Doosan DL06K iTIER4 Engine Shop Manual 950106-00344 – PDF DOWNLOAD
DESCRIPTION:
FOREWORD
- This Operation & Maintenance Manual is designed to provide the information on engine operation and maintenance manual to customers and service technicians of the DL06K industrial electronic control diesel engine provided by DOOSAN Infrac ore.
- 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.
- It is important to use precise operation and maintenance procedures to keep the engine in the best possible condition and ensure the best possible long term performance. This Operation & Maintenance Manual provides the specification, defined values, fault diagnosis, parts configuration diagrams, and figures, that allow users to understand, manage, and take actions conveniently and accurately.
- Please read this Operation & Maintenance Manual carefully before handling the engine, to ensure that the highest quality maintenance procedures can be applied and the technician’s safety can be protected through the use of proper work methods and operating procedures as recommended by DOOSAN Infracore and compiled here within.
- We are continually developing and investing in creating products with the best performance and quality, as well as the improvement of maintenance procedures. We are not obliged to reflect all design changes for product improvement in this Operation & Maintenance Manual, and this manual is subject to change without prior notice.
- We are always working to satisfy customer requirements and provide more convenient and safe maintenance procedures to its customers. If you find any incorrect information in this manual or have any inquiry, please contact our head office, dealers or authorized service shops near by your location for any services.
General Instructions:
- This Operation & Maintenance Manual is a manual designed for officially qualified professional service technicians. If maintenance procedures is performed by unqualified personnel, or without the specified tools and facilities, workers or others may be injured or their life can be threatened, or an error may occur that could fatally affect engine performance.
- Regular checkups and management are required to keep the engine in optimal condition and performing at its best. If any part needs to be replaced, the genuine part supplied by DOOSAN Infra core 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 Infra core will bear no responsibility. Please note that the work procedures described in this Operation & Maintenance Manual are the safest and most efficient work procedures, and you may be required to use special tools for some work items.
- Please contact us for genuine parts and special tools. This Operation & Maintenance Manual uses the following symbols to explain maintenance procedures, so that workers can make preparations and understand work items in advance
TABLE OF CONTENTS:
Doosan DL06K iTIER4 Engine Shop Manual 950106-00344 – PDF DOWNLOAD
DL06K Tier4 Interim……………………………………………………….. 0
FOREWORD……………………………………………………………… 5
CONTENTS……………………………………………………………… 7
1. Safety Regulations & Specifications…………………………………… 11
1.1. Safety Regulations…………………………………………….. 11
1.1.1. General notes……………………………………………. 11
1.1.2. To prevent accidents with injury to persons…………………. 11
1.1.3. To prevent damage to engine and premature wear………………. 12
1.1.4. To prevent pollution……………………………………… 13
1.1.5. Notes on safety in handling used engine oil…………………. 13
1.1.6. General repair instructions……………………………….. 14
1.2. Engine Specifications………………………………………….. 15
1.3. Engine Power………………………………………………….. 16
1.4. Engine Performance Curve……………………………………….. 17
1.4.1. Performance curve………………………………………… 17
1.5. Engine Assembly……………………………………………….. 23
1.5.1. Sectional drawing………………………………………… 23
1.5.2. Sectional drawing………………………………………… 24
1.5.3. Engine assembly………………………………………….. 25
2. Technical Information……………………………………………….. 26
2.1. Engine Model and Serial Number………………………………….. 26
2.2. Diagnostic Tool……………………………………………….. 26
2.3. Engine Character………………………………………………. 27
2.3.1. Cylinder block…………………………………………… 27
2.3.2. Piston, connecting rod, crankshaft…………………………. 27
2.3.3. Electronic control unit : ECU……………………………… 28
2.3.4. Fuel injection system…………………………………….. 28
2.3.5. Bleeding the fuel system………………………………….. 28
2.3.6. Injector and high pressure connector……………………….. 29
2.3.7. Common rail system……………………………………….. 29
2.3.8. Emission reduction system…………………………………. 30
2.3.9. Exhaust gas recirculation (EGR)……………………………. 31
2.3.10. Engine timing…………………………………………… 32
2.3.11. Valve………………………………………………….. 32
2.3.12. Lubrication system………………………………………. 33
2.3.13. Engine oil……………………………………………… 33
2.3.14. Oil filter and cooler……………………………………. 35
2.3.15. Fan belt……………………………………………….. 35
2.3.16. Air cleaner…………………………………………….. 35
2.3.17. Fuel filter…………………………………………….. 36
2.3.18. Recommended fuel………………………………………… 36
2.3.19. Inter cooler……………………………………………. 37
2.3.20. Turbo charger…………………………………………… 37
2.3.21. Cooling system………………………………………….. 38
2.3.22. Coolant pressure cap…………………………………….. 38
2.2.23. Cooling water…………………………………………… 39
2.3.24. Valve clearance adjust procedure………………………….. 41
2.3.25. Cylinder compression pressure…………………………….. 43
2.3.26. Battery………………………………………………… 43
2.3.27. Starting motor………………………………………….. 44
2.4. Diagnosis and Remedy…………………………………………… 45
2.5. Engine Inspection……………………………………………… 55
3. Disassembly and Reassembly of Major Components…………………………. 56
3.1. Engine Disassembly…………………………………………….. 56
3.1.1. General precautions………………………………………. 56
3.1.2. Cooling water……………………………………………. 56
3.1.3. Oil level gauge………………………………………….. 56
3.1.4. Engine oil………………………………………………. 56
3.1.5. Inter cooler…………………………………………….. 57
3.1.6. Cooling fan……………………………………………… 57
3.1.7. Belt……………………………………………………. 57
3.1.8. Alternator and air conditioner compressor…………………… 57
3.1.9. Breather………………………………………………… 58
3.1.10. Air pipe and air heater………………………………….. 58
3.1.11. Fuel filter…………………………………………….. 58
3.1.12. Intake stake……………………………………………. 58
3.1.13. Intake manifold…………………………………………. 59
3.1.14. Common rail and high pressure pipe………………………… 59
3.1.15. Fuel high pressure pump………………………………….. 59
3.1.16. EGR valve………………………………………………. 60
3.1.17. EGR cooler……………………………………………… 60
3.1.18. HC hydro-carbon…………………………………………. 61
3.1.19. HC dosing metering unit………………………………….. 61
3.1.20. Turbo charger…………………………………………… 61
3.1.21. Exhaust manifold………………………………………… 62
3.1.22. Cooling water pipe & thermostat…………………………… 62
3.1.23. Cooling water pump………………………………………. 62
3.1.24. Starting motor………………………………………….. 63
3.1.25. Oil filter……………………………………………… 63
3.1.26. Vibration damper………………………………………… 63
3.1.27. Cylinder head cover……………………………………… 64
3.1.28. Rocker arm……………………………………………… 64
3.1.29. Injector……………………………………………….. 64
3.1.30. Cylinder head…………………………………………… 65
3.1.31. Valve and valve stem seal………………………………… 65
3.1.32. Oil cooler……………………………………………… 66
3.1.33. Oil pan………………………………………………… 66
3.1.34. Front oil seal cover…………………………………….. 66
3.1.35. Oil pump & pipe…………………………………………. 67
3.1.36. Fly wheel………………………………………………. 67
3.1.37. Flywheel housing………………………………………… 67
3.1.38. Cam gear and idle gear…………………………………… 67
3.1.39. Timing gear case………………………………………… 68
3.1.40. Piston & connecting-rod………………………………….. 68
3.1.41. Bearing cap…………………………………………….. 69
3.1.42. Crankshaft……………………………………………… 69
3.1.43. Oil spray nozzle………………………………………… 70
3.1.44. Camshaft and tappet……………………………………… 70
3.1.45. Cylinder liner………………………………………….. 70
3.2. Inspection and Measurement on Major Parts………………………… 71
3.2.1. Cylinder block…………………………………………… 71
3.2.2. Cylinder head……………………………………………. 71
3.2.3. Inspection of valve and valve guide………………………… 73
3.2.4. Rocker arm………………………………………………. 77
3.2.5. Camshaft………………………………………………… 81
3.2.6. Crankshaft………………………………………………. 83
3.2.7. Piston assembly………………………………………….. 88
3.2.8. Injector projection………………………………………. 92
3.3. Engine Reassembly……………………………………………… 93
3.3.1. General precautions………………………………………. 93
3.3.2. Cylinder block…………………………………………… 93
3.3.3. Cylinder liner…………………………………………… 93
3.3.4. Oil spray nozzle…………………………………………. 93
3.3.5. Crankshaft………………………………………………. 94
3.3.6. Tappet and camshaft………………………………………. 96
3.3.7. Timing gear case…………………………………………. 96
3.3.8. Fuel high pressure pump…………………………………… 97
3.3.9. Gear system……………………………………………… 97
3.3.10. Flywheel housing………………………………………… 98
3.3.11. Rear oil seal…………………………………………… 99
3.3.12. Flywheel……………………………………………….. 99
3.3.13. Piston and connecting rod…………………………………100
3.3.14. Oil pump and oil pipe…………………………………….102
3.3.15. Oil seal………………………………………………..103
3.3.16. Oil pan…………………………………………………103
3.3.17. Crankshaft pulley and vibration damper……………………..104
3.3.18. Intake and exhaust valve………………………………….104
3.3.19. Cylinder head……………………………………………105
3.3.20. Injector………………………………………………..106
3.3.21. Rocker arm………………………………………………109
3.3.22. Intermediate cover……………………………………….109
3.3.23. Cylinder head cover………………………………………110
3.3.24. Oil Cooler………………………………………………110
3.3.25. Cooling water pump……………………………………….110
3.3.26. Starting motor…………………………………………..111
3.3.27. Common rail and high pressure pipe…………………………111
3.3.28. Intake manifold………………………………………….111
3.3.29. Exhaust manifold…………………………………………112
3.3.30. Turbo charger……………………………………………112
3.3.31. Cooling water pipe & thermostat……………………………112
3.3.32. HC dosing injection (HC hydro-carbon)………………………113
3.3.33. HC dosing metering unit…………………………………..113
3.3.34. EGR cooler………………………………………………113
3.3.35. EGR valve……………………………………………….114
3.3.36. Electrical control unit (ECU)……………………………..114
3.3.37. Crankshaft speed sensor…………………………………..115
and Camshaft speed sensor………………………………………..115
3.3.38. Fuel filter……………………………………………..115
3.3.39. Alternator and belt………………………………………115
3.3.40. Air pipe and air heater…………………………………..116
3.3.41. Cooling fan……………………………………………..116
3.3.42. Oil level gauge………………………………………….116
3.3.43. Others………………………………………………….116
3.4. Fuel Injection System…………………………………………..117
3.4.1. Common rail fuel-injection system…………………………..117
3.4.2. Major components of the common rail system…………………..117
3.4.3. Injection characteristics with common rail…………………..118
3.4.4. Fuel high pressure pump……………………………………119
3.4.5. Fuel system………………………………………………119
3.4.6. Fuel tank………………………………………………..119
3.4.7. Fuel delivery pump………………………………………..119
3.4.8. Fuel filter………………………………………………120
3.4.9. High pressure fuel delivery………………………………..120
3.4.10. High pressure system components……………………………120
3.4.11. Construction of the fuel high pressure pump…………………121
3.4.12. Pressure limiter valve……………………………………123
3.4.13. Injector………………………………………………..124
3.4.14. Crankshaft speed sensor…………………………………..126
3.4.15. Camshaft speed sensor…………………………………….126
3.4.16. Accelerator pedal sensor………………………………….127
3.4.17. Boost pressure and temperature sensor………………………127
3.4.18. Engine oil pressure and temperature sensor………………….127
3.4.19. Engine coolant temperature sensor………………………….128
3.5. Electrical System………………………………………………129
3.5.1. Electrical parts………………………………………….129
3.5.2. Harness of electric control unit……………………………130
3.5.3. Connector of electric control unit (ECU)…………………….133
3.5.4. Electric control unit……………………………………..134
3.6. Exhaust Gas Reduction System…………………………………….136
3.6.1. Tier 4 interim exhaust gas reduction device………………….136
3.6.2. Exhaust gas reduction system circuit diagram…………………137
3.6.3. Diesel oxidation catalyst : DOC…………………………….138
3.6.4. Diesel particulate filter : DPF…………………………….139
3.6.5. Instruction to DOC/DPF muffler installation and disassembly……143
3.6.6. HC dosing metering unit, MU………………………………..145
3.6.7. HC dosing injection unit, IU……………………………….146
3.6.8. EGR system……………………………………………….146
3.6.9. EGR cooler……………………………………………….148
3.6.10. EGR system installation and disassembly…………………….148
3.6.11. EGR cooler installation and disassembly…………………….148
3.6.12. Exhaust gas tempature sensor………………………………149
3.6.13. Caution while working at DPF assembly………………………151
3.7. Engine Diagnostic………………………………………………152
3.7.1. Method of confirmation for the fault code……………………152
3.7.2. Engine fault code and occurring condition……………………152
3.7.3. Input and output of the ECU………………………………..166
3.8. Operating Condition of the ECU…………………………………..166
3.8.1. Engine starting…………………………………………..166
3.8.2. Vehicle running…………………………………………..166
3.8.3. Engine idle adjusting……………………………………..166
3.8.4. Limp home function………………………………………..167
3.8.5. Diagnostic……………………………………………….167
3.8.6. Vehicle operating record…………………………………..167
4. Commissioning and Operation…………………………………………..168
4.1. Preparations…………………………………………………..168
4.2. Breaking-In……………………………………………………168
4.2.1. Operation of a new engine (Break-in)………………………..168
4.2.2. Check points for break-in………………………………….169
4.2.3. Operating after break-In…………………………………..170
4.3. Inspections after Starting………………………………………170
4.3.1. Pressure of lubricating oil………………………………..170
4.3.2. Temperature of cooling water……………………………….170
4.3.3. Over-speed control………………………………………..170
4.4. Operation in Winter Time………………………………………..171
4.4.1. Operation in winter time…………………………………..171
4.4.2. Prevention against freezing of cooling water…………………172
4.4.3. Prevention against excessive cooling………………………..172
4.4.4. Lubricating oil…………………………………………..172
4.5. Engine Components Check after Long Time Running……………………172
4.6. Maintenance and Care……………………………………………173
4.6.1. Periodical Inspection and Maintenance……………………….173
4.6.2. Exchanging of lubrication oil………………………………173
4.6.3. Oil level gauge…………………………………………..173
4.6.4. Oil exchange procedure…………………………………….173
4.6.5. Replacement of oil filter cartridge…………………………174
4.7. Cooling System…………………………………………………175
4.7.1. Coolant draining………………………………………….175
4.7.2. Cleaning of the cooling inside system circuit………………..175
4.8. Adjustment of Valve Clearance……………………………………176
4.8.1. General information……………………………………….176
4.8.2. Valve clearance adjust procedure……………………………176
4.9. Tightening the Cylinder Head Bolts……………………………….178
5. Maintenance of Major Components……………………………………….179
5.1. Cooling System…………………………………………………179
5.1.1. General descriptions and main data………………………….179
5.1.2. Specification…………………………………………….179
5.1.3. Thermostat……………………………………………….180
5.1.4. Cooling fan………………………………………………181
5.1.5. Diagnostics and troubleshooting…………………………….182
5.2. Lubrication System……………………………………………..183
5.2.1. General descriptions and main data………………………….183
5.2.2. Oil pump…………………………………………………183
5.2.3. Diagnosis and troubleshooting of cause of failure…………….185
5.3. Turbo Charger………………………………………………….186
5.3.1. Specification and construction……………………………..186
5.3.2. General information……………………………………….188
5.3.3. Function…………………………………………………189
5.3.4. How to handle the engine…………………………………..190
5.3.5. Routine inspection and maintenance………………………….191
5.3.6. Periodical servicing………………………………………192
5.3.7. Precautions for handling…………………………………..194
5.3.8. Diagnostics and troubleshooting…………………………….195
5.4. Air Cleaner……………………………………………………197
5.4.1. Maintenance of air cleaner (Only when engine is switched off)….197
5.4.2. Changing air cleaner element……………………………….197
5.4.3. Cleaning air cleaner elements………………………………198
5.5. Belt………………………………………………………….199
6. Special Tool List……………………………………………………201
Appendix………………………………………………………………204
1. Engine assembly DL06K…………………………………………….215
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