How to Solve the Problem of Black Smoke From the Doosan Excavator X120 Engine

 This article mainly introduces how to solve the problem of black smoke from the Doosan excavator X120 engine.

 

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                                             Fault description

  1. The engine has obvious black smoke when under heavy load. 2. There

 are no alarms or fault codes on the instrument panel  

 

 

Failure cause analysis  

1. Check whether the air filter element, oil-water separator, and fuel 

 

                   fine filter have exceeded the maintenance period or are dirty and need to be maintained in 

 

  advance. 

                2. Since there is no fault code, it is basically judged to be a mechanical failure, and 

 

                   the cylinder cutoff test is carried out by cutting off the oil (a special high-pressure common

 rail plug is required) 

 3. When the fuel injector of the 2nd cylinder is cut off, the black 

 

smoke is significantly reduced, so it can be judged that the 2nd cylinder injector is faulty. 

 

                  4.  After replacing the 2-cylinder injector, the equipment operates normally.  

 

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in conclusion 

 1. Due to the abnormal wear of the 2-cylinder injector, the fuel injection volume becomes 

larger, the atomization is poor, the combustion is insufficient, and the engine emits black smoke.

 

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How to Disassemble the Fuel System and ECM Cooling Plate of Cummins M11 Series Engine

 This article mainly introduces how to disassemble the Cummins M11 series engine fuel system and ECM cooling plate

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(1) Install the engine on the bench 

 ①Use the engine overhaul bench (Part No. 3375194) and the connecting plate (Part No. 3376432), and install the connecting disk to the overhaul bench with 5 bolts with a part number of 5/8-11 ?in. The tightening torque is 180N. , see Figure 2-43. 

 ② Install two guide pins (part number 3376488) at the screw holes 1 and 2 of the water channel cover, and use a lifting device to install the engine on the connecting plate of the bench, see Figure 2-44.  

 

 

 

 

③ Use 8 bolts (Part No. 3376434) to fix the connecting plate and the cylinder block together. The tightening torque is 47N, see Figure 2-45. ④ Remove the lifting lugs on the engine block, see Figure 2-46.

 

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⑤ Remove the fan hub bracket, see Figure 2-47. (2) Disassembly of fuel system components 

 ① Remove the fuel supply hose and fuel filter seat, see Figure 2-48.

 

② Remove the fuel supply pipe and return pipe from the cylinder head, and remove the fuel gear pump cooling pipe, see Figure 2-49. 

 ③ Remove the actuator wiring harness from the fuel pump fuel cut-off valve and label the wires for easy identification, see Figure 2-50.

 

 

3—Cooling Officer 

 ④ Remove the 4 mounting bolts, fuel pump, sealing gasket and star coupling connected to the fuel pump, see Figure 2-51. 

 ⑤ Remove the inspection hole cover and sealing gasket on the fuel pump side, see Figure 2-52.

  

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  (3) Removal of ECM and ECM cooling plate  

① If an atmospheric pressure sensor is installed on the engine, remove the atmospheric pressure sensor and connecting wires from the front bracket of the ECM, see Figure 2-53. 

 ② Remove the wire harness clamps from positions 1 and 2 on the ECM bracket, loosen the AMP connector mounting bolts on the sensor wire harness, and remove the actuator wire harness and sensor wire harness from the ECM, see Figure 2-54. 

 ③ Remove the ECM mounting bolts, star washer and ECM, see Figure 2-55. 

 ④ Remove the 4 fixing bolts, ECM cooling plate and mounting bracket, see Figure 2-56.

 

How to Remove Cummins M11 Engine thermostat, Torque converter cooling plate, oil cooler and oil filter

 This article mainly introduces how to remove the Cummins M11 engine thermostat, torque converter cooling 

plate, oil cooler and oil filter  

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① Loosen the coolant hose clamp, and remove the 4 bolts, thermostat housing and thermostat, see 

Figure 2-28. 

 

② The torque converter cooling plate restricts the flow of coolant through the thermostat housing to the

 water pump bypass hose. This allows the coolant to circulate through the remotely mounted torque 

converter oil cooler. Remove the torque converter cooling plate between the thermostat housing and 

the 

water pump bypass hose joint, see Figure 2-29.

 

 

③ Remove the 4 bolts between the oil cooler and the thermostat housing bracket flange, and remove 

the 

4 bolts between the oil cooler and the oil filter seat, the oil cooler and the sealing gasket, see Figure 2

  -30, and remove the oil cooler water inlet pipe, water outlet pipe and mounting flange.

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④ Remove the Jacobs@ engine brake oil supply pipe, and remove the turbocharger oil return pipe bracket mounting bolts, see Figure 2-31

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⑤ Remove 9 bolts, oil filter seat and sealing gasket, see Figure 2-32. Remove the supercharger oil return pipe from the cylinder block.

 

How to Deal with the Alarm and Speed limit of 1400RPM when the Doosan Excavator Engine is Working

This article mainly introduces how to deal with the problem of alarm and speed limit of 1400RPM when the doosan excavator engine is working.

 

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Fault phenomenon:

An alarm occurs during engine operation and the speed is limited to 1400RPM. 

 Inspection Method: 

 1) The vehicle has been working for 2200 hours, the equipment speed limit is 1400rpm, and the fault code retrieved is P1251: fuel balance leakage;

2) Check that the low-pressure oil line pressure is 70kpa, which is on the low side (normally around 90kpa); after cleaning the oil-water separator, the low-pressure pressure has increased, but the fault still occurs from time to time;

3) After low-pressure inspection, check the high-pressure system, connect the software to perform cylinder disconnection test and crankshaft acceleration test. There is no obvious abnormality in the working status of each cylinder;

4) Check that the resistance of the IMV valve is 3.2 ohms and is normal. Since the IMV valve is easy to disassemble, the 2018-04-27 13:49 Wang Xiaobo IMVi valve was replaced first and tested. After replacement, the equipment works normally.  

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When the P1251 fault code occurs in the engine, the casing should be arranged from simple to difficult. First, check the low-pressure fuel oil line, and then conduct troubleshooting of the high-pressure well rail system.

 

How to Disassemble the Exhaust Manifold and Intake Manifold of Cummins M11 Series Engine

 This Article explains how to disassemble the exhaust manifold and intake manifold of a Cummins M11 series engine.

 

① The exhaust manifold assembly consists of three sections. When disassembling, remove a bolt from 

the end of each section and then install two guide pins. (Part No. 3376488), remove the remaining bolts, 

and then remove the exhaust manifold, see Figure 2-25. 

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  ② Remove the intake manifold pressure sensor and temperature sensor wire connectors from the 

intake manifold, see Figure 2-26. 

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 ③ Remove the intake manifold joint and gasket from the top of the intake manifold, remove the two 

mounting bolts, and install the two guide pins (Part No. 3376488), remove the remaining bolts, and 

install the lifting frame to the rocker arm chamber shell with 4 M10 × 25 bolts. The tightening torque is

 47N·m, see Figure 2-27.

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How to Replace a Cummins B Series Engines Water Pump

    
How to Replace a Cummins B Series Engines Water Pump

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A Preparatory Steps:
Drain the coolant.

Remove the drive belt.
Remove the two capscrews and water pump, and com-plete the following steps.

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B Clean the sealing surface on the cylinder block.

C  Install the new sealing ring into the pump groove.

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Install the water pump.Torque Value: 24 Nom [18 ft-lb]

How to Remove Cummins M11 Turbocharger and Oil Return Pipe

This article mainly introduces how to disassemble the Cummins M11 turbocharger and the oil return pipe.

 

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  ① Remove the oil supply pipe and sealing gasket from the top of the turbocharger, remove the other end 

 

of the oil supply pipe from the oil filter seat, and then remove the oil return pipe and sealing gasket from 

 

the bottom of the turbocharger, see Figure 2-22. 

 

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 ② Remove the V-shaped clamp, exhaust elbow and O-ring from the exhaust port of the turbocharger 

 

compressor, remove 4 mounting nuts, remove the turbocharger and gasket, and block the supercharger

 

  For 

 

the oil supply hole and oil return hole, see Figure 2-23. 

 

 

③ Remove the turbocharger oil return pipe joint, see Figure 2-24.

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