Doosan DL06 Manual
  1. Manuals
  2. Brands
  3. Doosan Manuals
  4. Engine
  5. DL06
  6. Manual
Doosan DL06 Manual

Doosan DL06 Manual

Hide thumbs Also See for DL06:
Table of Contents

Advertisement

Quick Links

See also: Operating Manual
DL 06 Diesel Engine
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly
D110S-5, D130S-5, D160S-5
SB4228E01
Sep. 2011

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DL06 and is the answer not in the manual?

Questions and answers

Related Manuals for Doosan DL06

Summary of Contents for Doosan DL06

  • Page 1 SB4228E01 Sep. 2011 DL 06 Diesel Engine Specification System Operation Testing & Adjusting Disassembly & Assembly D110S-5, D130S-5, D160S-5...

  • Page 3: Important Safety Information

    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 5: Table Of Contents

    5.5. Belt ............ 187 1.5. Engine Assembly ........ 15 6. Special Tool List ......190 2. Technical Information 7. Engine assembly DL06 – EUTFC 2.1. Engine Model and Serial Number ..18 ............204 2.2. Diagnostic tool (EDIA) ......19 2.3. Engine character ......... 19 2.4.

  • Page 7: Safety Regulations

    Before putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the “critical” points. If you are unsure, ask your DOOSAN representative or service man. For reason of safety we recommend you attach a notice to the door of the...
  • Page 8 (3) When carrying out checking, setting and repair work Checking, setting and repair work must be carried out by authorized personnel only. Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench could lead to injury. DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 9 (2) If faults occur, find the cause immediately and have it eliminated in order to prevent more serious of damage. (3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting from the installation of other parts which are supposedly "just as good”.
  • Page 10 - Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents. After washing apply a fatty skin cream to the skin. Change oil-soaked clothing and shoes. Do not put oily rags into your pockets. DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 11 4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN parts necessarily. 6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

  • Page 12: Engine Specifications

    Cooling method Pressurized circulation Cooling water capacity(engine only) (lit) 10.6 Type Wax pallet type Open at (° C) 71°C (82°C) Thermostat Open wide at (° C) 90°C (95°C) Valve lift (mm) 10 (10) DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 13 Alternator (voltage – capacity) (V - A) 24 - 60 Starting motor(voltage–output) (V - kW) 24 – 4.5 Air heater capacity (V – A) 12V – 1.3kW x 2ea Battery capacity (V - AH) 24 - 150 DL06 Diesel Engine Safety Regulations & Specifications...

  • Page 14: Engine Power

    Tier-2 EUTFB 140/2,100 59/1,400 2,420 Tier-2 DL06 EUTFC 160/2,100 67/1,400 2,420 Tier-3 EUTFD 140/2,100 59/1,400 2,420 Tier-3 * Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349) DL06 Diesel Engine Safety Regulations & Specifications...

  • Page 15: Engine Performance Curve

    Revolution (rpm) Performance ISO 1585 (SAE J1349) Output (max.) 103 kW (140 PS) / 2,100 rpm Torque (max) 579 N.m (59 kg.m) / 1,400 rpm Fuel consumption (min.) 224 g/kW.h (165 g / PS.h) DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 16 Revolution (rpm) Performance ISO 1585 (SAE J1349) Output (max.) 118 kW (160PS) / 2,100 rpm Torque (max) 657 N.m (67 kg.m) / 1,400 rpm Fuel consumption (min.) 224 g/kW.h (165 g / PS.h) DL06 Diesel Engine Safety Regulations & Specifications...

  • Page 17: Engine Assembly

    1.5. Engine Assembly 1.5.1. Sectional drawing (longitudinal) Cooling water pump Cylinder head Thermostat Push rod Injector Tappet Piston Vibration damper Piston pin Oil suction pipe Oil filler cap Crank shaft Intermediate cover Cam shaft DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 18 1.5.2. Sectional drawing Oil spray nozzle Rocker arm Oil cooler Valve Connecting rod Cylinder block Fuel high pressure pipe Oil pump Common rail Oil level gauge High pressure connector Drain plug Caliper DL06 Diesel Engine Safety Regulations & Specifications...
  • Page 19 1.5.3. Engine assembly (1) DL06 (Fork lift) Flywheel housing Fuel high pressure pump Air pipe Air compressor Engine control unit(ECU) (intercooler to intake manifold) (if equipped) Oil filter Oil filler cap Lifting hook (rear) Crank shaft pulley Exhaust manifold Cylinder head cover...

  • Page 20: Engine Model And Serial Number

    They are also referred to as engine model and serial number because of their location. Engine serial No. (example 2 : DL06 Fork lift) DL06 6 00001 FA Engine model suffix (EUTFA) Serial no. Production year (2006)

  • Page 21: Diagnostic Tool (Edia)

    2.3. Engine character DOOSAN ‘s DL06 diesel engine apply the over head valve and the turbocharger, is the electric control engine of the air cooling type by the cooling fan. The fuel is stored under pressure in the high-pressure accumulator (the "Common Rail") ready for injection.
  • Page 22 The connecting rods are die-forged, diagonally split and can be removed through the top of the cylinders together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze ready-to fit type bearings. DL06 Diesel Engine Technical Information...
  • Page 23 Pressure generation and fuel injection are completely decoupled from each other in the "Common Rail" fuel injection system. The injection pressure is generated independent of engine speed and injected fuel quantity stored in the ECU. DL06 Diesel Engine Technical Information...

  • Page 24: Engine Timing

    (B gear Z=18) Camshaft gear (Z=56) Crankshaft gear (Z=44) Oil pump gear (Z=33) Viewed from flywheel housing 2.3.6. Valves The overhead valves are actuated via tungsten carbide tappets, push rods and rocker arms from the camshaft. DL06 Diesel Engine Technical Information...
  • Page 25 Main bearing (Crank shaft) Oil filter by-pass (1.9 ~ 2.3 kg/cm Oil filter (full flow and by-pass) Oil pressure regulating valve (5.3~5.7kg/cm Oil pump Oil suction pipe Relief valve (9 ~10.5 kg/cm (timing gear case) DL06 Diesel Engine Technical Information...
  • Page 26 The following oils are also recommended. Engine oil SAE No. API No. ACEA-E5 DL06 SAE 10W40 (API CI-4) Engine oil capacity Engine oil capacity Engine model Oil pan inside Total (lit) Suffix Max (lit) Min (lit) Fork lift EUTFA/B/C/D DL06 Diesel Engine Technical Information...
  • Page 27 Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Oil filter Change the oil filter cartridge and cartridge simultaneously at every replacement of engine oil. Oil cooler Oil filter and cartridge DL06 Diesel Engine Technical Information...
  • Page 28 Drain water in cartridge with loosening the valve under cartridge Priming pump manually from time to time. The filter cartridge should be Primary fuel filter and cartridge replaced at every 40,000 km (500Hr). Drain plug DL06 Diesel Engine Technical Information...
  • Page 29 (500Hr). Fuel filter and cartridge 2.3.14. Fuel requirements DOOSAN diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets specification . For maximum fuel ASTM D (Grade Low Sulfur) economy, Number 2-D fuel whenever possible. When temperatures are below -7 °C, use Number 1-D fuel.
  • Page 30 Lubricity (wsd 1.4 @ 60°C) Viscosity (40°C) 2.0 ~ 4.5 °C ≤ 360 Distillation (95%) Note: The cloud point should be 6 °C below the lowest expected fuel temperature to prevent clogging of fuel fitters by crystals DL06 Diesel Engine Technical Information...
  • Page 31 2.3.17. Bleeding the fuel system Loosen the fuel delivery pipe connected to the fuel high pressure pump from the secondary fuel filter, operate manually the priming pump until bubbles are not found, and bleed the system. DL06 Diesel Engine Technical Information...
  • Page 32 Fouled air pollutes and clogs the air fins of intercooler. As a result of this, the engine output is decreased and engine malfunction is occurred. So you always check whether the intake air systems like air filter element are worn or polluted. DL06 Diesel Engine Technical Information...
  • Page 33 If impeller is severely polluted, dip the impeller into solution and may be better to clean it with stiff brush. Then one thing to beware is to dip only impeller part and so do not support by impeller but bearing housing. DL06 Diesel Engine Technical Information...
  • Page 34 Be sure to mix soft water with antifreeze solution. Cylinder head cover Cylinder head Cylinder liner To radiator Thermostat Water pump Oil cooler Cylinder block Cooling water pipe From radiator DL06 Diesel Engine Technical Information...
  • Page 35 You can check the quantity of anti-freeze and anti-corrosion agent by using a FLEETGUARD test kit simply as follow. (Fleetguard CC2602M or DOOSAN 60.99901-0038) DL06 Diesel Engine Technical Information...
  • Page 36 How to judge the strip a) Compare FREEZEPOINT (end pad) to chart and record result. b) Next compare MOLYBDATE (middle pad) to chart and record result. c) Finally compare NITRITE test to chart and record result. DL06 Diesel Engine Technical Information...
  • Page 37 The content of the anti-freeze and anti-corrosion agent can be regulated by this way. NOTE: Every year coolant must be replaced. It is essential the coolant should be mixture of fresh water, proper anti-freeze and anti-corrosion agent. DL06 Diesel Engine Technical Information...
  • Page 38 As for the valve clearance, adjust it when in cold, as follows. Engine model Intake valve (X) Exhaust valve (X) DL06 0.3 mm 0.4 mm DL06 Diesel Engine Technical Information...
  • Page 39 Valve adjusting nut Torque 3.0+0.5 kg.m Push rod Caliper Valve adjusting No. 1 cylinder is located at the side where cooling fan was installed. Cooling fan Exhaust valve Intake valve Fly wheel Valve clearance adjusting position DL06 Diesel Engine Technical Information...
  • Page 40 ◈ ◈ Add 180° rotation Adjusting of valves (Type 2) Adjusting of the valve overlapping on cylinder is done as follow. When each cylinder is valve overlap (Firing cylinder no. order) Valve adjusting cylinder No DL06 Diesel Engine Technical Information...
  • Page 41 Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition. Inspect for amount of electrolytic solution, and replenish if insufficient. Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish. DL06 Diesel Engine Technical Information...
  • Page 42 The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator. The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all, against moisture and water. Wiring diagram DL06 Diesel Engine Technical Information...
  • Page 43 Solenoid Magnetic switch Motor Solenoid switch Battery terminal IMPORTANT : Always disconnect the battery earth cable before starting work on the electrical system. Connect up the earth cable last, as there is otherwise a risk. DL06 Diesel Engine Technical Information...

  • Page 44: Diagnosis And Remedy

    The following description summarizes the probable cause of and remedy for general failure by item. Inspect the electrical parts problem with EDIA and refer diagnostic manual. Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. DL06 Diesel Engine Technical Information...
  • Page 45 DL06 Diesel Engine Technical Information...
  • Page 46 DL06 Diesel Engine Technical Information...
  • Page 47 DL06 Diesel Engine Technical Information...
  • Page 48 Inspect cylinder head gasket DL06 Diesel Engine Technical Information...
  • Page 49 DL06 Diesel Engine Technical Information...
  • Page 50 DL06 Diesel Engine Technical Information...
  • Page 51 Replenish or replace Fan belt loosened, worn, Adjust or replace damaged Cooling water pump's Repair or replace function lowered Water temperature Replace regulator's operation poor Valve clearance incorrect Adjust Exhaust system's resistance Clean or replace increased DL06 Diesel Engine Technical Information...
  • Page 52 Replace tappet, cam Turbocharger inner part Repair or replace damaged 6) Fuel consumption Injection timing incorrect Check Fuel injection amount Adjust excessive excessive Tire air pressure incorrect Use of low speed gear is too frequent DL06 Diesel Engine Technical Information...
  • Page 53 Wear of valve stem seal Replace seal Cylinder head gasket’s leak Replace gasket (3) Oil leak Looseness of connection Replace gasket, repair parts Various parts' packing poor Replace packing Oil seal poor Replace oil seal DL06 Diesel Engine Technical Information...

  • Page 54: Engine Inspection

    Check the battery charging Engine Check the compression When adjust pressure necessary Adjust intake / exhaust When О valve clearance necessary ●) The engine oil change interval is determined by engine use and oil grade. DL06 Diesel Engine Technical Information...
  • Page 55 For the analogous parts not the original parts are poor in qualities and gives ill performances, it may rather bring early engine failure. DL06 Diesel Engine Technical Information...

  • Page 56: Engine Disassembly

    This will prevent Drain valve a person from scalding with hot steam spouted out from the filler port. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 57 Drain plug 3.1.5. Cooling fan Remove the fan guide and bracket. Remove the flange fixing bolts, and then take off the flange and cooling fan. Cooling fan DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 58 Loosen the tension adjusting bolts of the alternator and air con. compressor, then take off the Alternator cooling fan. Water pump Crankshaft pulley Air con. compressor Idle pulley Alternator Water pump Crankshaft pulley DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 59 Be careful about the mixing of foreign matter into interior of the turbocharger. 3.1.9. Breather Loosen the clamp screw to remove the rubber hose. Remove the breather valve assembly. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 60 2) Do not reuse the fuel high pressure pipe after remove its. 3.1.12. Fuel high pressure pump Remove the fuel high pressure pump fixing bolts and take off the fuel high pressure pump by pushing to backward. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 61 Remove the oil pipe and cooling water pipe connected to the air compressor from the cylinder block and air compressor. Unscrew the air compressor fixing bolts and take off the air compressor. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 62 Water pump pulley 3.1.18. Exhaust manifold Unscrew the exhaust manifold fixing nuts and remove the heat shield from the exhaust manifold. Then disassemble the exhaust manifold and gasket. Scrap the used gasket. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 63 3.1.21. Rocker arm Remove the rocker arm bracket fixing bolts in reverse order of assembling and disassemble the rocker arm. Take out the push rod. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 64 Remove the cooling water pipe gasket and finish the surface with a Thermostat scraper. housing CAUTION : Be sure that piece of the gasket do not come into the cooling water passage. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 65 Remove the electric control unit fixing bolts, then take off the electric control unit and bracket. 3.1.26. Starting motor Unscrew the starter fixing nuts and remove the starter being careful not to damage its gears. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 66 3.1.29. Front oil seal cover Disassemble the oil seal using an oil seal removing jig. Oil seal cover Remove the cover fixing bolts and disassemble the cover from the Oil seal timing gear case. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 67 3.1.32. Timing gear case Remove the timing gear case assembling bolts. By tapping lightly with a urethane hammer the right and left back of timing gear case's connecting part, disassemble the timing gear case. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 68 In order for connecting rod cap not to be swapped, temporarily assemble to the corresponding connecting rod. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 69 Piston ring jig (4) Clean the piston thoroughly. 3.1.35. Cylinder liner Be careful not to generate any damage at cylinder block. Disassemble the cylinder liner with a special tool or hand. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 70 In order for the disassembled crankshaft to be prevented from bends or damage, put it on the special lathe and store. Disassemble the metal bearings in turn and store them. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 71 Pull out the tappet. Check for damage, scratch, wearing state and if abnormal, tear down. 3.1.40. Oil spray nozzle Remove the valve screws of oil spray nozzle and disassemble it. DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 72: Inspection And Measurement On Major Parts

    Remove carbon from the cylinder head lower surface, and then should be careful not to scratch the surface. Check any crack or damage that can not found by naked eyes through the hydraulic or magnetic particle test. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 73 Standard Limit 0.15 mm 0.3 mm 4) The hydraulic test The hydraulic test of cylinder head is same as the cylinder block test. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 74 Measure the thickness of valve head and if beyond the limit value, replace the valve. Standard Limit Intake valve 3.3~3.7 mm 1 mm or less Exhaust valve 3.3~3.7 mm 1 mm or less DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 75 Assemble the valve at the valve seat of the cylinder head, and check the amount of depression of the valve from the lower portion of the cylinder head using a dial gauge. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 76 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. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 77 Spring Set Length Limit force Intake 39.4 mm 28.8 kg ±2 kg exhaust 29.67 mm 50 kg ±2 kg valve Spring tester DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 78 1) Disassemble the snap rings that are located at one end of rocker arm shaft by a plier. 2) Disassemble in the order of washer, rocker arm, rocker arm bracket, rocker arm spring. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 79 Rocker arm shaft Replace the rocker arm if the amount of wear is beyond the specified limit. Standard Limit φ24.939 ∼ φ24.960 mm φ24.90 mm DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 80 Standard Limit φ24.991 ∼ φ25.012 mm φ25.04 mm Standard Limit Rocker arm and shaft clearance 0.14 mm 0.031~0.073 mm or less DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 81 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. Limit 0.25 mm or less Push rod length 344 mm DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 82 Standard Limit Intake 46.025 mm 45.73 mm Cam lobe height Exhaust 47.782 mm 47.48 mm Cam journal diameter (A,B) φ55.92∼φ55.95mm φ55.65 mm DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 83 Support the camshaft on two V- blocks and check for run-out using a dial indicator. Correct or replace the cam shaft if the amount of run-out is beyond the value indicating need for servicing. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 84 (Be sure to use grinding paper which has been immersed in oil.) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 85 CAUTION : In case of regrinding, the grinding the "R" part of bearing end should be correctly done and avoid sharp corners or insufficient fillet. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 86 Torque 30±2 kg.m Compare the two values obtained through measurement of main bearing inside diameter with the outside diameters of crankshaft journals to determine the oil clearance. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 87 Standard Limit 0.030 ∼ 0.081 mm 0.15 mm If the clearance deviates from the specified range, have the crankshaft journals and pins ground and install undersize bearings. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 88 This is the oil clearance. 4) Bearing spread and crush Inspection Check to see that the bearing requires a considerable amount of finger pressure at reassembly operation. Spread = φA - φB DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 89 0.085 ∼ 0.125 mm Standard 5) Crank shaft end play Assemble the crankshaft to the cylinder block. With a dial gauge, measure crankshaft end play. Standard Limit 0.14 ∼ 0.33 mm 0.4 mm DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 90 3 points (cylinder top ring contacting face, middle, and oil ring contacting face on BDC) in a direction at an angle of 45°. Take the mean value with the largest and smallest values excepted. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 91 Check the marking numbers (red line) of cylinder liner. b) Assemble the piston whose marking is just same with the second digit (A or B) of the assembled liner’s marking. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 92 Standard Limit 1st ring 2nd ring 0. 05 ~ 0.09 mm 0.15 mm Oil ring 0.03 ~ 0.07 mm 0.15 mm DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 93 Standard Limit 0.006 ∼ 0.020 mm 0.08 mm When replacing the piston, be sure to replace the piston pin together. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 94 Assemble the connecting rod to the piston and measure connecting rod small end side clearance. If the measured values are beyond the limit, replace the connecting rod. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 95 If the measured valves are beyond the limit, replace the seal ring. 2.0 mm (Thickness of seal ring) 3.0 mm (Projection of nozzle) DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 96: Reassembly

    3.3.3. Cylinder liner Stand the cylinder block so that the flywheel faces downward. Thoroughly clean the liner flange fitting surface and bore inside with compressed air to prevent the entry of foreign substances. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 97 : 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. Front side Rear side DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 98 Coat engine oil to the pin and journal of crankshaft. Install the oiled thrust washers with the oil groove facing outward. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 99 : With impact wrench, tighten up to about 15 kg.m (4) Fourth stage : With torque wrench, tighten up to about 25 kg.m (5) Fifth stage : By means of torque wrench, tighten finally in the specified torque. (30±2 kg.m). DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 100 However, in case of tightening the bolts, ● tighten primarily the bolts of both end parts and then do the rest. Relief valve Relief valve 2.6 +0.5 kg.m Timing gear case fixing 4.4 +0.5 kg.m bolt DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 101: Gear Train

    Step idle gear (B) and “1” and “1” Camshaft gear High pressure pump driving gear Step idle gear 6.2 +0.5 kg.m Idle gear High pressure idle gear 6.2 +0.5 kg.m Camshaft gear Crank gear DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 102 11.2 +1.0 kg.m When the bolts are tightened, remove the guide bar. Apply lubricating oil to the outside of the oil seal and insert it to the flywheel housing using a press. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 103 After that take out the guide bar, then install a bolt in the hole where the guide bar had been inserted. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 104 Install the snap rings and check to CAUTION: Direction of snap ring is see that it is securely assembled. assembling to be positioned the opposite side DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 105 Use care not to damage the cylinder liner and piston, and slightly lift and insert the piston into the cylinder so that the ring may not be damaged by the fillet of the liner. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 106 If no end play is found, remove and reinstall or replace the connecting rod bearing. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 107 Put the new oil seal on the oil seal Oil seal hole of timing gear case cover aligning the center of them, then assemble the oil seal using an oil seal fitting jig. Torque 2.2+0.5 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 108 Oil pan 2.2+0.5 kg.m Torque Drain plug 10+1.0 kg.m Align the bolt holes with gasket holes to prevent damage to the gasket and tighten. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 109 After installing valve springs and spring retainer, press the retainer with a jig, then install the cotter pin. Tap the valve stem lightly with a rubber hammer to check that the valve is assembled correctly. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 110 Coat the cylinder head bolts with 13 17 engine oil, and tighten in proper sequence to the specified torque according to bolt tightening order. 15 11 23 19 DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 111 The injector set to injector fixing bracket with the fixing bolt, then assemble temporarily it. Fuel high pressure Injector fixing bracket Temporarily connector fixing nut torque 0.3 kg.m 0.25 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 112 Install the rocker arm, bracket, rocker arm, washer, spring and snap ring in the described sequence. Install the rocker arm and bracket in the same direction. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 113 Oil cooler Oil filter and cartridge 3.3.22. Starting motor Insert the starter into the flywheel housing and tighten the fixing nuts. Torque 8.0+1.0 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 114 2.5+0.5 kg.m Fuel high pressure Side of fuel high pressure connector 2.8+0.5 kg.m Torque pipe Common rail from fuel high pressure pump 2.1+0.5 kg.m Common rail and fixing bolt 2.2+0.5 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 115 Projection face Assemble the exhaust manifold and the heat resisting plate, the tightening order of bolts is from the middle to left and right alternately. Torque 5.0+0.5 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 116 Head cover 2.2+0.5 kg.m Torque Intermediate cover 3.1+0.5 kg.m Fit the oil filler cap on the cylinder head cover. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 117 Coat the oil on the O-ring of attached face of air compressor, install it to the fly wheel housing. Assemble the air compressor a’ssy tighten to the specified torque. (Carefully damage the O-ring) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 118 3.3.33. Crankshaft speed sensor Measure the clearance of the Crankshaft speed sensor assembling part of the sensor and fly wheel, then assemble it with the shim. 1. 0 ±0.1mm clearance Torque 1.0+0.5 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 119 Fuel feed pump → Fuel filter → Fuel high pressure pump → Common rail. Fuel pipe 3.0+0.5 kg.m Torque Fuel temp sensor 2.2+0.5 kg.m Fixing bracket 4.4+0.5 kg.m DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 120 3.3.38. Cooling fan & fan clutch Install the flange to the crankshaft pulley, then assemble the fan clutch and cooling fan to the fan flange. Torque of cooling fan 2.2+0.5 kg.m Cooling fan DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 121 Assemble the guide tube and oil level gauge on the oil pan. 3.3.40. Others Assemble by connecting the other sensor, harness, fuel and oil line. DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 122: Fuel Injection System

    ECU on the basis of the stored map. The ECU then triggers the solenoid valves that the injector at each engine cylinder injects accordingly. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 123 Independently of each other, injected fuel quantity and injection pressure should be definable for each and every engine operating condition. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 124 The injectors are connected to the common rail by high pressure pipe, comprise a nozzle, and a solenoid valve which is energized by the ECU to switch it on (start of injection), When the solenoid valve is switched off injection ceases. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 125 The pump draws the fuel from the fuel tank and continually delivers the required quantity of fuel in the direction of the high pressure pump. Fuel delivery pump 1. Fuel inlet 2. Driving gear 3. Fuel outlet DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 126 The return fuel from the pressure control valve and from the low pressure stage is also led into this collector line together with the fuel used to lubricate the high pressure pump. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 127 The inlet valve closes when the pump piston passes through the bottom dead center (BDC) and, since it is impossible for the DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 128 After the injector use the fuel from the common rail for fuel injection, the pressure oscillation of the common rail is maintained constantly by the common rail volume. The fuel pressure is calculated DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 129 ECU. Electric connections Evaluation circuit Diaphragm High pressure connection Mounting thread DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 130 As soon as the hydraulic force drops below the force on the nozzle-needle pressure shoulder, the nozzle needle opens and fuel is injected through the spray holes into the combustion chamber. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 131 These operating states result from the distribution of the forces applied to the injector's components. With the engine at standstill and no pressure in the rail, the nozzle spring closes the injector. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 132 Force distribution in the injector is similar to that during the opening phase. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 133 The rotational speed defines the number of crankshaft rotations per minute. This important input variable is calculated in the ECU using the signal from the inductive crankshaft speed sensor. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 134 Shim The output signal is inputted to the ECU where, with the help of a programmed characteristic curve, it is used for calculating the boost pressure. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 135 & is inputted into ECU. temperature sensor 3.4.19. Engine coolant temperature sensor The engine coolant temperature sensor measure in the engine coolant circuit and measuring data is inputted into ECU. DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 136: Electrical System

    Common rail pressure sensor Coolant temperature sensor Air heater Boost pressure & temperature sensor Fuel pressure limit valve Starter Fuel temperature sensor Camshaft speed sensor Engine oil pressure & temperature sensor Alternator DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 137 3.5.2. Harness of electrical control unit a) Harness of electrical control unit DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 138 Harness of electrical control unit (A) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 139 Harness of electrical control unit (B) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 140 3.5.3. Connector of electrical control unit (ECU) Engine side connector Vehicle side connector DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 141 Controller area network 1, low 1.53 B_D_CANH1 B_D_CANH1 Controller area network 1, high 1.54 I_S_RMTSET O_S_RL11 Remote PTO set 1.56 O_S_CSLP O_S_RL33 Cold start lamp 1.57 O_V_FAN1 O_V_RL24 Motor fan relay 1 supply (BAT+ ) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 142 Oil pressure sensor ground 2.25 G_R_BPS G_R_ACT06 Boost pressure sensor ground 2.26 G_R_CTS G_R_PAS01 Coolant temperature sensor ground 2.27 I_A_OPS I_A_ACT03 Oil pressure sensor input signal 2.28 I_A_OTS I_A_PAS04 Oil temperature sensor signal DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 143 Injector 4 “High Bank 2” ; Cylinder no. 4 3.15 O_P_SV22 O_P_SV22 Injector 6 “High Bank 2” ; Cylinder no. 6 3.16 O_P_SV21 O_P_SV21 Injector 5 “High Bank 2” ; Cylinder no. 5 DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 144 Black Coolant temperature sensor ground(-) 2.35 ECU no. 35 Fuel temperature sensor no.1 White Fuel temperature sensor signal 2.26 ECU no. 26 Fuel temperature sensor no.2 Black Fuel temperature sensor ground(-) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 145 3.5.6. Engine harness – 2 Fuel metering unit (MEU) ECU side Injector intermediate connector Injector Injector Injector Injector Injector Injector cylinder cylinder cylinder cylinder cylinder cylinder Intermediate connector of injector DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 146 White Low side of injector 5 3.02 White High side of injector 6 3.15 White Low side of injector 6 P_03 3.09 White Fuel metering unit(high side) 936059-1 3.10 Black Fuel metering unit(low side) (AMP) DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 147 High side of injector 4 99013-00102 Low side of injector 4 (AMP) High side of injector 5 Low side of injector 5 High side of injector 6 Low side of injector 6 DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 148: Engine Diagnostic

    3.6. Engine Diagnostic 3.6.1. Method of confirmation for the fault code The method of performing the DL06 engine diagnostic are method by using the EDIA and method of confirming the indicator code using the blinking times of the vehicle’s engine indicator lamp.
  • Page 149 Main relay is short on circuit to * Power supplying is abnormal ground * When the main relay is shorted to ground, depending on whether the main relay is 1,2 or 3 DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 150 Low side Power stage 7 * Not use Low side Power stage 8 * Not use Low side Power stage 9 * Not use Low side Power stage 10 * variable speed limit DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 151 * Segment speed is above threshold and if the interrupt detection status is not in-active. Accelerator pedal unplausibility 10.7 * Not use (APP3) 10.8 Smooth running control seg-0 * Not use 10.9 Smooth running control seg-1 * Not use DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 152 C : Case of requirement for the check after running (no emergency check). B : Case of requirement for the check and measure after running at the low speed at the time of occurring. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 153 • Cruise - SET / INC switch Communication • Cruise - SET / DEC switch • Door open sensing switch • Engine diagnostic communication • CAN communication • Engine brake switch • Diagnostic switch DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 154: Operating Condition Of The Ecu

    - When the switch [RESUME] is stored at the condition of depressing, the last stored value keep constantly after start the engine. - When the engine is stopped at the condition of doing not depressed [RESUME] switch, return to the first value. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 155 The ECU is operated by automatic sensing. Operation condition - State of vehicle speed sensor : normal - Vehicle speed : state of stop - Engine speed : idle speed - Parking brake : state of operation DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 156 Little influence on performance, but the check is needed. - Defect of serious level : lamp is blinked. Engine power is dropped Engine power is not dropped, but the check is needed unavoidably after low speed operating. DL06 Diesel Engine Disassembly and Reassembly of Major Components...
  • Page 157 - Fuel quantity according to the division : total, idle state, PTO - Fuel consumption rate. - operating mileage. - Engine operating time, ECU using time. The monitoring is possible by using diagnostic tool. DL06 Diesel Engine Disassembly and Reassembly of Major Components...

  • Page 158: Preparations

    DOOSAN do not guarantee the field claim. 4.2. Breaking-In DOOSAN engine for the vehicle is operated during a short time for the engine last approving test, therefore operator must execute the process of proper breaking in the engine during the first 5,000 km(50 Hr), then The maximum performance of the engine have the maximum performance , and the life of the engine can be prolonged.
  • Page 159 Both of these conditions reflect normal engine operation. Watch the engine water temperature gauge and be sure there is proper water circulation. The water temperature gauge needle will fluctuate if water level in expansion tank is too low. DL06 Diesel Engine Commissioning and Operation...

  • Page 160: Inspections After Starting

    Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal. Confirm the following things through warning lamps and gauge panel. DL06 Diesel Engine Commissioning and Operation...
  • Page 161 This engine with ECU should not be run at the over-speed rating speed for a regular time, if the vehicle is speeded, the fuel and ignition is shut off until the engine speed is up to the proper level. DL06 Diesel Engine Commissioning and Operation...

  • Page 162: Operation In Winter Time

    Operation 3 : After the engine is cranked, convert the key switch to the ON position. Behavior - As the engine is cranked, air heater is heated for 180 seconds (3 minute after-heating) to reduce and to element quickly white smoke. DL06 Diesel Engine Commissioning and Operation...
  • Page 163 Drop of thermal efficiency caused by excessive cooling increases fuel consumption, therefore prevent the engine from excessive cooling. If the temperature of coolant does not reach to normal condition (78 ~ 85°C) after continuous operation, examine the thermostat or the other cooling lines. DL06 Diesel Engine Commissioning and Operation...

  • Page 164: Engine Components Check After Long Time Running

    Below components that affect power and performance to be checked are:. - Components affecting intake & exhaust Air cleaner, inter-cooler, turbo charger, silencer, etc - Components affecting lubrication & cooling Air & oil filter, anti- freeze, etc DL06 Diesel Engine Commissioning and Operation...

  • Page 165: Maintenance And Care

    CAUTION: Do not add so much engine oil that the oil level rises above the max. marking on the oil level gauge. Over lifting will result in damage to the engine. DL06 Diesel Engine Commissioning and Operation...
  • Page 166 Thereafter shut down the engine. After waiting for about 10 minutes measure the quantity of oil and refill the additional oil if necessary. 4.6.5. Replacement of oil filter cartridge At the same times of oil exchanges, replace the oil filter cartridge. Oil filter and cartridge DL06 Diesel Engine Commissioning and Operation...
  • Page 167 Lightly apply oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring. Turn 3/4 ~ 1 turns further with the filter wrench. CAUTION : It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement. DL06 Diesel Engine...

  • Page 168: Cooling System

    When removing the pressure filler cap while the engine is still hot, cover the cap with a rag, then turn it slowly to release the internal steam pressure. This will prevent a person from scalding with hot steam spouted out from the filler port. DL06 Diesel Engine Commissioning and Operation...
  • Page 169 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. DL06 Diesel Engine Commissioning and Operation...
  • Page 170 At the radiator, the heat absorbed in the coolant is radiated to cool down and the coolant recirculates to the water pump Cylinder head Thermostat Cylinder block Water Oil cooler pump DL06 Diesel Engine Maintenance of Major Components...
  • Page 171 Item In moderate climates In tropical climates Type Wax-pallet type 82 °C 71 °C Open at 95 °C 90 °C Open wide at Valve lift 10 mm or more 10 mm or more DL06 Diesel Engine Maintenance of Major Components...
  • Page 172 (2) When draining out or replenishing coolant, do it slowly so that air is bled sufficiently from the entire cooling system. (3) Replacing thermostat If the thermostat is detected defective, retrace with a new one. DL06 Diesel Engine Maintenance of Major Components...
  • Page 173 4. Cooling system Water pump bearing Replace bearing noisy defective Fan loosely fitted or bent Retighten or replace fan Fan out of balance Replace fan Fan belt defective Replace fan belt DL06 Diesel Engine Maintenance of Major Components...

  • Page 174: Lubrication System

    (2) Remove the oil pump cover fixing nuts and disassemble the oil pump cover. The oil pump cover is fixed with the two dowel pins. (3) Disassemble the drive gear and driven gear. DL06 Diesel Engine Maintenance of Major Components...
  • Page 175 Oil clearance 0.050 ~ 0.085 mm Reassembly (1) For reassembly, reverse the disassembly sequence. DL06 Diesel Engine Maintenance of Major Components...
  • Page 176 Correct or replace Oil pressure gauge Correct or replace defective Various bearings worn Replace 2. Oil deteriorates Restriction in oil filter Replace filter element quickly Gases leaking Replace piston rings and cylinder liner DL06 Diesel Engine Maintenance of Major Components...

  • Page 177: Turbo Charger

    Maximum allowable temperature of exhaust gas at turbine 750 °C inlet Lubricating system External oil supply Weight Approx 11 kg 2) Construction Impeller casing Air inlet Turbine casing Gas outlet Bearing casing Gas inlet Impeller Oil supply Turbine Oil return DL06 Diesel Engine Maintenance of Major Components...
  • Page 178 Journal bearing Oil seal plate Hose Thrust bearing Gasket Elbow Piston ring seal (turbine) Hex bolt Hex nut Piston ring seal Lock nut Clamp plate Retaining ring Snap ring Retaining ring Oil stopper DL06 Diesel Engine Maintenance of Major Components...
  • Page 179 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. DL06 Diesel Engine Maintenance of Major Components...
  • Page 180 4) Sealing at compressor shaft In order for the compressed intake air and lubricating oil not to leak, a seal plate and a seal ring are made to the double structures. DL06 Diesel Engine Maintenance of Major Components...
  • Page 181 2) If there are the leakage of oil, gas, that there are no leakage of oil, air, particularly oil, for the oil gas and air. pressure lowers, it causes a burn of bearing to be stuck. DL06 Diesel Engine Maintenance of Major Components...
  • Page 182 DL06 Diesel Engine Maintenance of Major Components...
  • Page 183 2) Guide for checking rotor end play Disassemble the turbocharger from the engine, then check the rotor axial play and radial play. When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports with taps, etc DL06 Diesel Engine Maintenance of Major Components...
  • Page 184 For reassembly of the turbocharger or handling it after reassembly operation, be sure to observe the following precautions. Especially, exercise extreme care to prevent foreign matters from entering the inside of the turbocharger. DL06 Diesel Engine Maintenance of Major Components...
  • Page 185 Be sure to use heat resisting steel bolts and nuts. Do not interchange them with ordinary steel bolts and nuts when performing reassembly operation. Apply anti-seizure coating to the bolts and nuts. Assemble each joint on the exhaust pipes securely to prevent gas leaks. DL06 Diesel Engine Maintenance of Major Components...
  • Page 186 4. Unusual sound or Disassemble/repair 1) Rotor assembly coming in contact vibration or replace Disassemble/repair 2) Unbalanced rotation of rotor or replace Disassemble/repair 3) Seized up or replace 4) Each joint loosened Check and correct DL06 Diesel Engine Maintenance of Major Components...

  • Page 187: Air Cleaner

    On removing the hexagon nut, take out the dirty cartridge and renew or clean. Wipe the cleaner housing with a damp cloth, in particular the sealing surface for the element. DL06 Diesel Engine Maintenance of Major Components...
  • Page 188 The cartridge must be dry before it is reinstalled. - Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean the air cleaner elements. DL06 Diesel Engine Maintenance of Major Components...

  • Page 189: Belt

    Check belts for cracks, oil, overheating and wear (3) Testing by hand Poly belt Poly belt will be properly tensioned if the deflection force “F” is applied mid-way between the belt’s tangent points with the pulley. DL06 Diesel Engine Maintenance of Major Components...
  • Page 190 Slowly depress pad (3) until the spring can be heard to disengage. This will cause the indicator to move upwards. If pressure is maintained after the spring has disengaged a false reading will be obtained. DL06 Diesel Engine Maintenance of Major Components...
  • Page 191 27 - 36 34 – 45 No of rib (Rubber) Oil and heat resistant insulation 41 – 57 Stretch resistant tension member 48 – 66 Oil and abrasion resistant backing 59 - 73 DL06 Diesel Engine Maintenance of Major Components...

  • Page 192: Special Tool List

    Oil seal insert assembly (Front) EF.121-256 EF.121-257 Oil seal assembly jig (Rear) EF.121-258 EF.123-065 Valve spring compression EF.123-365A Cylinder liner puller EF.121-250 Only DL06 engine Piston insert EF.120-208 All engine EF.121-253 Valve stem seal punch DL06 Diesel Engine Special Tool List...
  • Page 193 EF.121-181 Cam shaft hole cover punch EF.121-252 Step idle gear pin assembly Slave piston disassembly & EF.120-239 assembly (Engine brake) 60.99901-0027 Filler gauge EF.121-260 Wear ring punch(rear) 65.98801-0001 Filter wrench T7610001E Snap ring plier DL06 Diesel Engine Special Tool List...
  • Page 194 Injector insert EF.120-278 High pressure connector dummy T7621010E Piston ring plier A463560 EDIA Diagnostic tool A463564 USB GATEWAY (Module) MAIN CABLE A463565 (Gateway - 14pin connector) 14 PIN CONNECTOR A463566 (Main Cable - Harness) DL06 Diesel Engine Special Tool List...
  • Page 195 USB CABLE A463567 (Notebook - Gateway) DL06 Diesel Engine Special Tool List...
  • Page 196 Fuel high pressure pipe – Connector M14 x 1.5 2.8+0.5 kg.m Fuel high pressure pipe – Common rail M14 x 1.5 2.5+0.5 kg.m Fuel high pressure pipe – Pump M14 x 1.5 2.1+0.5 kg.m Fuel filter 4.4+0.5 kg.m DL06 Diesel Engine Special Tool List...
  • Page 197 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 DL06 Diesel Engine Special Tool List...
  • Page 198 30g↓ Replace piston piston Top ring Width of 2nd ring 2.47~2.49 Replace ring piston ring Piston Oil ring 3.97~3.99 ring Piston ring Top ring 0.30~0.45 Standard gauge Replace ring 2nd ring 0.60~0.80 inside diameter: DL06 Diesel Engine Special Tool List...
  • Page 199 0.03~0.07 0.15 Cross Install by Direction of ring gap 120° Outer diameter of φ39.94 Replace piston pin φ39.994~φ40.000 piston pin Piston Clearance between Replace one worn piston pin and its 0.006~0.020 0.08 more bush DL06 Diesel Engine Special Tool List...
  • Page 200 Roundness of big-end 0.007 0.25 inner diameter Parallelness of Replace con- small end side and big 0.50 Allowable weight Management of Replace same 10g ↓ difference per con-rod’s grade degree con-rods (A ~I) DL06 Diesel Engine Special Tool List...
  • Page 201 Use with valve guide from valve guide assembly jig spring seat side and valve Exhaust 12.8 ~13.2 of cylinder head spring seat φ35.800~φ35.8 Valve seat Intake assembly part’s inner φ32.000~φ32.0 diameter of Exhaust cylinder head DL06 Diesel Engine Special Tool List...
  • Page 202 Tappet assembly part’s φ28.010~φ28.0 inner diameter of cylinder block φ27.962~φ27.9 Tappet Diameter of tappet Replace tappet Clearance between Replace if tappet & tappet hole of severely worn or 0.028~0.069 0.13 cylinder block deformed DL06 Diesel Engine Special Tool List...
  • Page 203 Submerge in Test for leakage water and (air pressure) 1.2 ~ 1.3 replace if air Cooling Radiato (kg/cm bubbles found system Pressure valve for opening pressure (kg/cm Differential pressure 0.05 regulating valve DL06 Diesel Engine Special Tool List...
  • Page 204 φ90.000~φ90.0 B grade Inner φ90.010~φ90.0 Replace same diameter C grade grade of cylinder φ90.020~φ90.0 D grade compre compre ssor ssor φ89.910~φ89.9 B grade Diameter Replace same φ89.920~φ89.9 of piston grade C grade DL06 Diesel Engine Special Tool List...
  • Page 205 Fuel high pressure pump 0.103 ~ 0.182 Gear gear & idle gear Drive back Crankshaft gear & oil system 0.073 ~ 0.239 lash pump driving gear Air compressor (PTO) 0.074 ~ 0.163 gear & cam gear DL06 Diesel Engine Special Tool List...
  • Page 206 7. Engine assembly DL06 – EUTFC DL06 Diesel Engine Engine assembly DL06 – EUTFC...

Table of Contents

Save PDF