Page 1 SB4391E00 Aug. 2012 DL06 Diesel Engine (interim Tier Ⅳ) Specification System Operation Testing & Adjusting Disassembly & Assembly D110S-5, D130S-5, D160S-5...
Page 3 The DL06K industrial electronic control diesel engine is designed and manufactured to satisfy all requirements, such as low noise, economical power consumption, high-speed, and durability by applying DOOSAN's latest technologies in order to provide the best engine to its customers, and meet interim Tier-4 emission regulation.
Page 4 DL06K Interim Tire-4 Diesel Engine Foreword...
Page 5 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
Page 6 DL06K Interim Tire-4 Diesel Engine Important Safety information...
Page 7: Table Of Contents
INDEX 1. Safety Regulations & 5. Maintenance of Major Components Specifications......... 8 ............174 1.1. Safety Regulations ........ 8 5.1. Cooling System ......... 174 1.2. Engine Specifications ......13 5.2. Lubrication system ......178 1.3. Engine Power ........14 5.3. Turbo Charger ........181 1.4.
Page 8 DL06K Interim Tire-4 Diesel Engine Index...
Page 9 If any part needs to be replaced, the genuine part supplied by DOOSAN and specified in the Parts Book should be used. Use of uncertified, similar parts, or recycled parts may cause serious damage to the engine. If such a part is used, DOOSAN will bear no responsibility.
Page 10: Safety Regulations & Specifications
(1) Engine starting and operation Please read "Caution" in the manual carefully before starting an engine. If you don't understand anything, please contact Doosan. Please attach the "Authorized personnel only" warning sign on the engine for safety, and remind the engine driver that the driver is responsible for safety in the engine room.
Page 11 CAUTION: Do not replace or disassemble pipes or hoses (engine fuel circuit, engine oil circuit, coolant circuit, and compressed air circuit) while the engine is running. Fluid spattering may cause injury. Check the amount of oil in the oil pan, and use a container large enough to hold engine oil when replacing it.
Page 12 (3) Please use genuine spare and maintenance parts recommended by DOOSAN. DOOSAN will bear no responsibility for damage due to the use of unauthorized parts. (4) Keep the following points in mind, in addition to the above instructions.
Page 13 1.1.4. To prevent pollution (1) Engine oil filter elements, fuel filters Pour used oil into the oil collection drum. Pay special attention not to spill oil on the ground or into the ocean. Leaked oil can pollute sources of drinking water. Separate oil and oil filter cartridge as wastes of environmental pollution, and dispose them according to the prescribed regulations.
Page 14 4. It is recommended to use the proper tools and special tools for maintenance of the specified parts, considering efficiency and reliability of the maintenance work. 5. Make sure to use the genuine Doosan replacement parts. 6. Use the new cotter pin, gasket, O-ring, sealing, oil seal, lock washer, and self lock nut when maintaining these parts.
Page 15: Engine Specifications
1.2. Engine Specifications DL06K Engine model Items LDF00/LDF01 Water-cooled, 4 cycle, In-line, Engine type Turbo charged & inter-cooled Combustion chamber type Direct injection type Cylinder liner type Replaceable dry liner Timing gear system Gear driven type No. of piston ring 2 compression ring, 1 oil ring 6 –...
Page 16: Engine Power
DL06K Engine model Items LDF00/LDF01 Type Wax pallet type Open at (°C) Thermostat Open wide at (°C) Valve lift (mm) Water temperature indicator Water temperature sensor mounted Turbo charger Exhaust gas driven type Engine stop system Fuel feeding shut-off by ECU Alternator (voltage –...
Page 17: Engine Performance Curve
1.4. Engine Performance Curve 1.4.1. Performance curve DL06 – LDF00 1000 1500 2000 Revolution EL4OM001 Performance KS-R 1004 Output (rating) 140 PS / 2,100 rpm 65 kgf·m / 1,400 rpm Torque (max) DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications...
Page 18 DL06 – LDF01 1000 1500 2000 Revolution EL4OM002 Performance KS-R 1004 Output (rating) 160PS / 2,100 rpm Torque (max) 74 kgf·m / 1,400 rpm DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications...
Page 19: Engine Assembly
1.5. Engine Assembly 1.5.1. Sectional drawing EL4OM003 Cooling water pump Cylinder head Thermostat Vibration damper Exhaust valve Oil pan Intake valve Oil suction pipe Piston Connecting rod Cylinder head cover Camshaft Intermediate cover Tappet DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications...
Page 20 1.5.2. Sectional drawing EL4OM004 Fuel filter Cylinder block Oil spray nozzle Cylinder liner Oil cooler Crankshaft Caliper Oil level gauge Rocker arm Oil drain valve Fuel high pressure connector Oil pump Fuel high pressure pipe DL06K Interim Tire-4 Diesel Engine Safety Regulations &...
Page 21 1.5.3. Engine assembly (1) DL06K EL4OM006 Flywheel housing Mounting bracket Breather Cooling water pump Breather pipe Water outlet pipe Exhaust manifold Intake manifold Oil filter cap Air heater EGR cooler Throttle valve Turbo charger Starting motor Alternator Air compressor DL06K Interim Tire-4 Diesel Engine Safety Regulations &...
Page 22: Technical Information
Engine model and serial number The serial number is required for (Cylinder block) the warranty or parts ordering. EK3OM010 Engine serial No. (Example 1 : DL06-LDF00) DL06K 140 2 0001 Main type specification Serial no Production year (2012) Power Engine model Engine serial No.
Page 23: Diagnostic Tool
2.2. Diagnostic tool Electrical problems in vehicles mounted with the DL06K engine can be checked conveniently, using a laptop computer. IB3O302I 1) Diagnostic by laptop computer Please see the Fault Diagnosis Device Manual for more details on how to use a fault diagnosis device.
Page 24 2.3.1. Cylinder block The cylinder block is made of single alloy cast iron, and put under the crankshaft axis line to increase strength. In addition, the cylinder liner can be replaced with a dry one. The cylinder head is built-in. 2.3.2.
Page 25 2.3.3. Electric control unit : ECU The ECU is used to supply fuel. The ECU is connected to various types of sensors, and controls the engine with the value set in these sensors for optimal operation. CAUTION: Electronic Control Unit (ECU) EK1OM012 Make sure to disconnect the ground wire of the battery cable before removing the connector of the ECU.
Page 26 2.3.6. Injector and high pressure connector Be careful not to put any foreign objects inside the injector and High pressure fuel Injector harness connector nut connector high pressure connector when O-ring performing disassembly Injector maintenance. O-rings and cooper washers should be replaced with new one, Seal ring when reassembling the engine.
Page 27 2.3.8. Emission reduction system Tier4 Interim DL06K engine has both oxidation catalyst system and exhaust reduction system as an emission reduction system. Operating principle : The oxidation catalyst system reduces HC and CO in exhaust gas and induces DBF temperature increase during HC injection to regenerate exhaust particles in DPF and reduce exhaust.
Page 28 2.3.9. Exhaust gas recirculation (EGR) To reduce exhaust gas, the EGR (Exhaust Gas Recirculation) circulates some of exhaust gas combusted in the engine to the intake side, and supplies it to the engine after cooling for re-combustion to reduce NOx emission amount. Operating principle : To reduce NOx exhaust gas amount emitted from the engine, the exhaust gas that contains almost no oxygen is circulated to the intake side, so that concentration of oxygen supplied to the engine can be reduced for the...
Page 29 2.3.10. Engine timing Camshaft, oil pump, fuel high pressure pump are driven by gear connection inside the engine flywheel housing. EK4OM009 2.3.11. Valve The overhead valve is operated by the valve tappet, push rod, and rocker arm on the camshaft. DL06K Interim Tire-4 Diesel Engine Technical Information...
Page 30 2.3.12. Lubrication system The engine runs with the forced lubrication system. Oil pressure is generated and supplied by gear revolution of the oil pump, which is meshed directly with the crankshaft located at the rear side of the cylinder block. The oil pump sends oil sucked by the oil pan with the intake pipe via the oil filter and oil cooler.
Page 31 The following oils are also recommended. Manufacture Engine oil SAE No. API No. Enterprise ACEA-E5 Genuine oil SAE 15W40 Kixx DX Euro (API CI-4) DL06K SK : ZIC XQ5000 ACEA-E5 Recommended oil SAE 15W40 Shell : Rimula R4L (API CI-4) 15W40 Engine oil capacity Engine oil capacity...
Page 32 Oil filter & cooler 2.3.14. The oil cooler is composed of flat tubes and cooled down by cooling water Check oil pressure and oil leak, and Oil cooler repair or replace the oil filter, if necessary. Replace the oil filter cartridge each Oil filter time you replace engine oil.
Page 33 2.3.18. Recommended fuel The fuel quality is very important for satisfactory engine performance, engine life extension, and complying with the allowable exhaust gas level. Doosan engines are designed to use diesel fuel sold in the market. Please use proper fuel by referring to the following fuel selection table, in order to obtain the optimal engine performance.
Page 34 2.3.19. Inter cooler The air cooling method is used for the inter cooler, and the sufficient cooling capacity is provided. The life and performance of the inter cooler heavily depends on the intake air conditions. Dirty air pollutes and blocks inter cooler fins. As a result, it drops the engine output and cause engine failure.
Page 35 2.3.20. Turbo charger No special maintenance is required for the turbo charger. Each time you replace engine oil, you should also check the leak or blocking of the oil pipe. The air filter should be managed carefully, so that no foreign object goes into the filter.
Page 36 2.3.21. Cooling system Cooling water is used to cool down the engine. The cooling water pump is driven by the belt. The impeller type pump is used that doesn't require maintenance. Check the cooling water level by opening the cooling water cap of the expansion tank, and refill cooling water, if necessary.
Page 37 Viscosity of antifreeze and anticorrosive agent can be check with cooling water check paper. (Fleet card number: CC2602M or Doosan number: 60.99901-0038) Cooling water concentration measurement method (1) When cooling water temperature is between 10 and 55 °C, drain cooling water and fill the plastic cup by half.
Page 38 CAUTION : Do not measure longer than 75 seconds. If the test takes longer, the color will be changed. Test paper discriminance Test paper a) Compare glycol/freeze point (end pad) in the table with the test paper color. b) Compare molybdate (middle pad) in the table with the test paper color. c) Lastly, compare nitrite in the table with the test paper color.
Page 39 CAUTION: If the color is different when compared, find the lower number column. (e.g. If the color of "c" section in the test paper is between D and F of the standard color table (nitrite), select the position E.) CAUTION : To prevent internal corrosion of the engine cooling system, drain cooling water every year and replace with new cooling water.
Page 40 2.3.24. Valve clearance adjust procedure Rotate the crankshaft to make #1 cylinder piston to reach the compression TDC (top dead center) and then, adjust the valve clearance. Unfasten the rocker arm fixing nut and insert the clearance gauge between rocker arm and valve and then, adjust each clearance with adjusting screw and fasten the fixing nut.
Page 41 The cylinder that the cooling fan is assembled is the cylinder number 1. Intake valve Cylinder no. Cooling fan Exhaust valve Flywheel Valve clearance adjusting position EK4OM014 Adjusting of valves (Type 1) Cylinder no. Intake Exhaust Intake Exhaust Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Valve adjusting #1 cylinder top dead center (#6 cylinder valve overlap)
Page 42 2.3.25. Cylinder compression pressure Warm up and stop the engine. Injector Remove the injector fixing bracket and fuel high pressure connector, and Fuel high pressure connector Fixing bracket injector. Install the special tool (compression pressure gauge) at the injector installation hole, and insert the EG9OM173 compression pressure gauge to the hole.
Page 43 2.3.27. Starting motor The starter motor is installed at the rear side of the left flywheel housing (seen from the flywheel side). When disassembling the engine, soak the starter motor pinion gear and ring gear into fuel and clear with brushes. Then, apply grease to prevent corrosion.
Page 44: Diagnosis And Remedy
2.4. Diagnosis and Remedy The following description summarizes the probable cause of and remedy for general failure by item. Inspect the electrical parts problem with diagnostic tools and refer diagnostic manual. Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
Page 45 2. Engine overheated Operating state 1. Overload Cooling system 2. Radiator core clogged Check coolant level Normal Too low Check fan belt tension, Inspect cooling water leakage wear or damage etc. Normal Repair Normal External Internal Replace Retighten Engine disassembly Replace Check fresh radiator tank cap Normal...
Page 46 3. Output insufficient Chassis Engine Inspect by SCAN-200 diagnostic tool Check for clutch slip Adjust or replace clutch Others Check for air mixing in fuel Inspect air cleaner Inspect fuel supply pump Repair Normal Normal Polluted Inspect air leakage Replace of air piping line Repair Check valve clearance...
Page 47 4. Oil pressure lowered Check if oil pressure gauge indicates wrongly Check oil amount To low Normal Use recommended oil Check cooling (replenish) temperature Too high Normal Refer to engine overheat Inspect oil quality Normal Check oil Water mixed in oil Improper relief valve Disassemble engine...
Page 48 5. Fuel consumption excessive Case according to use conditions 1. Overload 2. Frequence use of low gear position at high speed Inspect fuel leakage 3. Frequence use of high gear position at low speed Fuel leakage Normal Retighten Inspect injector (Injection pressure Replace atomizing state, etc.)
Page 49 6. Oil consumption excessive Case according to use conditions 1. Excessive oil infusing 2. Continuous operation in low speed or extremely cold state Inspect oil leakage Inspect oil leakage Clean · Replace Normal Oil leakage Check oil quality External Internal Check compressed Replace with...
Page 50 7. Engine knocking Inspect combustin of fuel & oil (carbon residue of exhaust gas) Unconfirmed Confirm Inspect compressed Disassemble pressure engine Confirm Too low Check valve clearance and Inspect high pressure cylinder head gasket crush pump Replace Normal Adjust Normal Adjust Disassemble Check fuel quality...
Page 51 8. Battery discharge Battery Wiring, Switch Alternator Inspect cut wire shorts and Check electrolytic liquid amount Check fan belt tension & damage loose connections Normal Abnormal Repair · Replace Check charged stated Adjust Adjust Discharging Disassemble alternator Voltage regulator Battery room damage Battery self dischage Battery over charging Normal...
Page 52 Condition Causes Remedies 1) Starting difficult (1) Starting motor trouble Refer to diagnostics (2) Fuel system trouble Refer to diagnostics (3) Compression pressure lack ● Valve's poor shut, stem distortion Repair or replace ● Valve spring damage Replace valve spring ●...
Page 53 Condition Causes Remedies 5) Engine noisy For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. ● As the wear of bearing or crankshaft (1) Crankshaft Replace bearing & grind progress, the oil clearances increase crankshaft ●...
Page 54 Condition Causes Remedies 7) Oil Consumption Excessive ● Clearance between cylinder liner & Replace (1) Oil level elevated piston. ● Wear of piston ring, ring groove Replace piston, piston ring ● Piston ring's damage, stick, wear Replace piston ring ● Piston ring opening's disposition Correct position improper ●...
Page 55: Engine Inspection
2.5. Engine Inspection 2.5.1. Regular check and maintenance Regular check and maintenance are required to keep the best engine performance and prevent malfunction. – The following items should be checked everyday. – The following items should be maintained regularly and thoroughly. –...
Page 56: Disassembly And Reassembly Of Major Components
3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly 3.1.1. General precautions Prepare the shelf to keep various tools, repair parts, and parts after disassembly. Perform the maintenance work in bright and clean place. Wash your hands when assembling the engine. Keep the disassembled parts by order of disassembly.
Page 57 3.1.4. Engine oil Open the drain plug of the oil pan and drain engine oil to the prepared container. Drain valve EK4OM033 3.1.5. Belt Unfasten the tension adjustment bolts and fixing bolts of the air conditioner compressor, air compressor, and alternator, and disassemble the belt.
Page 58 3.1.8. Air pipe and air heater Loosen and remove fixing bolts of the air pipe and air heater. Be careful not to input any foreign object into the turbo charger. EL4OM010 3.1.9. Fuel filter Loosen the hollow screws of the fuel filter and disassemble the fuel hose.
Page 59 3.1.12. Common rail and high pressure pipe Disassemble the high pressure pipe between fuel high pressure connector and common rail. Loosen the fixing bolts of the common rail and disassemble the common rail. CAUTION : 1) Seal the common rail after disassembly, so that no foreign object is inserted.
Page 60 CAUTION : 1) Seal the EGR valve and exhaust pipe after disassembly, so that no foreign object is inserted. EK4OM080 3.1.15. EGR cooler Loosen the fixing bolts that connect the EGR cooler and bracket, and remove the EGR cooler. Detach the pipe and hose connected to the EGR cooler.
Page 61 CATION : Seal the HC injection device, exhaust pipe, and hose after disassembly, so that no foreign object is inserted. EK4OM098 3.1.17. HC dosing metering unit Loosen the fixing bolts of the HC dosing metering unit and remove from the bracket. CAUTION : Seal the HC dosing metering unit after disassembly, so that no foreign...
Page 62 3.1.20. Cooling water pipe & thermostat Loosen the fixing bolts of the cooling water pipe, and disassemble the cooling water pipe assemble dot the thermostat housing. Remove the cooling water thermostat and O-ring. Clean the gasket mounting surface of the cooling water pipe with a scraper. EK4OM074 CAUTION : Be careful that the gasket piece is not...
Page 63 3.1.22. Starting motor Loosen assembly nuts of the starter motor, and disassemble the starter motor while paying attention not to damage the starter motor gear. EK4OM050 3.1.23. Oil filter Remove the oil filter cartridge using special tools. Oil cooler Oil filter EK4OM041 3.1.24.
Page 64 3.1.26. Rocker arm Loosen the bolts for rocker arm bracket assembly in reverse order of assembly, and detach rocker arm components. EK4OM053 Disassemble the push rod. EK4OM054 3.1.27. Injector Loosen the fixing bolts of the fuel high Bolts Injector type pressure connector, and detach the Fixing bracket fuel high pressure connector.
Page 65 3.1.28. Cylinder head Loosen and disassemble the cylinder Lifting hook head bolts in reverse order of assembly. Head bolt - Phase 1 : Loosen by one or two cogs. – Phase 2 : Loosen the entire bolt and disassemble. Disassemble the cylinder head bolts by phase 1 and 2.
Page 66 3.1.30. Oil cooler Loosen the fixing bolts of the oil cooler and disassemble the oil cooler EK4OM057 3.1.31. Oil pan Disassemble the oil fan fixing bolts, and detach the oil pan. Remove the oil pan gasket. Oil pan fixing bolt EK4OM058 3.1.32.
Page 67 3.1.34. Fly wheel Disassemble the flywheel fixing bolts, and install the guide bolts, and detach the flywheel. Loosen the bolts in reverse order of assembly and in phases. EK4OM060 3.1.35. Flywheel housing Remove the bolts for flywheel housing assembly, and disassemble the flywheel housing.
Page 68 3.1.38. Piston & connecting-rod Disassemble the connection rod cap bolts in reverse of assembly. Disassemble the bolts by phase 1 and 2, using the same method of the cylinder head bolts. Beat the top and bottom of the connecting rod cap softly with EFM2026I urethane hammer, and disassemble the bearing cap and bearing.
Page 69 (3) Remove the piston ring with a pliers. Disassemble jig no. : T7621010E. (4) Clean the piston thoroughly. EH4OM048 3.1.39. Bearing cap Remove the bearing cap fixing bolts in reverse order of assembly and in phase, and disassemble the bearing cap.
Page 70 3.1.41. Oil spray nozzle Unscrew the crankshaft pulley fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly. EK4OM065 3.1.42. Camshaft and tappet Disassemble the camshaft by rotating it, in order to prevent the damage. Keep the disassembled crankshaft on the special shelf, so that it is not bent or damaged.
Page 71: Inspection And Measurement On Major Parts
3.2. Inspection and Measurement on Major Parts 3.2.1. Cylinder block Clean the cylinder block thoroughly, and check for any crack or damage. If there is any crack or severe damage, replace it and if there is minor one, correct it. Check for any clogging or corrosion in the oil passage and water passage.
Page 72 b) Distortion of lower surface As shown in figure, measure the cylinder head’s distortion at 6 directions with horizontal ruler and clearance gauge. If the measured value is beyond the limit value, correct it by means of the fine grinding paper or grinding EH6OM028 machine.
Page 73 3.2.3. Inspection of valve and valve guide 1) Valve After cleaning valve with fuel, check it. Valve stem outer diameter Measure the valve stem outer diameter at 3 positions (top, middle, and bottom), and check for any wear and if beyond the limit value, replace the valve.
Page 74 2) Valve guide Put the valve in the cylinder head, and measure the valve guide and valve clearance with valve movement. If the Measuring clearance is big, measure the valve, point and replace the valve or valve guide, which is more worn-out. EA0M4052 <...
Page 75 < Valve depression > (mm) Valve Dimension standard Limit Description Valve seat Intake valve 0.35 ~ 0.85 0.65 Exhaust valve 0.35 ~ 0.85 0.65 EE1OM068 < Valve angle > (mm) Intake valve (B) Exhaust valve (B) ° ° Replace the valve seat, if the valve insertion distance exceeds the limit of Valve seat tolerance.
Page 76 4) Valve spring Visual check Check the appearance of valve spring and if necessary replace the spring. Valve spring free length Use a vernier caliper to measure the valve spring free length. If the measured value is less than the specified limit, the valve spring must be replaced.
Page 77 5) Assembling cylinder head Clean the cylinder head, and replace Valve guide the valve steam seal with new one. Put the steam seal in the cylinder head valve guide, using the special tool. Assembly tool item number : EF.121-253 Valve seat Spray engine oil on the valve stem EE1OM069 and valve guide, and assemble the...
Page 78 2) Inspection of rocker arm assembly Rocker arm shaft Rocker arm shaft run-out Place the rocker arm shaft on two V-blocks and inspect the shaft for bend using a dial gauge. If the amount of this run-out is small, press the shaft with a bench press to correct the run-out.
Page 79 Rocker arm bushing diameter Measure the inside diameter of the rocker arm bushing with an inside micrometer or vernier calipers, and compare the measured values with the rocker arm shaft diameter. If the clearance exceeds the limit, replace either bushing or shaft, whichever EE1OM073 worn more.
Page 80 Outside diameter of tappet With an outside micrometer, measure the tappet outside diameter if the measured value is beyond the limit, replace tappets. (mm) 24.90 ~ 27.982 Standard EDM2061I Push rod run-out Use a feeler gauge to measure the push rod run-out. Roll the push rod along a smooth flat surface as shown in the figure.
Page 81 3.2.5. Camshaft 1) Camshaft end play Push the camshaft gear toward the opposite cylinder block. With a feeler gauge, measure the clearance between the thrust plate and camshaft gear. If the end play is excessive, replace Feeler gauge the thrust plate. EA0M4067 (mm) Standard...
Page 82 3) Between camshaft journal and camshaft bush With an outside micrometer, measure the camshaft journal diameter. Camshaft bearing Measure the inside diameter of the camshaft bushing on the cylinder block using a cylinder bore indicator, and compare the measured value with the camshaft outside diameter to EH6OM031 determine the clearance.
Page 83 3.2.6. Crankshaft 1) Inspection of crankshaft a) Defect check Check the scratch or crack of the crankshaft journal and crank pin with naked eyes. Check crack of the crankshaft through the magnetic particle inspection test and crack detection by penetration of penetrant (color check). If any crack is found, replace the crankshaft.
Page 84 In case that pin’s wear is more than "R" the limit value, grind the crankshaft journal and crank pin, and use the "R" "R" undersized bearings. Be sure to use grinding paper which "R" "R" "R" has been immersed in oil. Normal Poor Poor...
Page 85 b) Oil clearance between crankshaft and bearing (Method 1 : dial gauge) Main bearing clearance Install the main bearing in the cylinder block, tighten the bearing cap to specified torque, then measure the inside diameter. Torque 30 kg•m EH6OM036 Compare the two values obtained through measurement of main bearing inside diameter with the outside diameters of crankshaft journals to determine the oil clearance.
Page 86 Compare the two values obtained through measurement of connecting rod bearing inside diameter with the outside diameters of crankshaft pins to determine the oil clearance. (mm) Standard Limit EH6OM038 0.030 ~ 0.081 0.15 If the clearance deviates from the specified range, have the crankshaft journals and pins ground and install undersize bearings.
Page 87 Crankshaft bearing crush Install the bearing and cap in the cylinder block, retighten the bolts to specified torque, unscrew out one bolt completely, then measure the clearance between the bearing cap and cylinder block using a feeler gauge. (mm) EH6OM040 Standard 0.065 ~ 0.105 Connecting rod bearing crush...
Page 88 3.2.7. Piston assembly Disassembly of piston assembly Disassemble piston according to the disassembly process. 1) Piston inspection a) Visual check Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove. b) Clearance between the piston and cylinder liner With an outside micrometer, measure the piston outside diameter at a point 12 mm away from the lower...
Page 89 2) Piston rings a) Visual check Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. b) Piston ring gap Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the Feeler gauge cylinder liner wall.
Page 90 3) Piston pin inspection The measured values are beyond the limit (0.08 mm or greater), replace the piston pin. (mm) Piston pin Standard Limit 39.994 ~ 40.000 39.94 EA0M4031 Measure the clearance between the piston pin and connecting rod bushing, and replace either of them, whichever damaged more, if the measured value is beyond the limit.
Page 91 4) Connecting rod inspection a) Distortion Check the connecting rod for distortion. As shown in the figure below, install the connecting rod to the connecting rod tester, and check for distortion using a feeler gauge. If the connecting rod is found distorted, never re-use it but replace with a new one. b) Holes alignment (parallelism) Measure the alignment of the connecting rod piston pin bushing holes...
Page 92: Engine Reassembly
3.3. Engine Reassembly 3.3.1. General precautions Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. Arrange the general and special tools in order for engine assembly operation. To wet each sliding part, prepare the clean engine oil. Prepare service materials such as sealant, gaskets, etc.
Page 93 3.3.5. Crankshaft Install the main bearing (refer to assemble sequence : right figure) machined with two holes in the cylinder block so that the key is aligned with the key groove, then apply oil to the bearing surface. EH6OM062 Key groove Oil port and passage EA0M4083 Put the wear ring into the heater to...
Page 94 Install the oiled thrust washers with the oil groove facing outward. EAMD076S Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers. EAMD077I Install the bearing cap by matching Tightening order the cylinder block No.
Page 95 <Tightening Order> (1) First stage : Spray engine oil on bolts. (2) Second stage : Fasten with 5 kgf•m torque until bolts are tightened. (3) Third stage : Fasten up to 15 kgf•m with a torque wrench. (4) Fourth stage : Fasten up to 25 kgf•m with a torque wrench.
Page 96 3.3.8. Fuel high pressure pump Assemble the fuel high pressure pump, using the dedicated jig. Gear nut torque 11 kgf•m Fixing bolt torque 4.4 kgf•m When assembling a new fuel high pressure pump, open the plug screw and refill 60 mℓ fuel. EK4OM047 Install the fuel high pressure pump n the timing gear case located at the rear side of the flywheel housing.
Page 97 Install the idle gear by adjusting it to Fuel high pressure pump gear the crankshaft gear, camshaft gear, and idle gear mark. Fuel high pressure < Gear mark > pump idle gear Crankshaft gear Idle gear(A, B) Camshaft gear "0" and "0" and idle gear (A) Camshaft gear "1"...
Page 98 3.3.11. Rear oil seal Install the oil seal on the crankshaft, and assemble the oil seal, using the oil seal jig. Oil seal jig EA8M3003 3.3.12. Flywheel Heat the ring gear with a gas burner evenly to inflate the ring gear, and assemble it, using the hammer.
Page 99 Tighten fixing bolts in fastening order with the pre-defined torque, using a torque wrench. Bolt specification M14 × 1.5 Torque 20 kgf•m EE1OM081 3.3.13. Piston and connecting rod Heat the piston at 100 °C at 5 minutes, using the piston heater. EA3M2058 When assembling the piston and connecting rod, the weight adjustment...
Page 100 Assemble the piston ring to the piston, using the piston ring flier. Top ring 2nd ring Oil ring EE1OM082 To prevent that piston rings are upside down, make the section marked with "Y' or "TOP" on the upper side of the ring connection part face upward.
Page 101 Make sure that the manufacture serial Install the opening part of numbers impressed on the connecting the snap ring on the opposite rod cap and connecting rod big end are side of upper/lower side identical, and install the connecting rod cap by aligning it with dowel pin. Wet the fixing bolts with engine oil, semi-tighten them with hand, tighten Same number marking position...
Page 102 3.3.15. Oil seal Apply engine pile on the inner side of the oil seal, and install the oil seal on the cover. Oil seal cover Adjust the new oil seal to the center of Oil seal the oil seal cover hole, and assemble the oil seal using the assembly jig.
Page 103 3.3.17. Crankshaft pulley and vibration damper Mount the vibration damper on the crankshaft pulley, and fasten fixing bolts in fastening order with the predefined torque. Vibration 6.2 kgf•m damper Torque Crankshaft 20 kgf•m EK4OM051 pulley Bolt tightening order EE1OM155 3.3.18. Intake and exhaust valve Check the "I"...
Page 104 3.3.19. Cylinder head Blow out the bolt hole of the cylinder head with compressed air to remove foreign object. Clean the contact surface of the cylinder head gasket. At this time, be careful not to put any Model number mark foreign object into the combustion Manufactured date chamber.
Page 105 < Tightening order of bolts by steps > (1) First stage : Coat the bolts with engine oil. (2) Second stage: Fasten the screw by one or two cogs with hands, and fasten under 4 kgf•m temporary fastening torque. (3) Third stage : Tighten at about 6 kgf•m with a wrench. (4) Fourth stage : Tighten at rotating angle method 90°...
Page 106 < Injector and high pressure connector assembly procedure > 1) The injector should be assembled correctly on the following procedure. Injector High pressure connector Coat the engine oil on O-ring (Be careful not to allow the engine oil to go into the hole for high pressure connector) Lubricant positions - O-ring...
Page 107 5) (3) Coat the fresh and clean engine oil on O-ring, Hold down shoulder and Thread of fixing nut. Grasp high pressure connector with balls vertical and insert it into the hole on while aligning the balls of connector and slot of the head. Push the connector into the hole until feeling it contacted.
Page 108 3.3.21. Rocker arm Apply oil to the rocker arm bush and axis, and assemble the bracket to the rocker arm on the cylinder head, using the fixing bolts. Fasten the bolts with the zigzag fastening method, using the pre- defined torque EK4OM054 Torque 3.75 kgf•m...
Page 109 3.3.23. Cylinder head cover Assemble the new rubber gasket to the cylinder head cover and install it on the cylinder head, and fasten the fixing bolts with pre-defined torque. Torque 2.2 kgf•m Assemble the oil injection hole cap to EK4OM003 the cylinder head cover.
Page 110 3.3.26. Starting motor Insert the starter into the flywheel housing and tighten the fixing nuts. Torque 8.0 kgf•m EK4OM079 3.3.27. Common rail and high pressure pipe Install the common rail on the cylinder block. Install the fuel supply pipe between the common rail and fuel high pressure connector, and fasten cylinders one be one with the pre-defined torque.
Page 111 3.3.29. Exhaust manifold Install the exhaust manifold gasket on the stud bolt of the cylinder head, and adjust the gas outlet of the cylinder head to the gasket hole. EK4OM020 Be careful not to change the gasket front and rear side. Projection face Torque 5.0 kgf•m...
Page 112 3.3.32. HC dosing injection (HC hydro-carbon) Assemble the HC injection device to the exhaust pipe, using the fixing bolts. EK4OM038 Assemble the cooling water hose to the HC injection device. Assemble the HC injection device. EK4OM098 3.3.33. HC dosing metering unit Assemble the HC dosing metering unit to the bracket, using assembly bolts.
Page 113 Assemble the pipe and hose to the EGR cooler. Do not reuse the gasket. See Chapter 3.6.9 for more details on disassembly and assembly. EK4OM072 3.3.35. EGR valve Assemble the exhaust pipe to the EGR cooler together with the gasket, using the fixing bolts.
Page 114 3.3.37. Crankshaft speed sensor and Camshaft speed sensor Measure the clearance between the assembly part of the crankshaft RPM sensor and flywheel, and adjust the clearance using the shim. Assembly clearance 1.0 mm Torque 1.0 kgf•m Measure the clearance between the EK4OM081 assembly part of the crankshaft RPM detection sensor and the timing gear,...
Page 115 3.3.40. Air pipe and air heater Assemble the air pipe and air heater using the fixing bolts of the throttle bolts. Be careful not to input any foreign object into the turbo charger. EL4OM010 3.3.41. Oil level gauge Apply the adhesive (Loctite #262) to the guide tub.
Page 116: Fuel Injection System
3.4. Fuel Injection System 3.4.1. Common rail fuel-injection system Pressure generation and fuel injection are completely decoupled from each other in the common rail injection system. The electric control unit(ECU) determine the fuel quantity, injection timing, and injection pressure in order to show the optimum performance on the condition for operation of the engine, then inject the fuel in the cylinder.
Page 117 The engine speed is measured by the crankshaft speed sensor, and the camshaft speed sensor determines the firing sequence (phase length). The electrical signal generated across a potentiometer in the accelerator pedal module informs the ECU about how far the driver has depressed the pedal, the engine is equipped with a turbo charger and boost pressure control, the boost pressure sensor also measures boost pressure.
Page 118 3.4.4. Fuel high pressure pump A radial-piston pump is used as the high pressure pump for pressure generation. Pressure is generated independently of the injection process. The speed of the high pressure pump is coupled directly to the engine speed with a non-variable transmission ratio.
Page 119 3.4.8. Fuel filter Fuel filter inadequate filtering can lead to damage at the pump components, delivery valves, and injector nozzles. The fuel filter cleans the fuel before it reaches the high pressure pump, and thereby prevents premature wear at the pump's sensitive components.
Page 120 3.4.11. Construction of the fuel high pressure pump 1) Function The fuel high pressure pump has the lower pressure and high pressure phase. The pump transfers high pressure fuel during perfect service life of the vehicle under all operating conditions. In addition, the pump supplies fuel needed for a quick start or abrupt pressure change inside the common rail.
Page 121 4) Fuel delivery rate Since the high-pressure pump is designed for large delivery quantities, excess high-pressure fuel is delivered during idle and part load operation. This excess fuel is returned to the tank via the pressure control valve. 5) Fuel metering shut off valve If the switch of the fuel high pressure pumping blocking valve is turned off, the fuel quantity supplied to the...
Page 122 7) Common rail pressure sensor The fuel flows to the rail pressure sensor through an opening in the common rail, the end of which is sealed off by the sensor diaphragm. Pressurized fuel reaches the sensor’s diaphragm through a blind hole. The sensor element for converting the pressure to an electric signal is mounted on this diaphragm.
Page 123 3.4.13. Injector The solenoid valve installed on the fuel injector adjusts the beginning of fuel injection and injection quantity, and the fuel injector replaces the function of existing engine's nozzle and nozzle holder. Fuel is supplied to the injector via the high pressure connection connector installed on the cylinder head, and supplied to the valve control chamber via the supply hole.
Page 124 (1) Method of operation The injector’s operation can be subdivided into four operating states with the engine running and the high pressure pump generating pressure. a) Injector closed (with high pressure applied) b) Injector opens (start of injection) c) Injector opened fully d) Injector closes (end of injection) These operating states result from the distribution of the forces applied to the injector’s components.
Page 125 nozzle has now opened fully, and fuel is injected into the combustion chamber at a pressure almost equal to that in the fuel rail. Force distribution in the injector is similar to that during the opening phase. (4) Injector closes (end of injection) As soon as the solenoid valve is no longer triggered, the valve spring forces the armature downwards and the ball closes the bleed orifice.
Page 126 3.4.15. Camshaft speed sensor The camshaft controls the engine's intake and exhaust valves. It turns at half the speed of the crankshaft. When a piston travels in the direction of TDC, the camshaft position determines whether it is in the CAM SHAFT SPEED SENSOR compression phase with subsequent EK4OM084...
Page 127 3.4.17. Boost pressure and temperature sensor The boost pressure & temperature sensor are connected to the intake manifold by the O-ring and measures the intake manifold's absolute pressure and temperature. The output signal is inputted to the BOOST PRESS TEMP SENSOR ECU where, with the help of a EK4OM085 programmed characteristic curve, it is...
Page 128: Electrical System
3.5. Electrical System 3.5.1. Electrical parts 2. BPTS 1. EGR 3. TVA 4. CTS 9. RPS 6. INJ 12. Fuel Temperature Sensor 11. CAM 8. Resistance 10. CRS 7. OPTS 5. FMU EL4OM014 1. Exhaust gas recirculation actuator sensor (EGR) 7.
Page 129 3.5.2. Harness of electric control unit 1) Vehicle connector Term.30 (BAT+) G_G_BAT1 V_V_BAT1 G_G_BAT2 V_V_BAT2 G_G_BAT3 V_V_BAT3 G_G_BAT4 V_V_BAT4 G_G_BAT5 V_V_BAT5 Ignition switch (BAT-) I_S_T15 Terminal 15 I_S_CRCMOD CC/PTO mode switch B_D_CANH0 Controller Area Network 0 B_D_CANL0 G_C_GND B_D_CANH1 O_V_RH21 Battery plus output 21 "UB2 Pin 1"...
Page 130 2) Engine connector 2.01 W 2.50 C3ZH 2.19 B 0.75 C3ZH 2.18 O 0.75 AESSXF 2.25 W 2.50 C3ZH 2.17 W 0.75 AESSXF 2.02 W 2.50 C3ZH 2.26 W 2.50 C3ZH Vbat W 0.75 C3ZH 2.03 W 2.50 C3ZH GND B 0.75 C3ZH EGR Valve 2.27 W 2.50 C3ZH Connector...
Page 131 The wiring number can be checked by marking on the wire. Ø.75 2.68 AESSX Wiring type (C3ZH, AESSXF) Wiring size Wiring color (B : Black, W : White, O : Orange) ECU PIN No. Symbols on the circuit diagram have the following meaning. (Twist wire Two wires are twisted together.
Page 132 3.5.3. Connector of electric control unit (ECU) Vehicle side connector Engine side connector EJ9OM058 DL06K Interim Tire-4 Diesel Engine Disassembly and Reassembly of Major Components...
Page 133 3.5.4. Electric control unit Figure Signs Pin No. Circuit name Fuel Metering Unit 2.58 Fuel metering unit (O_V_MEU) 2.58 2.83 2..83 Fuel metering unit (O_T_MEU) 2.06 Oil Press/Temp Sensor GND (G_R_OPS) Oil Press Temp Sensor 2.13 Oil Temp Sensor Signal (I_A_OTS) OPTS Oil Press/Temp Sensor PWR 2.31...
Page 134 Figure Signs Pin No. Pin No. 2.49 Injector #1 High (O_P_SVH11) 2.73 Injector #1 Low (O_P_SVL11) 2.51 Injector #3 High (O_P_SVH13) 2.75 Injector #3 Low (O_P_SVL13) Injector Connector 2.50 Injector #2 High (O_P_SVH12) 2.74 Injector #2 Low (O_P_SVL12) 2.75 2.51 2.73 2.49 2.03 2.27 2.74...
Page 135: Exhaust Gas Reduction System
3.6. Exhaust Gas Reduction System Doosan EPA Tier4 interim compliant engine satisfies industrial exhaust gas related regulations all over the world by utilizing Doosan core technologies. 3.6.1. Tier 4 interim exhaust gas reduction device The exhaust gas reduction device is enhanced with the aid of DPF where DOC is applied and EGR to reduce NOx in the exhaust gas.
Page 136 3.6.2. Exhaust gas reduction system circuit diagram Fuel return Fuel entry Injection Fuel filter pump Fuel tank Metering unit (MU) Sensor Actuator Engine CAN communication Diagnosis CAN communication Injection unit Temperature Temperature Differential (IU) sensor pressure sensor sensor Exhaust Engine Temperature manifold exhaust...
Page 137 3.6.3. Diesel oxidation catalyst : DOC Introduction DOC is a device where HC and CO are oxidized. DOC also raises the temperature of DPF by helping oxidization of HC (diesel) sprayed during the active regeneration mode while transforming NO into NO2 to cause the passive regeneration of soot inside DPF.
Page 138 3.6.4. Diesel particulate filter : DPF Introduction DPF (Diesel Particulate Filter) prevents PM (Particulate Matter) from contaminating the air when exhausted without proper treatment. DPF consists of DPF itself, 3 units of exhaust gas temperature sensor and differential pressure sensor. DPF has a structure that is similar to honeycomb. When exhaust gas reaches the DPF, PM piles up inside DPF while the rest goes through the DPF.
Page 139 DPF regeneration lamp and switch 1) High temperature caution lamp : DPF Regeneration process release extreme amount of heat, therefore, flammable objects near the pipe must be removed. EJ9OM061 2) Regeneration lamp : Regeneration lamp turns on during the regeneration or when the regeneration is necessary.
Page 140 Soot Quantity 140% DPF Lamp Blinking + MIL, Engine derated 50% Regen. Disabled (DPF should be replaced) 120% DPF Lamp Blinking 100% Forced Regen DPF Lamp ON (Operation Warning) Active Regen Operation Time (Hr) Operation Time Fuel Quantity (Liter) Fuel Quantity <...
Page 141 1) Active regeneration ECU initiates active regeneration under below conditions. Regeneration generates heated exhaust gas, and the regeneration caution lamp and temperature caution lamp turn on to notify the driver. Driver can still maneuver the machinery or automobile but need caution. The regeneration process takes 20 to 30 minutes, and the lamps turn off when the process is over.
Page 142 5. The engine revolution will increase up to 1,400 rpm (depends on the model and type of vehicle operating) and starts the regeneration process. 6. The regeneration lamp and HEST lamp turn on as the process begins, and the process takes approximately 20 minutes. 7.
Page 143 3.6.5. HC dosing metering unit, MU HC supply device is supplying HC fuel to exhaust pipe to initiate DPF regeneration. It’s consists of fuel pressure sensor, shut off valve which controls the amount of fuel spayed and fuel spraying valve Injection Fuel filter pump...
Page 144 Removal 1) Fuel supply pipe and injection unit pipe attached to metering unit should be removed before removing 3 pieces of M8 bolt. Installation 1) Place metering unit on the bracket EK4OM029 and fix it together by screwing 3 pieces of M8 bolt. - M8 bolt assembling torque = 2.2 kgf•m - Fuel pipe union nut torque = 2 kgf•m WARNING : When Working on the “Air Extraction”...
Page 145 3.6.7. EGR system 1) Introduction EGR performs recirculation of a portion of exhaust gas to reduce the generation of NOx. Exhaust gas released from the back of exhaust manifold and flows back into the engine with cooled air intake from the inter cooler. 2) Feature EGR cooler is installed to lower exhaust gas temperature.
Page 146 EK4OM088 EK4OM089 DL06K Interim Tire-4 Diesel Engine Disassembly and Reassembly of Major Components...
Page 147 3.6.8. EGR cooler 1) Introduction EGR cooler is heat exchanging device that reduces the temperature of recirculating exhaust gas. EGR cooler enhances fuel efficiency while reducing the amount of NOx generation. 2) Feature High efficient tube & fin type applied. 3.6.9.
Page 148 3.6.11. Exhaust gas temperature sensor DPF temperature sensor DPF temperature sensor EL4OM018 The following temperature sensors were applied at the DOC upstream, DPF upstream, and DPF downstream position, order measure temperature of the DOC and DPF, which is the post processing unit. EH8OM021 DPF differential pressure sensor.
Page 149 EGR valve The EGR valve is applied to main the optimal EGR. EK4OM093 DL06K Interim Tire-4 Diesel Engine Disassembly and Reassembly of Major Components...
Page 150 3.6.12. Caution while working at DPF assembly Be cautious of below when handling and assembling DPF. 1) DOC and DPF must be protected from shock that can be caused by dropping and hitting when being removed. 2) Technical failure can be occurred when substance from outside infiltrates into the differential pressure sensor pipe during replacement.
Page 151: Engine Diagnostic
3.7. Engine Diagnostic 3.7.1. Method of confirmation for the fault code Doosan specified the occurrence conditions for the following fault codes, as the fault diagnosis unit can handle the fault fast and accurately. Please check the fault code using the fault diagnosis device (laptop).
Page 152 Fault code Fault content Occurrence conditions P0562 DFC_BattULo Low Battery voltage indication P0563 DFC_BattUSRCMax SRC high for battery voltage sensor P0562 DFC_BattUSRCMin SRC low for battery voltage sensor 9. Timeout error of CAN Module A C028 DFC_BusDiagBusOffNodeA BusOff error CAN A 10.
Page 153 Fault code Fault content Occurrence conditions 19. Vehicle cutoff switch error C125 DFC_ComRxVehCutOffSwtErr Vehicle cutoff switch error 20. Error message from VGT actuator C40D DFC_ComRxVGTB2EDC VGT actuator error 21. Timeout error of CAN receive frame TCU C121 DFC_ComTSC1TETO Timeout error of CAN receive frame TCU 22.
Page 154 32. Camshaft sensor P0341 DFC_EpmCaSI1ErrSig camshaft signal diagnose - disturbed signal P0340 DFC_EpmCaSI1NoSig camshaft signal diagnose - no signal P0340 DFC_EpmCaSI1OfsErr camshaft offset angle exceeded 33. Crankshaft sensor P0336 DFC_EpmCrSErrSig crankshaft signal diagnose - disturbed signal P0335 DFC_EpmCrSNoSig crankshaft signal diagnose - no signal 34.
Page 155 Dynamic Pressure Monitoring -pressure P1062 DFC_HCIMonPresDsMax downstream in excess of maximum threshold Dynamic Pressure Monitoring -pressure P1063 DFC_HCIMonPresDsMin downstream below minimum threshold Pressure Equalization Test Error = FCT_ERROR P1064 DFC_HCIMonPresEqlTstErr in Pressure Equalization state Pressure Increase Downstream Maximum Test P1065 DFC_HCIMonPresIncDsMaxTstErr Error = FCT_ERROR in Pressure Increase- Pressure Increase Test Downstream Error =...
Page 156 Fault code Fault content Occurrence conditions 40. Metering Unit upstream pressure sensor SRC high for Hydrocarbon Dosing Valve P1088 DFC_HDVUsPSRCMax Upstream Pressure Sensor SRC low for Hydrocarbon Dosing Valve Upstream P1089 DFC_HDVUsPSRCMin Pressure Sensor 41. Metering Unit Hyrocarbon doser intake fuel temperature SRC high in Hydrocarbon Dosing valve upstream P108A DFC_HDVUsTSRCMax...
Page 157 Fault code Fault content Occurrence conditions 47. Solenoid power stage 2 (Cylinder 5) P0202 DFC_IVDiaCylNoLd_1 Cylinder 5 injection open load Cylinder 5 injection special pattern for special P0266 DFC_IVDiaCylPttDet_1 cases P0265 DFC_IVDiaCylShCir_1 Cylinder 5 injection general short circuit 48. Solenoid power stage 3 (Cylinder 3) P0203 DFC_IVDiaCylNoLd_2 Cylinder 3 injection open load...
Page 158 Fault code Fault content Occurrence conditions 57. Injection Misfire detection cylinder 2 P0305 DFC_MisfDetMisfireCyl_4_C Injection Misfire detection cylinder 2 58. Injection Misfire detection cylinder 4 P0306 DFC_MisfDetMisfireCyl_5_C Injection Misfire detection cylinder 4 59. Monitoring Misfire detection multiple cylinder P0300 DFC_MisfDetMisfireMul_C Monitoring Misfire detection multiple cylinder 60.
Page 159 Fault code Fault content Occurrence conditions 68. DPF Pressure sensor offset diagnostic the monitoring of the offset of the differential P2453 DFC_NplPresSensPPFltDiff pressure sensor have been concluded and that no errors have occurred in the process 69. ECU power stage module Error report "WDA active"...
Page 160 Fault code Fault content Occurrence conditions 80. Forced regeneration switch short circuit to battery of regeneration demand P107A DFC_PFltSwtSCBDem switch DPF(Diesel Particulate Filter) Regeneration P107C DFC_PFltSwtExtDemPlaus inhibition switch and Forced regeneration switch plausibility test 81. Forced regeneration inhibit switch regeneration inhibition switch short circuit to P107B DFC_PFltSwtSCBInh battery is detected...
Page 161 Fault code Fault content Occurrence conditions P0088 DFC_RailMeUn42 Maximum rail pressure (second stage) P1050 DFC_RailMeUn7 Error detection by metering unit set value in overrun Plausibility check of the volume flow of the P0251 DFC_RailMeUn8 metering unit at low idle 89. Rail pressure sensor P0193 DFC_RailPSRCMax Rail pressure sensor voltage above upper limit...
Page 162 Fault code Fault content Occurrence conditions 96. Air Inlet temperature P0113 DFC_TCACDsSRCMax SRC High for boost temperature P0112 DFC_TCACDsSRCMin SRC Low for boost temperature P0113 DFC_TIntkVUsSRCMax SRC High for boost temperature P0112 DFC_TIntkVUsSRCMin SRC Low for boost temperature 97. Engine ECU temperature Physical Range Check high for ECU temperature P0669 DFC_TECUPhysRngHi_0...
Page 163: Operating Condition Of The Ecu
3.7.3. Input and output of the ECU Engine output Engine Injector output Fuel high pressure pump Input and output of ECU - fuel metering unit Coolant temperature sensor Fuel temperature sensor Boost pressure and temperature sensor Vehicle output Oil pressure and Preheating relay output temperature sensor Preheating display lamp...
Page 164 3.8.4. Limp home function The limp home is a function which the vehicle can be operated to the maintenance shop with minimum condition for traveling on the condition of taking safety when the defect code is occurred. Application condition - Accelerator pedal is trouble : The vehicle is operated by constant engine speed no relation to depressing of the accelerator pedal.
Page 165: Commissioning And Operation
4.1. Preparations At the time of initial commissioning of a new or overhauled engine make sure to have observed the“Technical information for the installation DOOSAN’s vehicle engines”. Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.
Page 166 4.2.2. Check points for break-in During the break-in (the initial running of the engine) period, be particularly observant as follows : Check engine oil level frequently. Maintain oil level in the safe range, between the “min.” and “max.” marks on dipstick. IMPORTANT : If you have a problem getting a good oil level reading on the oil level gauge, rotate the oil level gauge 180°...
Page 167: Inspections After Starting
4.2.3. Operating after break-In When starting a cold engine, always allow the engine to warm up gradually. Never run the engine at full throttle until the engine is thoroughly warmed up. Be sure to check the oil level frequently during the first 50 Hr of operation, since the oil consumption will be high until the piston rings are properly seated.
Page 168: Operation In Winter Time
4.4. Operation in Winter Time Pay special attention to the freezing of cooling water and the viscosity of lubricating oil. 4.4.1. Operation in winter time CAUTION : 1. Preheating devices are attached to the engine for improving the starting abilities at extremely low temperature.
Page 169: Engine Components Check After Long Time Running
4.4.2. Prevention against freezing of cooling water When not using anti-freeze, cause the diffusion of corrosion in inner part of the engine, cause drop the cooling efficiency, cause being frozen to burst in winter, therefore the whole cooling water should be completely discharged after engine running. The freezing of cooling water is the reason of fatal damage on the engine, always use by mixing the anti-freeze.
Page 170: Maintenance And Care
4.6. Maintenance and Care 4.6.1. Periodical Inspection and Maintenance Regular inspection and maintenance are essential for preventing failure of the engine, and keeping the capabilities of the engine at the maximum level. 4.6.2. Exchanging of lubrication oil Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel economy, combustion chamber deposits and engine wear.
Page 171 Refill with new engine oil at the oil filler neck on the head cover and the lubricating oil in accordance with the oil capacity of the engine through oil filler. Be careful about the mixing of dust or contaminator during the supplement of oil.
Page 172: Cooling System
4.7. Cooling System The coolant must be changed at intervals of 1,200 Hr operation or 1 Radiator cap year whichever comes first. If the coolant is being fouled greatly, it will Radiator lead an engine overheat or coolant blow off from the expansion tank. 4.7.1.
Page 173: Adjustment Of Valve Clearance
7) Fill cooling system with hot water. 8) Run engine at idle for 30 minutes. At the same time continuously replenish the water leaking from the bore in drain plug by adding fresh water. CAUTION : Periodically clean the circuit interior with a cleaner 4.8.
Page 174 No. 1 cylinder is assembled with the flywheel. Intake valve Cylinder no. Cooling fan Exhaust valve Flywheel Valve clearance adjusting position EK4OM014 Adjusting of valves (Type 1) Cylinder no. Intak Intak Intak Intak Intak Intak Valve adjusting Exhaust Exhaust Exhaust Exhaust Exhaust Exhaust...
Page 175 4.9. Tightening the Cylinder Head Bolts Coat the engine oil on the cylinder 21 25 21 25 head bolt, assemble with specified 13 17 13 17 torque according to the order of the assembling. 20 16 20 16 EE1OM087 < Cylinder head bolts > Specification M13 ×...
Page 176: Maintenance Of Major Components
5. Maintenance of Major Components 5.1. Cooling System 5.1.1. General descriptions and main data This engine is a water cooling engine. Combustion heat from the combustion chamber and heat of the engine oil are absorbed by coolant and released outside the engine for normal operation of the engine.
Page 177 5.1.3. Thermostat General descriptions and main data The thermostat maintains a To radiator constant temperature of coolant (90 ~ 95 °C) and improves thermal efficiency of the engine by preventing heat loss. Bypass Namely, when the temperature of valve From cooling To bypass water pipe coolant is low, the thermostat valve...
Page 178 Inspecting 1) Check the wax pallet and spring for damage. 2) Put the thermostat in a container of water, then heat the water slowly and check temperature with a thermometer. If the valve lift is 0.1 mm (starting to open) at temperature of 75 °C and 9.5 mm or more (opening wide) at temperature of C, the thermostat is normal.
Page 179 5.1.4 Diagnostics and troubleshooting Complaints Possible causes Corrections ● Lack of coolant ● Replenish coolant 1. Engine overheating ● Radiator cap pressure valve ● Replace cap spring weakened ● Fan belt loosened or broken ● Adjust or replace fan belt ●...
Page 180: Lubrication System
5.2. Lubrication system 5.2.1. General descriptions and main data General descriptions All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated through the oil cooler and oil filter, and this filtrated oil is forced through the main oil gallery in the cylinder block from where it is distributed to lubricate the various sliding parts, and fuel injection pump in order to ensure normal engine performance.
Page 181 Inspection and correction 1) With steel rule and feeler gauge, measure the axial end play of the oil pump gear. Replace if the measured value is beyond the limit. Steel plate 0.03 ∼ 0.136 mm End play limit Feeler gauge EQM4008I 2) With a feeler gauge, measure the amount of backlash between the...
Page 182 5.2.3. Diagnosis and troubleshooting of cause of failure Complaints Possible causes Corrections ● Poor oil ● Use suggested oil 1. Oil consumption excessive ● Oil seal or packing leaky ● Replace ● Pistons or piston rings worn ● Replace pistons and/or piston rings ●...
Page 183: Turbo Charger
5.3. Turbo Charger Specification and construction 5.3.1. Main data and specification Specification DL06K Model BorgWarner WGT Air pressure at compressor outlet 2.86 kgr/cm At maximum Air suction of turbine revolution 180 g/s output Speed of turbine revolution 148 krpm Maximum allowable speed 183 krpm 700 °C Maximum allowable temperature of exhaust gas at turbine inlet...
Page 184 3) Components of turbocharger EK4OM031 Bearing housing O - ring Hex bolt Turbine housing Oil baffle Actuator ass’y Turbine wheel ass’y Inlet baffle Hose clamp Compressor wheel Thrust collar Actuator clip Compressor housing Heat protector cover Cover plate Journal bearing Oil seal plate Hose Thrust bearing...
Page 185 4) Operating principle Turbine wheel and shaft assembly Oil inlet Compressor housing Turbine housing Exhaust pipe Exhaust gas discharge Fresh air inlet Compressor wheel Oil outlet Intake manifold EA0M8001 The turbocharger is an piece of equipment which increases the engine's power by sucking air at a high density into the cylinder of the engine by making use of the exhaust heat energy of the engine.
Page 186 5.3.3. Function 1) Turbine The exhaust gas that is discharged from combustion chamber passes through turbine housing conveying an energy to turbine wings to give the rotating power, This is called as the turbine and in order not to influence a bad effect at bearing part, there are the seal ring and heat protector.
Page 187 5.3.4. How to handle the engine 1) Precautions for operation of the engine Operation following items must be observed at the starting, operation and stop of engine. Operation Caution Reason 1) Inspect oil quantity 2) After confirming that oil pressure 2) If engine is started quickly, of course rises by starting engine with starter beginning with every parts of engine,...
Page 188 Operation Caution Reason Following items must be confirmed. 1) Oil pressure 1) If the pressure is too low, abnormal At idling : 1.5 ~ 3.0 kg/cm wear or stuck may be caused. Or if At full load : 3.0 ~ 5.5 kg/cm too high, the oil leak may be generated.
Page 189 Recommended oil SAE 15W40 (API CJ-4) Shell : Rimula super * Recommended oil (Use the standard Doosan oil, if possible.) 5.3.6. Periodical servicing Make it a rule to check the turbocharger assembly for condition and contamination periodically. 1) Guide for checking the rotor for rotating condition The inspection of the rotor assembly for rotating condition should be performed by the degree of unusual sound.
Page 190 (1) Rotor axial direction end play Turbine wheel chamber Magnetic vise Move the turbine shaft in axial direction Dial gauge Standard : 0.038 ~ 0.093 mm Limit of werar : 0.24 mm EK1OM080 (2) Rotor radial direction end play Dial gauge Magnetic vise Oil outlet Radial play...
Page 191 (1) Lubricating system Before reassembling the turbocharger onto the engine, inject new oil in the oil inlet port and lubricate the journal and thrust bearings by rotating them with hand. Clean not only the pipes installed between the engine and oil inlet port but also the oil outlet pipe and check them for damage or foreign matters.
Page 192 5.3.7. Diagnostics and troubleshooting 1) When abruptly increasing the engine rpm after starting the engine, the crank shaft rotates at an excessive speed before the journal bearing of the crank shaft is not lubricated due to an insufficient supply of lubrication oil. When the turbocharger rotates under these conditions, cooling and lubrication are not smoothly executed causing burnt adhesion of the bearing and damage to parts.
Page 193 5.3.8. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black smoke 1) Air cleaner element clogged Replace or clean 2) Restrictions in air duct Check and correct 3) Leakage at intake manifold Check and correct 4) Turbo charger seized up and not Disassemble/repair or rotating replace...
Page 194 Checking items before and after removing the turbocharger Expected problem Items to check Power Oil con- Black Blue Troubleshooting Noise reduction leakage. sumption. smoke smoke Is there a torn or deformed intake Replace the hose system hose? Is the clamp Re-tighten the bolts properly connected? and he nuts...
Page 195: Air Cleaner
5.4. Air cleaner 5.4.1. Maintenance of air cleaner (Only when engine is switched off) Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway with dust. On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover (6) of the dust bowl and empty.
Page 196 5.4.3. Cleaning air cleaner elements By compressed air (wear goggles) - Use the air gun to clean the element down to the inside of the bottom of the element by spraying compressed air in 90 degree direction.. - Move the air gun up and down along the element, and blow the air from inside to outside until no dust is blown out of the element.
Page 197: Belt
Checking the air cleaner cartridge - Before reinstalling the cartridge, it must be checked for damage e.g. to the paper pleats and rubber gaskets, or for bulges and dents etc. in the metal jacket. - Damaged cartridges should not be reused under any circumstances.
Page 198 (3) Measuring tension ① Lower indicator arm (1) into the scale Apply tester to belt at a point midway between two pulleys so that edge of contact surface (2) is flush with the V- belt. Slowly depress pad (3) until the spring can be heard to disengage.
Page 199: Special Tool List
6. Special Tool List Part no. Figure Tool name Remark EF.121-299 Oil seal insert assembly (Front) EF.121-300 Oil seal assembly jig (Rear) EF.123-065 Valve spring compression tool EF.123-365A Cylinder liner disassembly tool DL06K EF.121-250 Dedicated tool Piston insertion tool Common EF.120-208 for engine EF.121-253...
Page 200 Part no. Figure Tool name Remark EF.121-181 Cam shaft hole cover punch EF.121-252 Step idle gear pin assembly jig 60.99901-0027 Gap gauge EF.121-260 Abrasion ring punch (rear) 65.98801-0001 Filter wrench T7610001E Snap ring plier EF.121-259 Crankshaft gear insert jig Compression pressure gauge EF.110-120 adaptor DL06K Interim Tire-4 Diesel Engine...
Page 201 Part no. Figure Tool name Remark T7621010E Piston ring pliers Failure diagnosis unit 860104-01045 Included below 17, 18, 19 items. Failure diagnosis unit 860104-01046 UVIM (CAN module) part Failure diagnosis unit 860104-01047 14-pin connector part Failure diagnosis unit 860104-01048 part DL06K Interim Tire-4 Diesel Engine Special Tool List...
Page 202 Appendix Tightening torque for major parts Screw Major parts Tightening torque (Diameter x pitch) Cylinder block bearing cap M16 x 2.0 30±2 kg.m Oil spray nozzle M10 x 1.25 2.1+0.5 kg.m Flywheel housing M12 x 1.5 11.2 +1.0 kg.m Crank pulley fixing bolt M14 x 1.5 20+0.2 kg.m Vibration absorber...
Page 203 Tightening torque for plug screw 10.0 10.0 12.0 12.0 15.0 Tightening torque for hollow screw(4-hole) SM25C 13.0 18.0 30.0 * SUM22L 11.0 16.0 20.0 35.0 STS304 11.0 16.0 20.0 35.0 * : Adopted in DOOSAN engine DL06K Interim Tire-4 Diesel Engine Appendix...
Page 204 Engine assembly tolerance (unit : mm) Stand value Limit Group Part Inspection item Correction Remark for use assembly Measure unworn Inside diameter of φ104.9~φ105.1 φ104.4 Replace liner portion beneath the cylinder liner rim of the upper side Amount of liner From top of 0.03 ~ 0.08 Cylinder...
Page 205 Stand value Limit Group Part Inspection item Correction Remark for use assembly Top ring Piston Limit for use is if Replace ring or ring side 2nd ring 0.05~0.09 0.15 for standard piston clearance clearance. Oil ring 0.03~0.07 0.15 Cross Install by Direction of ring gap 120°...
Page 206 (Unit : mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Radial run-out of Correct with a Horizontal and 0.01 journal and pin grinder vertical directions φ79.905~ Outside diameter of Use under φ78.905 φ79.925 journal sized bearings φ68.924~ respectively...
Page 207 Stand value Limit Group Part Inspection item Correction Remark for assembly for use φ55.92~ Diameter of camshaft φ55.65 φ55.95 journal Clearance between cam Replace cam 0.03 ~ 0.09 0.18 shaft and cam bush bush Replace thrust End play of camshaft 0.280 ~ 0.430 washer Correct or...
Page 208 Stand value Limit Group Part Inspection item Correction Remark for assembly for use When replacing Inner diameter of valve valve guide & seat φ7.000~φ7.015 guide work simultaneously by special tools Valve guide assembly φ13.000~ part’s inner diameter of φ13.018 cylinder head φ13.028~ Diameter of valve guide φ13.039...
Page 209 Stand value Limit Group Part Inspection item Correction Remark for assembly for use Permissible oil temperature this value in short time (°C) By-pass valve for oil filter 1.9~2.3 (kg/cm Operating 2.0~2.2 Spray pressure Replace valve nozzle Nozzle φ1.6 diameter Delivery volume l/min - Pump speed: 3,333rpm Replace gear 75 or more...
Page 210 Stand value Limit Group Part Inspection item Correction Remark for assembly for use Refer to adjust Fan belt depression Adjust table Operating temperature Cooling 82 ~ 95 Must not (permissible temp.) (°C) exceed this water Permissible temperature value temp in a short time (°C) Thermostat opening temperature °C (under Replace...
Page 211 ● Engine assembly DL06K...

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D110s-5 D130s-5 D160s-5 Dl06k

Doosan DL06 Operation Manual

1 Safety Regulations & Specifications

2 Technical Information

3 Disassembly and Reassembly of Major Components

4 Commissioning and Operation

5 Maintenance of Major Components

6 Special Tool List

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