Doosan DL06 Manuals

Manuals and User Guides for Doosan DL06. We have 2 Doosan DL06 manuals available for free PDF download: Operation Manual, Manual

Doosan DL06 Manual

Doosan DL06 Manual (207 pages)

Brand: Doosan | Category: Engine | Size: 11 MB

Table of Contents

Important Safety Information
3
Table of Contents
5
Index
5
1 Safety Regulations

7
2 Technical Information

20
- Engine Model and Serial Number
  20
- Diagnostic Tool (EDIA)
  21
- Engine Character
  21
  - Cylinder Block
    22
  - Piston, Connecting Rod, Crank Shaft
    22
  - Electric Control Unit: ECU
    23
  - Common Rail System
    23
  - Engine Timing
    24
  - Valves
    24
  - Lubrication System
    25
  - Engine Oil
    26
  - Oil Filter & Cooler
    27
  - Engine Oil Viscosity – Ambient Temperature
    27
  - Fan Belt
    28
  - Air Cleaner
    28
  - Pre Fuel Filter
    28
  - Fuel Filter
    29
  - Fuel Requirements
    29
  - How to Select Fuel Oil
    29
  - Fuel Oil Selection Chart
    30
  - Fuel Injection System
    31
  - Bleeding the Fuel System
    31
  - Injector & High Pressure Connector
    32
  - Inter Cooler
    32
  - Turbo Charger
    33
  - Cooling System
    34
  - Coolant Pressure Cap
    35
  - Cooling Water
    35
  - How to Use the Cooling Water Test Kit
    36
  - Valve Clearance Adjust Procedure
    38
  - Amount of Anti-Freeze
    38
  - Adjusting of Valves
    40
  - Battery
    41
  - Alternator
    42
  - Starter
    43
- Diagnosis and Remedy
  44
  - Engine Starting Impossible
    44
  - Engine Overheated
    45
  - Output Insufficient
    46
  - Oil Pressure Lowered
    47
  - Fuel Consumption Excessive
    48
  - Oil Consumption Excessive
    49
  - Engine Knocking
    49
  - Battery Discharge
    50
  - Troubleshooting Table
    51
- Engine Inspection
  54
3 Disassembly and Reassembly of Major Components

56
- Engine Disassembly
  56
  - Oil Level Gauge
    56
  - Cooling Fan
    57
  - Belt
    58
  - Air Pipe & Air Heater
    59
  - Breather
    59
  - Common Rail & High Pressure Pipe
    60
  - Fuel High Pressure Pump
    60
  - Air Compressor
    61
  - Power Steering Pump
    61
  - Turbocharger
    61
  - Cooling Water Pump
    62
  - Exhaust Manifold
    62
  - Cylinder Head Cover
    63
  - Intake Manifold
    63
  - Rocker Arm
    63
  - Cooling Water Pipe
    64
  - Injector
    64
  - Cylinder Head
    65
  - Electric Control Unit
    65
  - Starting Motor
    65
  - Front Oil Seal Cover
    66
  - Oil Pan
    66
  - Vibration Damper
    66
  - Cam Gear & Idle Gear
    67
  - Oil Pump
    67
  - Timing Gear Case
    67
  - Fly Wheel
    68
  - Piston
    68
  - Cylinder Liner
    69
  - Disassembly of Piston
    69
  - Bearing Cap
    70
  - Crank Shaft
    70
  - Flywheel Housing
    70
  - Cam Shaft & Tappet
    71
  - Oil Spray Nozzle
    71
  - Disassemble the Cylinder
    72
  - Inspection and Measurement on Major Parts
    72
  - Inspection of Cylinder Head
    72
  - Inspection of Valve and Valve Guide (Cylinder)
    74
  - Valve Spring Inspection
    76
  - Assembling Cylinder Head
    78
  - Rocker Arm Disassembly
    78
  - Inspection of Rocker Arm Assembly
    79
  - Rocker Arm Inspection
    80
  - Tappet and Push Rod Inspection
    81
  - Camshaft Inspection
    82
  - Rocker Arm Assembly Inspection
    82
  - Cam Shaft Run-Out
    83
  - Inspection of Crankshaft
    84
  - Crankshaft Bearing and Connecting Rod Inspection
    86
  - Crankshaft Run-Out
    86
  - Bearing Spread and Crush Inspection
    88
  - Oil Clearance between Crankshaft and Bearing
    88
  - Crank Shaft End Play Inspection
    89
  - Disassembly of Piston Assembly
    90
  - Piston Inspection
    90
  - Piston Rings Inspection
    92
  - Piston Pin Inspection
    93
  - Piston Ring Tension
    93
  - Connecting Rod Inspection
    94
  - Injector Projection
    95
- Reassembly
  96
  - Crankshaft
    97
  - Tappet & Cam Shaft
    100
  - Gear Train
    101
  - Oil Seal (Rear Side)
    103
  - Piston & Connecting Rod Assembly
    104
  - Oil Pump and Oil Pipe
    107
  - Oil Seal
    107
  - Oil Pan Assembly
    108
  - Crankshaft Pulley & Vibration Damper
    109
  - Intake and Exhaust Valves
    109
  - Cylinder Head Assembly
    110
  - Injector Assembly
    111
  - Oil Cooler & Oil Filter
    113
  - Starting Motor Installation
    113
  - Common Rail & High Pressure Pipe Assembly
    114
  - Fuel High Pressure Pump Assembly
    114
  - Exhaust Manifold Installation
    115
  - Intake Manifold Installation
    115
  - Cylinder Head Cover Installation
    116
  - Turbo Charger Installation
    116
  - Air Compressor Installation
    117
  - Cooling Water Pump Installation
    117
  - Thermostat Installation
    117
  - Crankshaft Speed Sensor
    118
  - Electrical Control Unit: ECU Installation
    118
  - Camshaft Speed Sensor
    119
  - Fuel Filter Assembly
    119
  - Air Pipe & Air Heater Assembly
    120
  - Alternator & Belt Installation
    120
  - Cooling Fan & Fan Clutch
    120
  - Oil Level Gauge Isntallation
    121
  - Common Rail Fuel-Injection System
    122
  - Fuel Injection System Description
    122
  - Injection Characteristics with Common Rail
    123
  - Major Components of the Common Rail System
    123
  - Fuel High Pressure Pump Description
    124
  - Fuel Delivery Pump
    125
  - Fuel System
    125
  - Fuel Tank
    125
  - High Pressure Fuel Delivery
    126
  - High Pressure System Components
    126
  - Construction of the Fuel High Pressure Pump
    127
  - Common Rail
    128
  - Fuel Delivery Rate
    128
  - Fuel Metering Shut off Valve
    128
  - Common Rail Pressure Sensor
    129
  - Injector Description
    130
  - Pressure Limiter Valve
    130
  - Injector Closed (at Rest Status)
    132
  - Injector Opens (Start of Injection)
    132
  - Crank Shaft Speed Sensor
    133
  - Injector Closes (End of Injection)
    133
  - Accelerator Pedal Sensor
    134
  - Boost Pressure & Temperature Sensor
    134
  - Cam Shaft Speed Sensor
    134
  - Engine Coolant Temperature Sensor
    135
  - Engine Oil Pressure & Temperature Sensor
    135
  - Electric Parts – Fork Lift
    136
- Electrical System
  136
  - Harness of Electrical Control Unit
    137
  - Connector of Electrical Control Unit (ECU)
    140
  - Electrical Control Unit
    141
  - Engine Harness
    144
  - Injector Harness (Outside)
    146
  - Injector Harness (Inside)
    147
- Engine Diagnostic
  148
  - Method by EDIA
    148
  - Method of Confirmation for the Fault Code
    148
  - Engine Fault Code and Occurring Condition
    149
  - Input and Output of the ECU
    153
  - Engine Idle Adjusting
    154
  - Engine Starting
    154
- Operating Condition of the ECU
  154
  - Vehicle Running
    154
  - Engine Stop During Long Time of Idling
    155
  - Maximum Speed Limit Function
    155
  - Safety Function When Door Is Opened
    155
  - Diagnostic
    156
  - Limp Home Function
    156
  - Vehicle Operating Record
    157
4 Commissioning and Operation

158
- Breaking-In
  158
- Operation of a New Engine (Break-In)
  158
- Preparations
  158
  - Check Points for Break-In
    159
  - Operating after Break-In
    160
- Inspections after Starting
  160
  - Pressure of Lubricating Oil
    161
  - Temperature of Cooling Water
    161
  - Over-Speed Control
    161
- Operation in Winter Time
  162
- Engine Components Check after Long Time Running
  164
  - Periodical Inspection and Maintenance
    165
  - Exchanging of Lubrication Oil
    165
  - Oil Level Gauge Check
    165
- Maintenance and Care
  165
  - Oil Exchange Procedure
    166
  - Replacement of Oil Filter Cartridge
    166
- Cooling System
  168
  - Coolant Draining
    168
  - Cleaning of the Cooling Inside System Circuit
    169
5 Maintenance of Major Components

170
- Cooling System Maintenance
  170
- Cooling System Maintenance Specification
  171
- Thermostat Maintenance
  171
- Cooling System Diagnostics and Troubleshooting
  173
- Lubrication System Maintenance
  174
- Oil Pump Maintenance
  174
- Lubrication System Diagnostics and Troubleshooting
  176
- Turbo Charger Maintenance
  177
- Components of Turbocharger View
  178
- Turbocharger General Information
  179
- Turbine
  179
- Compressor
  180
- Sealing at Compressor Shaft
  180
- How to Handle the Engine - Precautions
  181
- Routine Inspection and Maintenance
  182
- Air Intake System Care
  182
- Exhaust System Care
  182
- Lubricating System Care
  183
- Periodical Servicing of the Turbocharger
  183
- Guide for Checking the Rotor for Rotating Condition
  183
- Guide for Checking Rotor End Play
  183
- Guide for Disassembling/Cleaning and Checking the Turbocharger
  184
- Precautions for Reassembling the Turbocharger Onto the Engine
  184
- Turbocharger Diagnostics and Troubleshooting
  186
- Maintenance of Air Cleaner
  187
- Changing Air Cleaner Element
  187
- Cleaning Air Cleaner Elements
  188
- Belt Care
  189
- Measuring Belt Tension
  190
6 Special Tool List

192
7 Engine Assembly DL06 - EUTFC

206

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Doosan DL06 Operation Manual

Doosan DL06 Operation Manual (211 pages)

Interim Tier IV

Brand: Doosan | Category: Engine | Size: 27 MB

Table of Contents

Table of Contents
7
1 Safety Regulations & Specifications

10
- Safety Regulations
  10
- Engine Specifications
  15
- Engine Power
  16
- Engine Performance Curve
  17
- Engine Assembly
  19
2 Technical Information

22
- Engine Model and Serial Number
  22
- Diagnostic Tool
  23
- Z Appendix
  23
- Engine Character
  23
- Diagnosis and Remedy
  44
- Engine Inspection
  55
3 Disassembly and Reassembly of Major Components

56
- Engine Disassembly
  56
  - Inspection and Measurement on Major Parts
    71
- Engine Reassembly
  92
- Fuel Injection System
  116
- Electrical System
  128
- Exhaust Gas Reduction System
  135
- Engine Diagnostic
  151
- Operating Condition of the ECU
  163
4 Commissioning and Operation

165
- Preparations
  165
- Breaking-In
  165
- Inspections after Starting
  167
- Operation in Winter Time
  168
  - Engine Components Check after Long Time Running
    169
- Maintenance and Care
  170
- Cooling System
  172
- Adjustment of Valve Clearance
  173
5 Maintenance of Major Components

176
- Cooling System
  176
- Lubrication System
  180
- Turbo Charger
  183
- Air Cleaner
  195
- Belt
  197
6 Special Tool List

199

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