatment System
  - Exhaust Gas Reduction System (Tier-4 Final)
    - General Instructions
    - Aftertreatment
  - Exhaust Gas Reduction System (Stage-V)
    - General Instructions
    - Aftertreatment
    - DNOX 2.2 EVO System
    - DEF Tank
    - Supply Module
    - Dosing Module
    - Replacing the DEF Filter
    - Components of the DNOX 2.2 EVO System
    - Inspecting the DNOX 2.2 EVO System for Faults
    - DEF (Diesel Exhaust Fluid, Urea)
    - Diesel Oxidation Catalyst (DOC)
    - Diesel Particulate Filter (DPF)
    - Cautions for Handling the SDPF Assembly
    - Removing SDPF Ash and Cleaning DPF