Introduces Removaland Installation of Perkins 2806F Engine Electronic Unit Injector Sleeve

      This article mainly introduces Removaland Installation of Perkins 2806F Engine Electronic Unit Injector Sleeve

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Start By:
a. Remove the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Remove” for the correct procedure.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Drain the coolant from the engine. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

2. Install Tooling (A) in electronic unit injector sleeve
(1).
3. Tighten the nut on Tooling (A) until electronic unit
injector sleeve (1) is pulled free of the cylinder
head.
4. Remove O-ring seals (2) and O-ring seal (3) from
Installation Procedure

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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (B) to clean the bore in the cylinder
head for the electronic unit injector sleeve.
NOTICE
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
sealant debris.
 

NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Use Tooling (B) to clean the bore in the cylinder
head for the electronic unit injector sleeve.
NOTICE
Ensure that the electronic unit injector sleeve and the
cylinder head bore are completely free of oil, dirt, and
sealant debris.

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2. Install new O-ring seals (2) and a new O-ring seal
(3) to electronic unit injector sleeve (1).
Note: Do not apply Tooling (C) to the cylinder head
surfaces. Apply Tooling (C) to the electronic unit
injector sleeve only.
3. Apply a small continuous bead of Tooling (C) to
Surface (X) of electronic unit injector sleeve (1).
4. Lubricate O-ring seals (2) with clean engine oil.
5. Position Tooling (A) and the electronic unit injector
sleeve in the cylinder head. Use care not to
damage the O-ring seals on the electronic unit
injector sleeve.
6. Use Tooling (A) to install electronic unit injector
sleeve (1) in the cylinder head.
Note: Ensure that the electronic unit injector sleeve
is correctly seated into the cylinder head.
7. Remove Tooling (A). Use a clean towel and
remove excess Tooling (C).
8. Fill the cooling system with coolant. Refer to
Operation and Maintenance, “Refill Capacities” for
the cooling system capacity.
End By:
a. Install the electronic unit injectors. Refer to
Disassembly and Assembly, “Electronic Unit
Injector - Install”.

Introduces How to Remove and Install Perkins 2806F Engine v>Exhaust Cooler (NRS) l

       This paper mainly introduces how to Remove  and  Install Perkins 2806F Engine v>Exhaust Cooler (NRS) l

 

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Removal Procedure
Sulfuric Acid Burn Hazard may cause serious
personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.
1. Drain the coolant from the cooling system into a
suitable container for storage or for disposal. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct
procedure.

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2. x
M0070446 23
Disassembly and Assembly Section
Remove bolt (1) from clamp (2). Remove the
clamp and bolts from tube assembly (10).
3. Remove bolt (7) from clip (6). Remove the clip
from tube assembly (10).
4. Remove bolt (14) from clip (15). Remove the clip
from tube assembly (10).
5. Remove bolt (11) from elbow (12). Remove tube
assembly (10) and the elbow from NOx Reduction
System (NRS) exhaust cooler (16) and the water
temperature regulator housing. Remove O-ring
seal (3) (not shown) from the tube assembly.
6. Remove O-ring seal (13) (not shown) from elbow
(12).
7. Loosen hose clamp (5) for hose assembly (4).
8. Sufficiently loosen V-band clamp (9) and remove
tube assembly (8).
9. Remove bolts (23) and bolts (26). Remove elbow
(24), tube assembly (25), and elbow (26) from the
engine oil cooler and NRS exhaust cooler (16).
10. Remove elbow (24) from tube assembly (25).
Remove the tube assembly from elbow (26).
11. Remove O-ring seal (22) (not shown) and O-ring
seal (28) (not shown).
12. Attach a suitable lifting equipment onto NRS
exhaust cooler (16) and support the weight. The
weight of NRS exhaust cooler (16) is
approximately 18 kg (40 lb).
13. Sufficiently loosen V-band clamp (17) and V-band
clamp (19) to allow exhaust bellows (18) to be
removed.
14. Remove bolts (20), clamps (21), and bracket
(16a) from NRS exhaust cooler (16).
15. Use the lifting device to remove NRS exhaust
cooler (16) from the bracket.
16. Remove V-band clamp (17), V-band clamp (19),
and allow exhaust bellows (18)

1. Ensure all components of the NRS exhaust cooler,
tube assemblies are free from wear, damage, and
restriction. Replace any component that is worn,
damaged, or not free from restriction

2. Ensure that clamps (21) are correctly assembled
   with the rounded edges of clamp spacers are
   oriented. Refer to Illustration 36 for the orientation.
3. Attach a suitable lifting equipment onto NRS
  exhaust cooler (16). The weight of NRS exhaust
  cooler (16) is approximately 18 kg (40 lb).
4. Apply Tooling (A) threads of new V-band clamp
  (17) and new V-band clamp (19).
5. Install V-band clamp (17) and a new exhaust
  bellows (18). Ensure that the V-band clamp is
  correctly orientated and the bellows and V-band
  clamp is correctly seated onto the exhaust
  manifold.
6. Loosely install V-band clamp (19) onto exhaust
  bellows (18).
7. Use the lifting device to install NRS exhaust cooler
  (16) onto the bracket. Ensure that V-band clamp
  (19) and exhaust bellows (18) are correctly seated
   onto the NRS exhaust cooler.
8. Install bracket (16a) and loosely install new clamps
   (21) and bolts (20) to NRS exhaust cooler (16).
9. Apply Tooling (B) to both ends of tube assembly
   (25). Install the tube assembly to elbow (24) and
   elbow (26). Ensure that the elbows are correctly
   orientated.
10. Install a new O-ring seal (22) (not shown) and a
   new O-ring seal (28) (not shown) to the engine oil
   cooler and NRS exhaust cooler (16). Ensure that
   the O-ring seals are correctly seated into the
   recesses of the engine oil cooler and the NRS
   exhaust cooler
11. Position the assembly of elbow (24), tube
   assembly (25), and elbow (26) onto engine oil
   cooler and NRS exhaust cooler (16).
12. Install bolts (23) and bolts (26) to the assembly of
   elbow (24), tube assembly (25), and elbow (26).
   Hand tighten the bolts.
13. Install tube assembly (8) and V-band clamp (9).
   Hand tighten the V-band clamp. Tighten hose
   clamp (5) for hose assembly (4).
14. Install a new O-ring seal (13) (not shown) to
   elbow (12). Install a new O-ring seal (3) (not
   shown) to tube assembly (10).
15. Install tube assembly (10) and the elbow to NRS
   exhaust cooler (16) and the water temperature
   regulator housing. Install bolt (11) to the elbow.
   Install clamp (2) and bolt (1).
16. Install clip (6) and bolt (7) to tube assembly (10).
   Hand tighten the bolt.
17. Install clip (15) and bolt (14) to tube assembly
   (10). Hand tighten the bolt.

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Illustration 37 g06071264
Bolt (1)
Hose clamp (5)
Bolt (7)
V-band clamp (9)
Bolts (11)
Bolt (14)
V-band clamp (17) and V-band clamp (19)
Bolts (20) for the NRS cooler clamps
Bolts (11)
18. Ensure that NRS exhaust cooler (16) is
correctly aligned with the exhaust bellows (18)
before tightening bolts (20) for clamps (21).
19. Follow Step 19.a through Step 19.h to tighten the
bolts and the V-band clamps as listed in Illustration
37 .
a. Tighten bolts (20) to a torque of 40 N·m
 (30 lb ft).
b. Tighten V-band clamp (9) to a torque of 7.5 N·m
 (66 lb in).
c. Tighten hose clamp () to a torque of 7.5 N·m
 (66 lb in).
d. Tighten bolts (11) to a torque of 12 N·m
 (106 lb in)
e. Tighten bolt (1) to a torque of 47 N·m (35 lb ft).
f. Tighten bolts (14) to a torque of 25 N·m
 (221 lb in).
g. Tighten bolt (7) to a torque of 47 N·m (35 lb ft).
h. Tighten V-band clamp (17) and V-band clamp
 (19) to a torque of 7.5 N·m (66 lb in).
20. Fill the cooling system. Refer to Operation and
 Maintenance Manual, “Cooling System Coolant -
 Change” for the correct procedure.

 

Doosan DL220 Power Steering System DISASSEMBLY

  This article introduces Doosan DL220 Power Steering System DISASSEMBLY

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  It is very important to keep the inside of the steering unit clean.

Make sure that the outside of the steering unit is clean before
opening the unit. Use a wire brush and solvent to clean the
entire unit.
1. Remove steering column from steering unit. Bolt steering
unit to stabilizing base. Bolt base to work bench.
2. Remove bolts from steering unit end cover. See Figure 30.

3. Remove end cover from unit. See Figure 31.

4. Lift cylinder gear off unit. See Figure 32. Remove two Orings.

5. Remove spacer bushing and spacer from cylinder gear (If
equipped). See Figure 33.
NOTE: Refer to parts manual for our unit to determine if
these parts are installed.

6. Remove shaft from housing. See Figure 34.

7. Remove distributor plate from housing. See Figure 35.

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8. Remove O-ring from top of middle plate. See Figure 36.

9. Lift middle plate off housing. See Figure 37.

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10. Remove O-ring from housing. See Figure 38.

11. Unscrew threaded bushing and remove it. See Figure 39.

12. Remove cross pin. See Figure 40

13. Shake ball out of housing. See Figure 41.

14. Pull sleeve and spool out of housing. See Figure 42.

15. Remove thrust bearing and thrust washers from sleeve.
See Figure 43. Remove spacer ring. Be sure to remove
spacer ring. It can stick in sleeve.

16. Carefully slide control spool out of sleeve. See Figure 44.

17. Push neutral position springs out of groove in spool. See
Figure 45.

18. Remove dust seal from housing. See Figure 46. Remove

O-ring and backup ring from inside housing.

19. Figure 47, shows all parts removed from steering unit.
Clean all parts before assembly. Use only new O-rings and

seals. 

Installation of Fuel Pump for Isuzu 4JJ1 Euro 4n Series Engine

This article mainly introduces the Installation the Isuzu engine oil pump

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Installation
1. Install the O-ring to the supply pump.
· Apply soapy water to the O-ring.
2. Install the supply pump.
a. Install the space rubber A (4) to the cylinder block.
b. Insert the space rubber B(2) into the supply pump bracket(3).
c. Install the supply pump bracket (3) in the following sequence.
1. Temporarily tighten the nuts and bolt on the gear case side until they are firmly attached to the gear case.
2. Temporarily tighten the bolts on the cylinder block side until they are firmly attached to the cylinder block.
3. Tighten the nuts and bolt on the gear case side to the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lbft)
4. Tighten the bolts on the cylinder block side to the specified torque.
Tightening torque:25 N.m(2.5kg-m/18 lb-ft) NOTE:
· Do not hold the high pressure pipe of the pump instead of the handle when installing the supply pump.
· Make sure the O-ring is not protruding.

b. Confirm that the supply pump gear and the main gear (3) of the idle gear A are engaged. Push in the supply pump gear with the supplypump gear engaged with the sub gear(4) of the idle gear A

5. Install the timing chain and the supply pump sprocket.
a. Align the alignment mark (1) of the idle gear D and the blue plate(2) of the timing chain.
b. Align the alignment mark (3) of the supplypump sprocket and the yellow plate(4) of the timing chain.
c. Align the dowel pin of the supply pump gearand the notch of the supply pump sprocket, and install the supply pump sprocket.
d. Tighten the supply pump shaft nut with your hand.

8. Install the timing chain tensioner (2), gasket(3).
and oll feed pipe (1) and tighten at the specified torque.
Timing chain tensioner Tightening torque:
10N-m(1.0kg-m/87 lb-ft)
Oil feed pipe Tightening torque:
15N.m(1.5kg-m/11 lbt)

9. Remove the hook of the tensioner.
· Lightly push the area indicated with an arrow in the diagram.
The hook of the tensioner is removed, the plunger pushes the tension lever, and the chain is pulled.

10 tghten the supply pump shaft nut(1) at the specified torque.
Tightening torque:130 N-m(13.3kgm/96 b-t)

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11. Tighten the timing chain lever pivot at the specified torque.
Tightening torque:27 N-m(2.8 kg-m/20 lb-t)
12. Turm the crankshaft pulley 720°(two revolutions)
to make the tension in the chain even.
13. Align the alignment mark(1) of the camshaft bearing cap and the camshaft.

14. Install the cylinder head cover.
Refer to "Cylinder Head Cover"in Section 1B, Engine Mechanical.
15. Apply liquid gasket(TB-1207C or equivalent) to upper timing chain cover(1).
· After applying the liquid gasket, install the cover within five minutes.

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Legend
1. Lower chain cover
2. Bolt
3. Nut
19. Connect the camshaft position sensor connector
(1) and the engine coolant temperature sensor connector(2).
· Fasten the engine coolant temperature sensor connector harness to the connector with a clip
(3).

LNWA18SH30400120. Connect the fuel temperature sensor harness connector(1) and suction control valve harness connector(2).

21. Install the common rail.
Refer to "Common Rail"in this Section,
22. Install the A/C compressor bracket, and tighten at the specified torque.
Tightening torque:25N-m (2.5kg-m/18 lb-ft)
23. Install the A/C compressor adjust pulley, and tighten at the specified torque.
Bolt tightening torque:25N.m(2.5kg-m/18 lb-ft) Nut tightening torque:25 N-m(2.5kg-m/18 Ib-ft)

24. Install the A/C compressor.
· Install the A/C compressor, and tighten at the specified torque.
Tghtening torque:25 N-m(2.5kg-m/18 Ib-ft)
· Install the drive belt and adjust its tension using the adjust bolt of the tension pulley.
· Refer to "Drive Belt"in Section 1C, Engine Cooling
25. Install the engine oil level gauge guide tube, and tighten it at the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lb-A)
26. Install the left side fan guide bracket.
Refer to "Water Pump"in Section 1C, Engine Cooling.
27. Install the engine cover.
Tghtening torque:25 N-m(2.5 kg-m/18 lb-t)
28. Install the left side noise cover.
29. Install the dropping register harness connector.
30. Install the air cleaner outlet duct.
31. Install the radiator upper hose.
· Tighten radiator hose clip.
Tightening torque:5 N-m(0.5kgm/43 lb-in)32. Install the air intake duct and hose.
NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.

· Install the duct and hose between the intake throttle valve and intercooler.
· Use a new hose clamp, align it with the marking.
Tghtening torque:8 N.m(0.8 kg-m/69 lbin)

33. Connect the connector of the boost sensor.
34. Refl the coolant.
Supply Pump Relearn
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Fuel Supply Pump Learn Reseting with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter with the scan tool. Confirm the scan tool indicates Not Learned.
5. Start the engine and let idle until engine coolant temperature reads 20℃ (68F) or higher while observing the Fuel Supply Pump Status parameter with a scan tool. The scan tool parameter changes status Not Learned>Learned.

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