SB4228E01 Sep.
Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
INDEX 1. Safety Regulations & Specifications 5. Maintenance of Major Components 5.1. Cooling System .................................168 1.1. Safety Regulations ................................ 5 5.2. Lubrication system .............................172 1.2. Engine Specifications .......................... 10 5.3. Turbo Charger ...................................175 1.3. Engine Power ..................................... 12 5.4. Air cleaner .........................................185 1.4.
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1. Safety Regulations & Specifications 1.1. Safety Regulations 1.1.1. General notes z Day-to-day use of power engines and the service products necessary for running them presents no problems if the persons occupied with their operation, maintenance and care are given suitable training and think as they work.
(2) Maintenance and care z Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts. z Change the oil when the engine is warm from operation. CAUTION: There is a rise of burns and scalding. Do not touch oil drain plug or oil filters with bare hands. z Take into account the amount of oil in the sump.
z When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lifting gear in good condition. z When do electric weld, stop the engine, power off, then remove the wire harness’ connector which is connected to the ECU. z Do not weld the electric control unit (ECU) absolutely, and do not damage on it by electrical or mechanical shock. z When working on the electrical system disconnect the battery earth cable first. Connect it up again last in prevent short circuits. 1.1.3.
1.1.4. To prevent pollution (1) Engine oil, filter elements, fuel filters z Take old oil only to an oil collection point. z Take strict precautions to ensure that oil does not get into the drains or into the ground. The drinking water supply could be contaminated. z Filter elements are classed as dangerous waste and must be treated as such. (2) Coolant z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
CAUTION: Ensure that used engine oil is disposed of properly. - Engine oil can endanger the water supply. For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable. Collect and dispose of used engine oil carefully. For information on collection points please contact the seller, the supplier or the local authorities. 1.1.6. General repair instructions 1.
1.2. Engine Specifications Items Engine type Combustion chamber type Cylinder liner type Timing gear system No. of piston ring No.
Items Water temperature indicator Type Air compressor Capacity (cc/rev) (if equipped) Revolution ratio Type Capacity (l/min) Power steering Adjusting pressure pump 2 (kg/cm ) Revolution ratio Turbo charger Engine stop system Alternator (voltage – capacity) (V - A) Starting motor(voltage–output) (V - kW) Air heater capacity (V – A) Battery capacity (V - AH) DL06 Diesel Engine DL06 Engine model Water temperature sensor mounted Water cooled 305 1 : 0.
1.3. Engine Power tolerance : ±5% Engine model Model Performance Remark Suffix Power (PS / rpm) Torque (kg.
Fuel consumption (g/ps.h) Output (PS) Torque (kg.m) 1.4. Engine Performance Curve 1.4.1. Performance curve (140 PS) – D110/130S-5 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.) DL06 Diesel Engine 224 g/kW.h (165 g / PS.
Fuel consumption (g/ps.h) Output (PS) Torque (kg.m) 1.4.2. Performance curve (160 PS) – D160S-5 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.) DL06 Diesel Engine 224 g/kW.h (165 g / PS.
1.5. Engine Assembly 1.5.1.
1.5.2.
1.5.3.
2. Technical Information 2.1. Engine Model and Serial Number z The engine model and serial number is located on the engine as Engine number (located cylinder block) the illustrated. z These numbers are required when requesting warranty and ordering parts. They are also referred to as engine model and serial number because of their location. z Engine serial No. (example 2 : DL06 Fork lift) DL06 6 00001 FA Engine model suffix (EUTFA) Serial no.
2.2. Diagnostic tool (EDIA) The EDIA is a powerful tool to support the service personal diagnosing and repairing of electric system for vehicle with installed DL06 engine. < EDIA service tool > z Show the user the engine failure history now and before. z View each engine components working condition & data value. z Save engine data for checking engine condition. z Check power deviation of each cylinder. z Check compression deviation of each cylinder. z Operate engine by lap top control.
z Oil gallery cooling is used for the piston of the engine. The design of the gallery, the design and location of the oil spray nozzle and the quantity of oil flowing in the gallery are critical in order to achieve the desired temperature reduction. The cross section shape of the gallery should be designed to achieve sufficient oil movement to maximize cooling efficiency. 2.3.1. Cylinder block z The cylinder block is a single piece of alloy cast iron.
2.3.3. Electric control unit : ECU z This electric control unit is used to control the engine feed fuel. z ECU is connected with various sensors, control the engine to keep the optimum condition on the basis of input values from this sensors. CAUTION: Do not connect or disconnect the ECU to/from the wiring harness without first removing the negative (-) battery cable from the battery. Do not perform remove the inner parts of ECU. 2.3.4.
2.3.5. Engine timing z Camshaft, oil pump, air compressor, power steering pump, and fuel high pressure pump are driven by a gear train arranged at the inside of flywheel housing. Air compressor gear or PTO gear Idle gear (A gear Z=44) (B gear Z=28) High pressure pump driving gear (Z=33) High pressure pump idle gear (A gear Z=18) (B gear Z=18) Camshaft gear (Z=56) Crankshaft gear (Z=44) Oil pump gear (Z=33) Viewed from flywheel housing 2.3.6.
2.3.7. Lubrication system z The engine is equipped with force-feed lubrication. The pressure is produced by a gear pump whose drive gear is in direct mesh with the crankshaft gear at the flywheel end. z The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as to the small-end bearings and the rocker arms.
2.3.8. Engine oil z Check oil level with the oil level gauge and replenish if necessary. z Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ∼ 10 minutes for oil drain into the crankcase before checking oil level. The oil level must be between Max and Min lines on the gauge. z Engine oil should be changed at the specified intervals. Oil filter cartridge should be changed simultaneously.
Engine oil viscosity – ambient temperature Ambient temperature 2.3.9. Oil filter & cooler z Oil filter is assembled to the oil cooler. Oil cooler is plane tube and is cooled by the cooling water. z Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Oil filter and cartridge z Change the oil filter cartridge simultaneously at every replacement of engine oil.
2.3.10. Fan belt z Use a fan belt of genuine part, and replace if damaged, frayed. z Check the fan belt for belt tension, Alternator inspect suitability for specified Water pump dimensions. Crankshaft pulley Air con. compressor Idle pulley - Adjust the tension of poly belt when pressed down with specified force (F kg): (T) = 0.015 x S (Deflection : 1.5 mm per 100 mm) 2.3.11.
2.3.13. Fuel filter z The filter cartridge should be replaced at every 40,000 km (500Hr). Fuel filter and cartridge 2.3.14. Fuel requirements z DOOSAN diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets specification ASTM D (Grade Low Sulfur). For maximum fuel economy, Number 2-D fuel whenever possible. When temperatures are below -7 °C, use Number 1-D fuel. If Number 1-D fuel is not available, the mixture of one kerosene to two gallons of Number 2-D fuel can be used.
z Fuel oil selection chart Fuel classification Unit DIN EN 590 Cetane number - ≥ 51 Cetane index - ≥ 46 Density @ 15°C kg/m3 820 ~ 845 Poly aromatic hydrocarbon % (m/m) ≤ 11 Sulfur content mg/kg ≤ 50 Flash point °C ≥ 55 Ash content % (m/m) ≤ 0.01 Water content mg/kg ≤ 200 Particulate matter content mg/kg ≤ 24 Copper corrosion 50°C, 3h grade 1 Oxidation stability g/m3 ≤ 25 Lubricity (wsd 1.4 @ 60°C) g/m3 ≤ 460 Viscosity (40°C) mm2/s 2.0 ~ 4.
2.3.16. Fuel injection system z The fuel is stored under pressure in the common rail ready for injection. The injected fuel quantity is defined by the driver, and the start of injection and injection pressure are calculated by the ECU on the basis of the stored maps. The ECU then triggers the solenoid valves so that the injector (injection unit) at each engine cylinder injects accordingly.
2.3.18. Injector & high pressure connector Injector z Be careful to mix the foreign matter O-ring High pressure connector nut O-ring into the injector and inside of the connector for connecting the high pressure at disassembly and check. Injector harness connector Seal ring z O-ring and cupper washer should be changed with new one at reassembly. z Assemble after coat the oil on the O-ring. z Assemble after check serial number at replacement.
2.3.20. Turbo charger z The turbocharger needs not any specific maintenance. z Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. z Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection should be applied on the compressed air and exhaust gas pipes, For leaking air will bring the overheat engine, an immediate repair must be done.
2.3.21. Cooling system The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by belt from the crankshaft pulley. z Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add coolant if necessary z When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and then clean them with cleaning solution. z Be sure to mix soft water with antifreeze solution.
2.3.22. Coolant pressure cap z Check the pressure valve opening pressure using an expansion tank Radiator cap cap tester. z Replace the filler cap assembly if Radiator the measured valve does not reach the specified limit. NOTE : Because it is dangerous to open the pressure cap quickly when coolant is hot, after lowering the inside pressure of the tank by slowopening at first open it fully. Drain valve 2.2.23.
z How to use the cooling water test kit (1) When the cooling water temperature of engine is in the range of 10 ∼ 55 °C, loosen the plug for cooling water discharge and fill the plastic cup about a half. NOTE: In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure the accurate density. Take the cooling water sample necessarily loosening the cooling water discharge plug.
(4) Compare the end pad “a)” color of the strip with color block of a row at the upper part of the standard color chart (bellow of the letter “GLYCOL/FREEZEPOINT”). Same color in the block of the row means the content of anti-freeze in the coolant.
z Amount of Anti-freeze The anti-freeze, 33 ~ 50% of the whole coolant, is always to be used to prevent the cooling system from the corrosion. And in the winter the amount of anti-freeze shown in the following table should be used in accordance with the ambient temperature. As the individual freezing points corresponding to the proportions of antifreeze in the table are subject to change slightly according to the kind of antifreeze, you must follow the specifications provided by the antifreeze manufacturer.
Rocker arm Valve adjusting nut Torque 3.0+0.5 kg.m X Push rod Caliper X Valve adjusting z No. 1 cylinder is located at the side where cooling fan was installed.
● Adjusting of valves (Type 1) 1 Cylinder no. Valve adjusting #1 cylinder top dead center (#6 cylinder valve overlap) 2 3 4 5 6 Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake ● ● ● ◎ Add 180° rotation Add 180° rotation Add 180° rotation ◎ ◎ ○ ○ ◈ ◈ ○ ◈ z 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.
2.3.25. Battery z Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition. z Inspect for amount of electrolytic solution, and replenish if insufficient. z Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.
2.3.26. Alternator a) Alternator (24Vx60A) z The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator body interior limits the alternator voltage. z The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator. z The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all, against moisture and water.
2.3.27. Starter z The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-hand side. As parts of every engine overhaul, the starter pinion and ring gear should be cleaned with a brush dipped in fuel and then a coat of grease should be applied again. 24Vx4.5kW Battery terminal (+) M10 x Switch terminal (M5 x 0.8) Battery ground (-) M10 x 1.5 z Always protect starter motor against moisture.
2.4. Diagnosis and Remedy z The following description summarizes the probable cause of and remedy for general failure by item. z Inspect the electrical parts problem with EDIA and refer diagnostic manual. z Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
DL06 Diesel Engine 43 Technical Information
DL06 Diesel Engine 44 Technical Information
DL06 Diesel Engine 45 Technical Information
Inspect cylinder head gasket DL06 Diesel Engine 46 Technical Information
DL06 Diesel Engine 47 Technical Information
DL06 Diesel Engine 48 Technical Information
Condition 1) Starting difficult (1) Starting motor trouble (2) Fuel system trouble (3) Compression pressure lack Causes z z z z z z 2) Idle operation abnormal z z Refer to diagnostics Refer to diagnostics Valve's poor shut, stem distortion Valve spring damage Cylinder head gasket's leak Wear of piston, piston ring or liner Injection timing incorrect Air mixing at high pressure pump Remedies Repair or replace Replace valve spring Replace gasket Adjust Check by EDIA Remove air 3) Engine output insuffic
Condition 5) Engine noisy (1) Crankshaft (2) Connecting-rod and connecting-rod bearing Causes For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. z As the wear of bearing or crankshaft progress, the oil clearances increase.
Condition 7) Oil Consumption Excessive (1) Oil level elevated Causes z z z z z z (2) Oil level lowered z z (3) Oil leak z z z z z DL06 Diesel Engine Clearance between cylinder liner & piston Wear of piston ring, ring groove Piston ring's damage, stick, wear Piston ring opening's disposition improper Piston skirt part damaged or abnormal wear Oil ring's oil return hole clogged Oil ring's contact poor Looseness of valve stem & guide Wear of valve stem seal Cylinder head gasket’s leak Looseness of conne
2.5. Engine Inspection 2.5.1. Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to stop the engine. 2.5.2.
2.5.3. Use of original parts for repair and replacement z For engine is being mechanically harmonized with many parts, only when the original parts that the manufacture recommends to use is used, the engine trouble would be preventively maintained and capable to keep up the maximum performances. z For the analogous parts not the original parts are poor in qualities and gives ill performances, it may rather bring early engine failure.
3. Disassembly and Reassembly of Major Components 3.1. Engine Disassembly 3.1.1. General precautions z Maintenance operation should be carried out in a bright and clean place. z Before disassembly, provide parts racks for storage of various tools and disassembled parts. z Arrange the disassembled parts in the disassembly sequence and use care to prevent any damage to them. 3.1.2. Oil level gauge z Take out the oil level gauge. 3.1.3. Cooling water z Remove the radiator cap.
z Remove the cooling water drain plug from the cylinder block and various pipes, etc. and let the Drain plug (Cylinder block) cooling water discharge into the prepared vessel. 3.1.4. Engine oil z Remove an oil drain plug from the oil pan, and let engine oil discharge into the prepared vessel. Drain plug 3.1.5. Cooling fan z Remove the fan guide and bracket. z Remove the flange fixing bolts, and then take off the flange and cooling fan.
3.1.6. Inter cooler z Tear down the various hoses and air pipes from the inter cooler z Remove the intercooler fixing bolts and tear it down. 3.1.7. Belt z 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.
3.1.8. Air pipe & air heater z Remove fixing bolts, then take off the air pipe and air heater. z Be careful about the mixing of foreign matter into interior of the turbocharger. 3.1.9. Breather z Loosen the clamp screw to remove the rubber hose. z Remove the breather valve assembly.
3.1.10. Fuel filter z Loosen the hollow screws of filter and remove the fuel hose. z Remove fuel filter fixing bolts and disassemble the fuel filter. 3.1.11. Common rail & high pressure pipe z Remove the high pressure pipe of between fuel high pressure connecter and common rail z Remove the common rail fixing bolts and take off the common rail. NOTE: 1) Seal the pipe to prevent from mixing foreign material into inside of the pipe after disassembling.
NOTE: Seal the fuel high pressure pump to prevent from mixing foreign material into inside of the fuel line. 3.1.13. Turbocharger z Remove the oil supply pipe and oil return pipe between the turbo charger and the cylinder block. z Unscrew the turbo charger fixing bolts and take off the turbo charger from the exhaust manifold. 3.1.14. Power steering pump z Remove the oil hose between power steering oil pump and control unit of the vehicle.
3.1.16. Oil filter & cooler z Remove the oil filter fixing bolts and take off the oil filter from the oil cooler. z Remove the oil cooler fixing bolts and take off the oil cooler. Oil filter and cartridge Oil cooler Oil filter and cartridge 3.1.17. Cooling water pump z Remove the cooling water pump fixing bolts and disassemble the Water pump cooling water pump. Water pump pulley 3.1.18.
3.1.19. Intake manifold z Unscrew the intake manifold fixing bolts and remove the intake manifold from the cylinder head. z Disassemble the intake manifold gasket and clean the installed face using the scrapper. 3.1.20. Cylinder head cover z Remove the head cover fixing bolts and lift the cylinder head cover. 3.1.21. Rocker arm z Remove the rocker arm bracket fixing bolts in reverse order of assembling and disassemble the rocker arm. z Take out the push rod.
3.1.22. Injector z Remove the fuel high pressure Injector connecter fixing nuts and take off Injector bush the fuel high pressure connecter. z Fuel high pressure connecter Remove the harness connected Caliper to injector, then remove injector fixing bracket bolts and take off the injector. z Fixing nut Be careful about damage of the nozzle when take off the injector. z Take out the sealing from the nozzle hole of the cylinder head and scrap it.
3.1.24. Cylinder head z Remove the cylinder head bolts in Head bolt the reverse order of tightening but Torque wench remove it step by step. 1) First step : Loosen 1 ~ 2 threads 2) Second step : Remove by loosening fully. z Remove the total bolts simultaneously by the step of 1) and 2). ● Lay the removed bolts orderly not to damage the threads at all and store. z Prevent a collision between the bolt thread each other. z Take out the cylinder head gasket and scrap it.
3.1.27. Oil pan z Unscrew the oil pan fixing bolts and separate the oil pan. z Remove the oil pan gasket and discard it. 3.1.28. Vibration damper z Unscrew the crankshaft pulley fixing bolts in reverse sequence of installing sequence and remove the vibration damper assembly. Socket bolt 3.1.29. Front oil seal cover z Disassemble the oil seal using an oil seal removing jig. Oil seal cover z Remove the cover fixing bolts and disassemble the cover from the Oil seal timing gear case.
3.1.30. Oil pump z Unscrew the bracket fixing bolts of the oil suction pipe. z Unscrew the pipe fixing bolts of oil pump and disassemble the oil suction pipe. z Unscrew the oil pump fixing bolts, and disassemble the oil pump. 3.1.31. Cam gear & idle gear z Unscrew the camshaft gear fixing bolts and remove the camshaft gear. z Unscrew two bolts fixing the idle gear, then remove the idle gear and its pin. 3.1.32. Timing gear case z Remove the timing gear case assembling bolts.
3.1.33. Fly wheel z Remove the flywheel fixing bolts, install the guide bolts and disassemble it. z The bolt removal is done by the reverse order of assembling and by the steps. 3.1.34. Piston z Remove the connecting rod cap bolts in the reverse order of assembling but do by the step of 1 and 2 same as the cylinder head bolt removal.
(1) Remove the snap rings by means of the pliers. (2) Take out the piston pin from the piston as tapping it with a round wooden bar. (3) Remove the piston ring with the pliers. Piston ring jig (4) Clean the piston thoroughly. 3.1.35. Cylinder liner z Be careful not to generate any damage at cylinder block. z Disassemble the cylinder liner with a special tool or hand.
3.1.36. Flywheel housing z Remove the flywheel housing fixing bolts and disassemble the flywheel Gasket Fixing bolt housing. z Disassemble the oil seal of flywheel housing. Oil seal 3.1.37. Bearing cap z Remove the bearing cap assembling bolts by the step in the reverse order of assembling, and disassemble the bearing cap. (Remove by the same way as the cylinder head bolts' removal.) z Disassembled bearing caps are kept laid in order. 3.1.38.
NOTES : Do not mingle with the metal bearings and bearing caps randomly. To prevent mixing, temporarily assemble the metal bearings to the corresponding bearing caps in turn. 3.1.39. Cam shaft & tappet z In order for camshaft not to be damaged, disassemble turning it. z In order for the disassembled camshaft to be prevented from bends or damage, put it on the special lathe and store. z Pull out the tappet. z Check for damage, scratch, wearing state and if abnormal, tear down. 3.1.40.
3.2. Inspection and Measurement on Major Parts 3.2.1. Cylinder block z Clean the cylinder block thoroughly, and check for any crack or damage. z If there is any crack or severe damage, replace it and if there is minor one, correct it. z Check for any clogging or corrosion in the oil passage and water passage. z Carry out a leakage test for any crack or air leaking.
2) Distortion of lower surface z As shown in figure, measure the cylinder head's distortion at (t) 6 directions with horizontal A ruler and clearance gauge. B C D z If the measured value is beyond the limit value, correct it by means of the fine grinding E F paper or grinding machine. z If it is beyond the max. allowable value, replace the cylinder head. < Lower face warpage and height > Standard Limit 0.08 mm or less 0.15 mm Thickness : t 104.9 ~105.1mm (reference) 104.
(3) Inspection of valve and valve guide 1) Valve z After cleaning valve with fuel, check it. z 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. Dimension Description Intake valve stem Standard Limit φ6.963~φ6.977mm φ6.93 mm Exhaust valve stem φ6.950~φ6.964mm φ6.
2) Valve guide z Insert a valve into cylinder head and measure the clearance between valve guide and valve by valve movement. Measuring 측정위치 point z If the clearance is excessive, replace the valve. z Valve stem clearance Standard Intake valve Limit 0.023~0.052mm 0.1 mm Exhaust valve 0.036~0.065mm 0.15 mm z Assemble the valve to cylinder head's valve guide and see if it is centered with the valve seat using a special tool.
< Valve depression > Standard Limit Intake (A) 0.35 ∼ 0.65 mm 0.85 mm Exhaust (A) 0.35 ∼ 0.65 mm 0.85 mm Valve Valve seat < Valve angle > Intake valve (B) O 60 Exhaust valve (B) O 45 z It is necessary to work boring of inner diameter of it when replace the valve seat. z Apply valve lapping compound to the valve head seating face on the valve seat and lap the valve seat by turning it until it is seated in position, then wipe out the lapping compound.
Spring free length Standard Intake valve & Exhaust valve 53.4 mm z Valve spring inclination Use a surface plate and a square to measure the valve spring inclination. If the measured value exceeds the specified limit, the valve spring must be replaced. Standard Limit Valve spring 1.4 mm or less 2.0 mm inclination z Valve spring tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit, the valve spring must be replaced.
5) Assembling cylinder head z Clean the cylinder head Valve guide thoroughly. Replace the valve stem seal with new one, and by means of a special tool, press the stem seal into the valve guide of cylinder head. z Coat engine oil to valve stem Valve seat and valve guide and assemble the valve. However, be careful for the damage of valve stem seal. z Install the lower seat of valve spring to the valve guide of cylinder head. z After putting inner, outer springs, install the spring upper seat on it.
(2) Inspection of rocker arm assembly 1) Rocker arm shaft z 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 runout. Replace the shaft if the measured value exceeds the limit. Limit 0.1 mm z Rocker arm shaft diameter With an outside micrometer, measure the rocker arm shaft diameter at the point where the rocker arms have been installed.
2) Rocker arm z Visual check Visually check the face of the rocker arm in contact with the valve stem end for scores and step wear. If the wear is small, correct it with an oil stone or grinding paper of fine grain size. Rocker arm with a considerable amount of step wear should be replaced. z 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.
3) Tappet and push rod z Clearance Measure the clearance of the tappet and tappet holes of the cylinder block. If the value is beyond the specified limit, replace tappets. Standard Limit 0.028 ∼ 0.069 mm 0.13 mm z Visual check of tappet Visually check the face of the tappets in contact with the cam for pitting, scores or cracks, and replace if severely damaged. If the amount of cracks or pitting is small, correct with an oil stone or grinding paper.
4) Rocker arm assembly z Reassembling can be done in the reverse order of disassembling and following things should be heeded. z Check the oil supply hole of rocker arm shaft for any clog and clean thoroughly. z Be careful, not to occur any swap of position and reverse assembly. 3.2.4. Camshaft (1) Camshaft end play z Push the camshaft gear toward the opposite cylinder block. z With a feeler gauge, measure the clearance between the thrust plate and camshaft gear.
z Inspect the cam face for scratch or damage. z Slight step wear or damage on the cam face may be corrected with oil stone or oiled grinding paper. But, replace if severely damaged. (3) Between camshaft journal and camshaft bush z With an outside micrometer, measure the camshaft journal diameter.
Standard Limit 0.05 mm 0.15 mm 3.2.5. Crankshaft (1) Inspection of crankshaft 1) Defect check z By naked eyes, check for any scratch or damage on the crankshaft journal and crank pin. z By means of magnetic particle test and color check, check the crankshaft for any crack and if found, replace it. 2) Wear measuring z With an outside micrometer measure the diameter of the crankshaft journals and pins in the directions as shown, and compare the measured values to determine the amount of wear.
Standard Limit Journal diameter φ79.905∼φ79.925mm φ78.905 mm Pin diameter φ68.924∼φ68.944mm φ67.924 mm z In case that pin's wear is more than the limit value, grind the crankshaft journal and crank pin, and use the undersized bearings. z Be sure to use grinding paper which has been immersed in oil. Normal Poor Poor "R" part's specified value ① Crank pin's "R" : 3.3~3.7 ② Crank Journal "R" : 3.3~3.7 < Undersize bearings available > Standard 0.25 (Inside diameter is 0.
3) Crankshaft run-out z Support the crankshaft on Vblocks. z Turn the crankshaft with a dial indicator placed on the surface plate and take the amount of crankshaft run-out. Standard Limit 0.06 mm Less than 0.15 mm (2) Crankshaft bearing and connecting rod 1) Visual check z Visually check the crankshaft bearing and connecting rod bearing for scratch, uneven wear or damage.
Standard Limit 0.045 ∼ 0.110 mm 0.15 mm z Connecting rod bearing clearance Install the connecting rod bearing in the connecting rod bearing cap, tighten the connecting rod cap bolts to the specified torque, then measure the inside diameter. Torque 9.75±0.25kg.m z 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. Standard Limit 0.030 ∼ 0.081 mm 0.
3) Oil clearance between crankshaft and bearing (Method 2 : plastic gauge) z Assemble the crankshaft on the cylinder block and put plastic gauge on the journal and pin of crankshaft and then after assembling bearing cap, tighten the bolts at the specific torque. z Again after disassembling the bearing cap by removing the bolts, take out the flatted plastic gauge and measure the width of plastic gauge by means of plastic gauge measuring scale. This is the oil clearance.
z 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. Standard 0.065 ∼ 0.
3.2.6. Piston assembly (1) Disassembly of piston assembly Disassemble piston according to the disassembly process. (2) Piston inspection 1) Visual check z Visually check the pistons for cracks, scuff or wear, paying particular attention to the ring groove. 2) Clearance between the piston and cylinder liner z With an outside micrometer, measure the piston outside diameter at a point 12 mm away from the lower end of piston skirt in a direction at a right angle to the piston pin hole. Standard 12 mm φ99.
z Cylinder liner diameter Measure the liner inner side X diameter at ①, ② and ③ Y Y X measuring point across X-Y , Y-Y. ② X ③ Y Y Measure points: ① X ① 20 mm X ② 105 mm Y Y X ③ 185 mm z Inner diameter of cylinder liner z Standard Grade marks φ100.020 ~ φ100.031 mm Two red line (A) φ100.031 ~ φ100.042 mm One red line (A) Cylinder liner grade A grade : one red line B grade : two red line Outside diameter of piston Standard Grade marks φ99.93 ~ φ99.941 mm A φ99.941 ~ φ99.
(3) Piston rings 1) Visual check z Replace the piston rings with new ones if detected worn or broken when the engine is overhauled. 2) Piston ring gap z Insert the piston ring into the upper portion of the cylinder liner bore so that it is held at a right angle to the cylinder liner wall. Feeler gauge z Measure the piston ring gap with a feeler gauge. Standard Limit 1st ring 0.30 ∼ 0.45 mm 1.5 mm 2nd ring 0.60 ∼ 0.80 mm 1.5 mm Oil ring 0.25 ∼ 0.45 mm 1.
4) Piston ring tension ● With a tension tester, measure piston ring tension. Replace the piston ring if the measured value is beyond the limit. Standard 1st ring 1.47 ~ 2.21 kg 2nd ring 1.49 ~ 2.23 kg Oil ring 4.08 ~ 5.52 kg (4) Piston pin inspection ● Measure the amount of wear on the piston pin at the points as shown. z The measured values are beyond the limit (0.08 mm or greater), replace the piston pin. Standard φ39.994 ~ φ 40.000 mm Limit φ 39.
(5) Connecting rod inspection 1) Distortion z 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. z If the connecting rod is found distorted, never re-use it but replace with a new one. 2) Holes alignment (parallelism) z Measure the alignment of the connecting rod piston pin bushing holes with connecting rod big end holes. Standard Limit 0.02 mm 0.
Standard Limit 0.170 ~ 0.3 0.50 mm 3.2.7 Injector projection ● Insert a seal ring on the Cylinder head cylinder head and assemble Injector the injector. (Refer to 3.3 chapter for assembly order) ● Measure the clearance A between the cylinder head B bottom and injector tip. If the measured valves are beyond the limit, replace the seal ring. A (Thickness of seal ring) 2.0 mm B (Projection of nozzle) 3.
3.3. Reassembly 3.3.1. General precautions z Clean all the disassembled parts, particularly oil and water ports, using compressed air, then check that they are free from restrictions. z Arrange the general and special tools in order for engine assembly operation. z To wet each sliding part, prepare the clean engine oil. z Prepare service materials such as sealant, gaskets, etc. z Discard used gaskets, seal rings, and consumable parts, and replace with new ones.
z After the cleaning operation, make the cylinder liner dried up and push it into the cylinder block by hand. z Wet the liner inside diameter with engine oil. 3.3.4. Oil spray nozzle z Assemble the oil spray nozzle on the cylinder block with relief valve. 3.3.5. Crankshaft z 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.
z Put the crankshaft gear into the heater to heat it up to 150°C level for 10 minutes, push it over the crankshaft by means of a jig. Crankshaft gear Crankshaft gear Apply the ULTRA BLUE #587 Crank shaft z Semi-tighten bolts at both sides of the crankshaft, apply engine oil to journals and pins, then assemble the crankshaft with the cylinder block by tightening the fixing bolts. z Coat engine oil to the pin and journal of crankshaft. z Install the oiled thrust washers with the oil groove facing outward.
z Install the bearing and thrust washers to the bearing cap and apply oil to the bearing and thrust washers. z Install the bearing cap by matching the cylinder block No. with the bearing cap No. ● Apply oil to the entire part of the bearing cap bolts, then tighten in tightening sequence to specified torque. Torque 30±2 kg.m z After semi-tightening both bolts evenly, tighten them diagonally to the specified torque using a torque wrench as follows.
z Tighten the bearing cap in the sequence of 4 – 3 – 5 – 2 – 6 – 1 - 7. z Check to see that the assembled crankshaft turns smoothly with hand. 3.3.6. Tappet & cam shaft z Undercool a new bush with dry ice for about 2 hours and press it into position in the cylinder block using a bench press. After the pressing operation, measure the inside diameter of the cam bush to check if it is not deformed. z Apply engine oil to the entire face of the tappets and slide them into the tappet holes on the cylinder block.
3.3.8. Gear train z Install a thrust washer over the camshaft and assemble the cam gear by aligning it with camshaft dowel pin. z Tighten the cam gear fixing bolts to the specified torque. Camshaft thrust washer 1.0 +0.1 kg.m Camshaft gear fixing bolt 3.1 +0.5 kg.
z Check the amount of backlash between gears using a feeler gauge. < Back lash > Measuring position Standard Cam shaft gear & idle gear 0.074 ~ 0.163 mm Fuel high pressure pump gear & idle gear 0.103 ~ 0.182 mm Crankshaft gear & oil pump driving gear 0.073 ~ 0.239 Air compressor (PTO) gear & cam gear 0.074 ~ 0.163 < End play > Measuring position Standard Cam shaft gear 0.280 ~ 0.430 mm Step idle gear 0.107 ~ 0.183 mm Fuel high pressure pump idle gear 0.078 ~ 0.140 mm 3.3.9.
3.3.10. Oil seal (Rear side) z Apply lubricating oil to the outside of the oil seal and flywheel housing inside diameter and fit them over the crank shaft, then assemble the oil seal using an oil seal fitting jig. Oil seal jig 3.3.11. Fly wheel z Installation of flywheel ring gear With a gas burner, heat the ring gear evenly until heat expansion takes place, then install it using a hammer. z Do not allow the temperature of the ring gear to exceed 200°C.
z According to the order of tightening tighten it using a torque wrench to 1 specified torque. Bolt specification M14 x 1.5 Torque 20 +2.0 kg.m 6 8 4 3 7 5 2 3.3.12. Piston & connecting rod z In case of assembling the piston and connecting rod, assemble in order that the balance weight side of the connecting rod small end is in the opposite direction from the oil gallery port side (big end).
z Install the piston ring in the piston using piston ring pliers. z Identify the mark "Y" or "TOP" on Top ring the ring end to prevent the top and 2nd ring bottom of the piston ring from being Oil ring interchanged and make the marked portion face upward. “Y” or “TOP” z Adjust the angle among individual piston ring gaps to 90° and fit a Oil ring 2nd ring piston assembling jig onto the piston, use care not to match the ring gaps with the pin direction.
z Install the bearing in the View from crankshaft pulley connecting rod cap and apply oil. Piston oil gallery Spray nozzle z Make sure that the manufacture serial numbers impressed on the connecting rod cap and connecting CAUTION: Direction of snap ring is assembling to be positioned the opposite side rod big end are identical, and install the connecting rod cap by aligning it with dowel pin. z Wet the fixing bolts with engine oil, Serial no.
3.3.13. Oil pump and oil pipe z Install a dowel pin in the oil seal holder, then assemble the oil pump by tapping lightly with urethane hammer. z Tighten the fixing bolts with specified torque. M8 2.2+0.5 kg.m M10 4.4+0.5 kg.m Torque z Assemble the oil suction pipe with the delivery pipe to oil pump by the bolts. 3.3.14. Oil seal z Apply lubricating oil to the outside of the oil seal and the oil seal hole Oil seal cover of the timing gear case cover.
3.3.15. Oil pan z Remove the gaskets thoroughly that project at the timing gear case, case cover of cylinder block, and the contacting part of flywheel housing by means of a scraper. CAUTION : Be careful for the gasket pieces not fall into the engine during the work. z Coat the silicone at the gasket part that was removed (Contacting part), and attach the new oil pan gasket.
3.3.16. Crankshaft pulley & vibration damper z Insert the vibration damper to the crankshaft, and assemble by tightening the assembling bolts at the specified tightening torque according to bolt tightening order. Damper 6.2+0.5 kg.m Crankshaft pulley 20+2.0 kg.m Socket bolt Torque Bolt tightening order 3.3.17. Intake and exhaust valves z Identify the marks of "I" and "E" impressed on the valve head before assembling the valve with Valve marking position the valve head.
3.3.18. Cylinder head z Blow the bolt holes of cylinder block with a compressed air and remove the foreign matter. z Clean the head gasket contact surface thoroughly. However, be careful for the foreign material not Part no. mark and Production date to enter into the combustion chamber. z Assemble the new head gasket by aligning the holes with dowel pins of cylinder block with the right‘s mark facing upward.
< Cylinder head bolts > Specification M13×1.5×140 Torque 1st Tightening : 5 kg.m 2nd Tightening : 90° 3rd Tightening : 90° Final tightening : 90° < Tightening order of bolts by steps > (1) First stage : Coat the bolts with engine oil. (2) Second stage : Tighten 1 ~ 2 threads with hands. (3) Third stage : Tighten at about 5 kg.m with a wrench. (4) Fourth stage : Tighten at rotating angle method 90° with a wrench. (5) Fifth stage : Tighten at rotating angle method 90° with a wrench.
z Assemble the injector fixing bracket bolt with specified torque, and assemble the fuel high pressure connector fixing nut. Torque Injector fixing bracket bolt 3.1+0.3 kg.m Fuel high pressure connector fixing nut 5+0.5 kg.m Injector harness fixing nut 0.15+0.01 kg.m Fuel over flow pipe fixing nut 0.8 ~ 0.9 kg.m 3.3.20.
3.3.21. Oil cooler & oil filter z Install the oil cooler assembly and gasket onto the cylinder block, and tighten the fixing bolts. z Be careful not to be changed of the direction of assembling the gasket. Oil filter and cartridge Torque Oil cooler 2.2+0.5 kg.m Oil filter 4.4+0.5 kg.m Oil pipe 2.2+0.5 kg.m z Apply engine oil to the oil filter cartridge o-ring and assemble the cartridge using a filter wrench. Oil cooler Oil filter and cartridge 3.3.22.
3.3.23. Fuel high pressure pump z Assemble the gear of the fuel high pressure pump by using specified tool. Gear nut torque 11±0.5 kg.m Flange fixing bolt 4.4±0.5 kg.m Driving gear Fuel high pressure pump z Fill 60cc fuel at the fuel inlet before reassemble. z Install the fuel high pressure pump on the backside of the fly wheel housing. z Assemble the fixing bolts according to the sequence of assemble with specified torque. Hollow screw 3.0+0.5 kg.m Nipple 4.4+0.5 kg.m Torque 3.3.24.
3.3.25. Intake manifold z Put in the new gasket between the cylinder head and manifold, and assemble the intake manifold by tightening the fixing bolts. Torque 4.4 +0.5 kg.m 3.3.26. Exhaust manifold z Install the exhaust manifold gasket over the stud bolts by aligning the gasket with the exhaust port on the cylinder head so that the face and back of the gasket can be positioned correctly. z Install the exhaust manifold gasket. The projection face must be facing the exhaust manifold.
3.3.27. Turbo charger z Fit a new gasket over the stud bolts of the exhaust manifold before tightening those turbocharger fixing nuts. Turbo fixing nut 8.0+1.0 kg.m Hose clamp 0.5 kg.m Torque z Install the oil supply pipe and return pipe. z Tighten the clamps of rubber hose that is connected air pipe to the turbocharger. 3.3.28.
3.3.29. Thermostat z Attach the gasket to the cylinder to Radiator head, assemble the thermostat housing. z Install the gasket and O-ring to the Thermostat thermostat, assemble the cooling water pipe by tightening the fixing Thermostat housing bolts. Torque Thermostat housing 4.4+0.5 kg.m Water outlet 2.2+0.5 kg.m 3.3.30. Cooling water pump z Mount a new cooling water pump Water pump gasket.
3.3.32. Electrical control unit : ECU z Install the electric control unit fixing bracket on the cylinder block, then assemble the electric control unit. Torque ECU bracket 4.4 kg.m ECU fixing bolt 1.0+0.1 kg.m z Assemble the electric control unit Bracket (ECU) according to the right figure order. z Refer to the chapter of 3.4 about relation of the common rail system and the electric control unit. Rubber cushion Electric control unit 3.3.33.
3.3.34. Camshaft speed sensor z Measure the clearance of the assembling part of the sensor and fly wheel, then assemble it with the shim. Clearance 1. 0 ±0.1mm Torque 1.0 +0.5 kg.m Camshaft speed sensor 3.3.35. Fuel filter z Assemble the fuel filter on the intake manifold. z Assemble the fuel filter after fill the fuel into inside of the cartridge when replace the new fuel filter.
3.3.36. Alternator & belt z Install the alternator and the air con bracket using the fixing bolts. z Assemble the alternator, the airAlternator conditioner, idle pulley, and auto tensioner. Water pump z Install the belt using the auto Crankshaft pulley tensioner tool. (by torque wrench) Torque Alternator fixing bolt (M12x1.5) 7.7+0.5 kg.m Eye bolt (M12x1.5) 5.0+0.5 kg.m 3.3.37. Air pipe & air heater z Assemble the air pipe and air heater using the fixing bolts.
3.3.39. Oil level gauge z Apply sealant (Loctite #271) to the bottom side of the guide tube. z Assemble the guide tube and oil level gauge on the oil pan. 3.3.40. Others z Assemble by connecting the other sensor, harness, fuel and oil line.
3.4. Fuel injection System 3.4.1. Common rail fuel-injection system z 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.
3.4.2.
Common rail fuel injection Pm : Main injection pressure Ps : Max. injection pressure Injection pressure P Fuel injection PR (Pm) Time t z At the beginning of the injection process, the injected fuel quantity should be as low as possible (that is, during the ignition lag between the start of injection and the start of combustion) z The common rail system is a modular system, and essentially the following components are responsible for the injection characteristic.
z The required high-speed solenoid switching is achieved by using high voltages and currents. This means that the solenoid valve triggering stage in the ECU must be designed accordingly. The start of injection is controlled by the angle-time control system of the EDC(Electronic Diesel Control).This uses a sensor on the crankshaft to register engine speed, and a sensor on the camshaft for phase detection(working cycle). 3.4.5.
3.4.8. Fuel filter z 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. 3.4.9. High pressure fuel delivery z The high pressure stage of the fuel system in a common rail installation comprises.
z Fuel high pressure pipe These fuel high pressure pipes carry the high pressure fuel of up to 1600bar. They must therefore be able to permanently withstand the maximum system pressure and, during the pauses in injection, the sometimes high frequency pressure fluctuations which occur. They are therefore manufactured from the high pressure pipe. They have an outside diameter of 8.0 mm and an internal diameter of 3.0 mm.
fuel in the pumping-element chamber to escape, it can now be compressed beyond the delivery pressure. The increasing pressure opens the outlet valve as soon as the rail pressure is reached, and the compressed fuel enters the high pressure circuit. The pump piston continues to deliver fuel until it reaches TDC, after which the pressure collapses so that the outlet valve closes. The fuel remaining in the pumping-element chamber relaxes and the pump piston moves downwards again.
by the pressure sensor of the common rail, is maintained with required value by the pressure control valve. The fuel pressure is controlled at max. 1,600 bar in the common rail. Fuel limit valve No. 1 injector Fuel return No. 6 injector No. 2 injector No. 3 injector No. 4 injector Fuel inlet No.
3.4.12. Pressure limiter valve z The pressure limiter valve is at the connection end to the common rail, is closed by the cone shaped end of the plunger valve against inside of the valve body. At normal operating pressures (1600bar), a spring forces the plunger against the seat and the common rail remains closed.
Nozzle & needle z This indirect control of the nozzle needle using a hydraulic force-amplification system is applied because the forces which are necessary for opening the needle very quickly cannot be directly generated by the solenoid valve. The so-called control quantity needed for opening the nozzle needle is in addition to the fuel quantity which is actually injected, and it is led back to the fuel-return line via the control chamber's orifices.
2) Injector closed (at rest status) In the at rest state, the solenoid valve is not energized and is therefore closed. With the bleed orifice closed, the valves spring forces the armature's ball onto the bleed-orifice seat. The rail's high pressure builds up in the control valve, and the same pressure is also present in the nozzle's chamber volume.
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. The armature is a 2piece design. Here, although the armature plate is guided by a driver shoulder in its downward movement, it can "over spring" with the return spring so that it exerts no downwards-acting forces on the armature and the ball.
3.4.15. Cam shaft speed sensor z The camshaft controls the engine's Fixing Bolt intake and exhaust valves. It turns at half the speed of the crankshaft. Crank Shaft Sensor When a piston travels in the direction of TDC, the camshaft Shim position determines whether it is in the compression phase with subsequent ignition, or in the exhaust phase. This information cannot be generated from the crankshaft position during the starting phase.
3.4.18. Engine oil pressure & temperature sensor z The engine oil pressure and oil Fixing bolt temperature sensor measure in the engine lube oil and measuring data is inputted into ECU. Engine oil pressure & temperature sensor 3.4.19. Engine coolant temperature sensor z The engine coolant temperature sensor measure in the engine coolant circuit and measuring data is inputted into ECU.
3.5. Electrical System 3.5.1. Electric parts – Fork lift 2 3 Torque 1.0 kg.
3.5.2.
b) Harness of electrical control unit (A) DL06 Diesel Engine 136 Disassembly and Reassembly of Major Components
c) Harness of electrical control unit (B) DL06 Diesel Engine 137 Disassembly and Reassembly of Major Components
3.5.3.
3.5.4. Electrical Control Unit Abbreviation Pin no. Part name BOSCH DOOSAN 1.02 V_V_BAT+3 V_V_BAT+3 Battery plus 3 1.03 V_V_BAT+4 V_V_BAT+4 Battery plus 4 1.05 G_G_BAT-3 G_G_BAT-3 Battery minus 3 1.06 G_G_BAT-4 G_G_BAT-4 Battery minus 4 1.07 O_S_CHRLY O_S_RL04 Cold starter heater relay 1.08 V_V_BAT+1 V_V_BAT+1 Battery plus 1 1.09 V_V_BAT+2 V_V_BAT+2 Battery plus 1.10 G_G_BAT-1 G_G_BAT-1 Battery minus 1 1.11 G_G_BAT-2 G_G_BAT-2 Battery minus 2 1.
Signal Pin no. BOSCH Part name DOOSAN 1.59 G_R_RMTHR G_R_ACT09 Remote throttle ground 1.60 V_V_5VRMTHR V_V_5VSS2C Remote throttle, supply 1.61 I_A_RMTHR I_A_ACT09 Remote throttle input signal 1.62 I_A_TL I_A_PAS07 Torque limitation signal 1.64 I_S_CRCNEG I_S_DIG11 Cruise control activator/PTO,"Set / decelerate" 1.65 G_R_TL G_R_PAS07 Torque limitation ground 1.66 I_S_CONV I_S_DIG08 Clutch switch signal (Torque converter) 1.67 G_R_FSS G_R_DF06 Fan speed sensor ground 1.
Signal Pin no. BOSCH Part name DOOSAN 2.32 V_V_5VOPS V_V_5VSS1A Oil pressure sensor supply 2.33 V_V_5VBPS V_V_5VSS1C Boost pressure sensor supply 2.34 I_A_BPS I_A_ACT06 Boost pressure sensor signal 2.35 I_A_FTS I_A_PAS01 Fuel temperature sensor signal 2.36 I_A_BTS I_A_PAS03 Boost pressure temperature sensor signal 3.01 O_P_SVH21 O_P_SVH21 Injector 5 “High Bank 2” ; Cylinder no. 5 3.02 O_P_SVH22 O_P_SVH22 Injector 6 “High Bank 2” ; Cylinder no. 6 3.
3.5.5. Engine harness - 1 Crank shaft speed sensor Cam shaft speed sensor (CRS) (CAS) Common rail pressure sensor (RPS) Fuel temperature sensor Oil pressure sensor (OPTS) (FTS) Boost pressure sensor (BPTS) Water temperature sensor (CTS) Engine ECU Sensor pin no. 2.23 2.19 2.09 2.10 2.24 2.28 2.32 2.27 2.25 2.36 2.33 2.34 2.12 2.14 2.13 2.15 2.26 2.35 2.26 Pin position Signal ECU pin no. CRS CAS OPTS BPTS RPS CTS FTS DL06 Diesel Engine ECU no. 23 ECU no. 19 ECU no. 09 ECU no. 10 ECU no.
3.5.6.
1) Injector harness (outside) Fuel metering unit (MEU) ECU side Intermediate connector of injector Side of ECU Connector no. Destination Pin no. Connector no. White High side of injector 1 3.13 2 White Low side of injector 1 3.11 3 White High side of injector 2 3.06 4 White Low side of injector 2 5 White High side of injector 3 6 White Low side of injector 3 7 White High side of injector 4 3.14 8 White Low side of injector 4 3.01 9 White High side of injector 5 3.
2) Injector harness (Inside) Injector cylinder #6 Injector cylinder #5 Injector cylinder #4 Injector cylinder #3 Injector cylinder #2 Injector cylinder #1 Intermediate connector of injector Side of ECU harness Connector no. P_01 65.268105011 99013-00102 (AMP) DL06 Diesel Engine Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 Destination Connector no. Pin no.
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. DOOSAN recommend the using the EDIA, because it can be worked speedy and correctly. 3.6.2.
3.6.3. Engine fault code and occurring condition Fault code 1.1 1.2 Contents of trouble Relation to coolant temperature sensor is abnormal Relation to fuel temperature sensor is abnormal Lamp C C 1.3 Relation to boost air temperature sensor is abnormal C 1.
Fault code Contents of trouble Lamp Condition of occurring Abnormality by abnormal stopping of engine Relation to crank shaft speed sensor is abnormal Relation to cam shaft speed sensor is abnormal C 4.4 Engine speed sensor is abnormal C 4.5 Dater storage of EEPROM in ECU is abnormal C * Error is occurred during storing important data of operating in ECU to EEPROM when engine stop. 4.6 Initialization is not good after power supply to ECU C * ECU initialization is abnormal 4.
Fault code Contents of trouble Lamp Condition of occurring 7.6 Low side Power stage 11 N * Not use 7.7 Low side Power stage 5 N * Not use 7.8 Low side Power stage 4 N * Not use 7.9 Low side Power stage 14 N * Engine brake 2 * Brake 2 unit / cable / connector is abnormal 8.1 Low side Power stage 15 N * Not use 8.2 Low side Power stage 16 N * Not use 8.3 Low side power stage 17 N * Cold start lamp * Lamp unit / cable / connector is abnormal 8.
Fault code Contents of trouble Lamp Condition of occurring 11.1 Smooth running control seg-2 N * Not use 11.2 Smooth running control seg-3 N * Not use 11.3 Smooth running control seg-4 N * Not use 11.4 Smooth running control seg-5 N * Not use 11.5 Fan speed sensor N * Not use * Fan speed sensor / harness is abnormal 11.6 EBC1 message timeout N * Not use 11.7 Fuel pressure monitoring MPROPHIGH B * Same with fuel pressure monitoring MPROPHIGH. Only, this is critical error.
3.6.4.
3.7. Operating condition of the ECU 3.7.1. Engine starting z Setting of a basic temperature for decision of the fuel quantity. Set to a basic temperature the minimum value between coolant temperature and fuel temperature and intake air temperature. z Engine speed sensor signal measurement - Using by crankshaft speed sensor. - Using by camshaft speed sensor. - Supply to the engine after decided properly fuel quantity to starting the engine. 3.7.2.
3.7.4. Maximum speed limit function z Limit speed : 100 km/h z 80km/h : mixer, tank-rolley, concrete/high pressure gas transport car, the controller and operation unit and connecting unit should be sealed. z The ECU control the speed not to exceed the limit defined according to the vehicle class. 3.7.5. Safety function when door is opened z The vehicle limit the accelerating not to start on conditions of opened door. - City bus / a seat bus are adapted only - When the door is opened at stopping a vehicle.
z Full disabled condition - State of vehicle speed sensor : occurrence of trouble - Vehicle speed : running - Engine speed : change of speed more than idle speed - Parking brake : disabled z Temporarily disabled method - Pedal brake is depressed, clutch pedal is depressed, or accelerator pedal is depressed. 3.7.7.
z Method of confirmation of the fault code by using the CEL - The fault code is displayed one by one every time switch of the CEL is depressed. z Diagnostic by the EDIA - Diagnostic is executed by the connection EDIA to the connector in the relay box. 3.7.9. Vehicle operating record z The vehicle information related to the operating is recorded in the electric control unit (ECU). - The measurement of the operating record is possible after the accumulated value or the switch『reset』is depressed.
4. 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 engines. z Oil filler neck on cylinder head cover Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary. z The oil level must be between Max. and Min. lines on the gauge. The notches in the oil level gauge indicate the highest and lowest permissible oil levels.
Up to the first 5,000km (50Hr) z Engine should be run at fast idling until the temperature of the engine becomes normal operating condition. z Overload or continuous high speed operation should be avoided. z High speed operation with no load should be prevented. z Abrupt start and stop of the engine should be avoided. z Engine speed must be under 70% of its maximum speed. z Maintenance and inspection must be accomplished thoroughly. 4.2.2.
z At the end of the break-in period, remove break-in oil and replace the oil filter. z Fill oil pan with recommended engine oil. Refer to following table SAE no. Oil grade 10W40 ACEA-E5 （API CI-4） z Engine oil capacity Engine oil capacity Engine model Oil pan inside Use Suffix Max (lit) Min (lit) (lit) Truck EUTCA 19 15 21 EUTEA/C/F/G/H/I 27 17 29 EUTEB/D/J/K/L 22 16 24 EUTLA/B/C/D 27 20 29 EUTFA/B/C/D 27 17 29 Excavator Fork lift Total 4.2.3.
4.3.1. Pressure of lubricating oil The normal pressure comes up to 1.5 ~ 3 kg/cm2 at idling and 3.0 ~ 5.5 kg/cm2 at maximum speed. If the pressure fluctuates at idling or does not reach up to the expected level at high speed, shut down the engine immediately and check the oil level and the oil line leakage. 4.3.2. Temperature of cooling water The cooling water temperature should be 85 °C in normal operating conditions.
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. 2. Do not actuate the starter for longer than 10 seconds. If starting fails regardless of the preheating, start the preheating again after 30 seconds.
z Air heater major specification Rated voltage DC 22V (95A ±10%) Rated current 2.1 kW Caution air flow of assembly direction 4.4.2. Prevention against freezing of cooling water z 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.
4.4.4. Lubricating oil As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting. Therefore the lubricating oil for winter should be used to prevent this unstability. Refer to lubricating system section. 4.5. Engine components check after long time running z The purpose of an engine tune-up is to restore power and performance that's been lost through wear, corrosion or deterioration of one or more parts or components.
4.6. Maintenance and Care 4.6.1. Periodical Inspection and Maintenance In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital. z Daily inspections in bellow figure should be checked every day. z The maintenance should be executed thoroughly at regular intervals. (refer to appendix “General engine inspection cycle”.) 4.6.2. Exchanging of lubrication oil Engine oil and the oil filter are important factors affecting engine life.
4.6.4. Oil exchange procedure While the oil is still hot, exchange oil as follows. z Take out the oil level gauge. z Remove the drain plug from oil pan, then drain out the engine oil into a container. Drain plug z Refill with new engine oil at the oil Oil filler cap filler neck on the head cover and the lubricating oil in accordance with the oil capacity of the engine through oil filler. z Be careful about the mixing of dust or contaminator during the supplement of oil.
CAUTION : Don't forget tightening the drain plug after having drained engine oil. z Loosen the oil filter by turning it counter-clockwise with a filter wrench. z With a rag wipe clean the fitting face of the filter head and the oil filter cartridge so that new oil filter cartridge can be seated properly. z 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.
4.7. Cooling System The coolant must be changed at Radiator cap intervals of 40,000km (1200 Hr) operation or six months whichever comes first. If the coolant is being Radiator fouled greatly, it will lead an engine overheat or coolant blow off from the expansion tank. Drain valve 4.7.1. Coolant draining ● Remove the pressure cap. ● Open the drain valve at the radiator lower part to drain the coolant as Drain plug (Cylinder block) the right figure.
4.7.2. Cleaning of the cooling inside system circuit When the cooling system circuits are fouled with water scales or sludge particles, the cooling efficiency will be lowered. When the cooling system circuits are clogged, the water pump mechanical seal is damaged. The poor condition of the cooling system is normally due to use of unsuitable or no anti-freezing agents and corrosion inhibitor or defect.
5. Maintenance of Major Components 5.1. Cooling System 5.1.1. General descriptions and main data z This engine is water-cooling type. Heat from the combustion chamber and engine oil heat are cooled down by coolant and radiated to the outside, resulting in the normal operation of the engine.
5.1.2. Specification Item 1. Water pump 2. Thermostat Specification Type Pumping speed Delivery Pump head Pumping back pressure Operating temperature Centrifugal type 2,500 rpm about 200 liter/min or more 7.0 m Bellow 0.5 bar 71°C type 10mm or more (at 90°C) 71 ∼ 90°C Valve lift Operating temperature 5.1.3. Thermostat z General descriptions and main data The thermostat maintains a constant temperature of coolant (82 ∼ 95 °C) and improves thermal efficiency of the engine by preventing heat loss.
z 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 82 °C and 10 mm or more (opening wide) at temperature of 95 °C, the thermostat is normal.
5.1.4 Diagnostics and troubleshooting Complaints 1. Engine overheating Possible causes z z z z z z z z z z 2. Engine overcooling z z 3. Lack of coolant z z z z z z z 4.
5.2. Lubrication system 5.2.1. General descriptions and main data z 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 high pressure pump in order to ensure normal engine performance.
z 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 Steel plate is beyond the limit. End play limit Feeler gauge 0.03 ∼ 0.136 mm (2) With a feeler gauge, measure the amount of backlash between the oil pump drive gear and driven gear. Replace if the measured value is beyond the limit. Standard 0.312 ~ 0.476 mm Limit 0.64 mm (3) Measuring clearance between drive shaft and bushing a.
5.2.3. Diagnostics and troubleshooting Complaints 1. Oil consumption excessive Possible causes z z z z z z Oil pressure too low z z z z z z z 2.
5.3. Turbo Charger 5.3.1. Specification and construction 1) Main data and specification Specification DL06 Holset HX35, HX35W Honeywel GT35W 2 Approx. 1.9 kgr/cm 3 Approx. 15.9 m /min Approx.
3) Components of turbocharger z Make sure that servicing should be performed at the professional maintenance shop as authorized by Holset Company.
4) Operating principle The turbocharger is a system designed to make use of the engine exhaust gas energy to charge high-density air into the cylinders, thereby to increase the engine output. 5.3.2. General information The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn the fuel should be supplied to the cylinder.
2) Compressor It is connected to the same shaft with the turbine to make a revolving assembly, and receive the revolving force of turbine, and sends air to the suction manifold by suctioning and compressing it. This is called as the compressor. 3) Bearing (1) Thrust bearing Thrust bearing force is applied to the turbine wheel and an arrangement is made for the shaft not to shift.
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 At starting Caution Reason 1) Inspect oil quantity 2) After confirming that oil pressure rises by starting engine with starter (until the pointer of oil pressure gauge moves or pressure indicating lamp operates), the starting must be done.
Operation Caution Reason Following items must be confirmed. 1) Oil pressure 2 At idling : 1.5 ~ 3.0 kg/cm 2 At full load : 3.0 ~ 5.5 kg/cm During operation 2) When abnormal noises and vibration are generated, slow down the revolution and must stop it to investigate the causes. 1) At stopping the engine, perform the idling operation for 5 min. and then stop it. At stop 1) If the pressure is too low, abnormal wear or stuck may be caused. Or if too high, the oil leak may be generated.
3) Lubricating system In the lubricating system, a care must be paid to the oil quality and oil element replacement cycle. For the oil deterioration of turbocharger equipped engine, needless to speak of engine assembly itself, influences badly to the turbocharger too. Suggested engine oils for the turbocharger-mounted engine are as follows: Recommended oil Engine model DL06 SAE no. API no. SAE 10W40 ACEA-E5 (API CI-4) 5.3.6.
(1) Rotor axial direction end play (2) Rotor radial direction end play (3) If the measured axial and radial end plays are beyond the limit of wear, replace or repair the turbocharger.
(1) Lubricating system z 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. z 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. z Assemble each joint on oil pipes securely to prevent oil leaks. (2) Air intake system z Check the inside of the intake system for foreign matters.
5.3.7. Diagnostics and troubleshooting Complaints 1. Excessive black smoke 2. Excessive white smoke 3.
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. Be careful to assemble cover and bowl correctly. There is a recess in the cover rim and a lug on the collector which should register.
5.4.3. Cleaning air cleaner elements z By compressed air (wear goggles) - For the purpose, the air gun should be fitted with a nozzle extension which is bent 90° at the discharge end and which is long enough to reach down inside to the bottom of the element. - Moving the air gun up and down, blow out the element from the inside (maximum 5 bar) until no more dust comes out of the air cleaner pleats z By washing - Before washing, the element should be precleaned by means of compressed air, as described above.
z Knocking out dirt by hand - In emergencies, when no compressed air or cleaning agent is available, it is possible to clean the filter cartridge provisionally by hitting the end disk of the cartridge with the ball of one's thumb. - Under no circumstances should the element be hit with a hard object or knocked against a hard surface to loosen dirt deposits. z Checking the air cleaner cartridge - Before reinstalling the cartridge, it must be checked for damage e.g.
(T) = 0.015 x S (about 1.5mm per 100mm). T = 0.015 x *S (mm) (T : Deflection, S : Span) (D − d )2 S= C − 2 * 2 (mm) C : Distance of pulleys (mm) D : Large pulley diameter (mm) d : Small pulley diameter (mm) (4) Measuring tension ① Lower indicator arm (1) into the scale z Apply tester to belt at a point midway between two pulleys so that edge of contact surface (2) is flush with the Vbelt. z Slowly depress pad (3) until the spring can be heard to disengage. This will cause the indicator to move upwards.
② Reading of tension z Read of the tensioning force of the belt at the point where the top surface of the indicator arm (1) intersects with the scale. z Before taking readings make ensure that the indicator arm remains in its position.
6. Special Tool List No Part no. Figure Tool name 1 EF.121-255 EF.121-256 2 EF.121-257 EF.121-258 Oil seal assembly jig (Rear) 3 EF.123-065 Valve spring compression 4 EF.123-365A Cylinder liner puller Oil seal insert assembly (Front) Only DL06 engine EF.121-250 Piston insert 5 EF.120-208 6 Remark EF.
No Part no. Figure Tool name 7 EF.121-181 Cam shaft hole cover punch 8 EF.121-252 Step idle gear pin assembly 9 EF.120-239 Slave piston disassembly & assembly (Engine brake) 10 60.99901-0027 Filler gauge 11 EF.121-260 Wear ring punch(rear) 12 65.
No Part no. 14 EF.121-259 Crankshaft gear insert jig 15 EF.120-277 Injector insert 16 EF.
22 USB CABLE (Notebook - Gateway) A463567 DL06 Diesel Engine 193 Special Tool List
● Appendix z Tightening torque for major parts Major parts Cylinder block bearing cap Oil spray nozzle Flywheel housing Crankshaft pulley Vibration damper Flywheel Connecting rod cap Cylinder head Cylinder head cover Screw (Diameter x pitch) Tightening torque M16 x 2.0 30±2 kg.m M10 x 1.25 2.1+0.5 kg.m M12 x 1.5 11.2 +1.0 kg.m M14 x 1.5 20+0.2 kg.m M10 x 1.5 6.2+0.5 kg.m M14 x 1.5 20 +2.0 kg.m M12 x 1.5 M13 x 1.5 9.75+0.25 kg.m 5kg.m + 90°+ 90°+ 90° M8 2.2 +0.5 kg.
Standard bolt tightening torque table Refer to the following table for bolts other then described above Diameter x pitch (mm) M5 M6 M7 M8 M8x1 M10 M10x1 M12 M12x1.5 M14 M14x1.5 M16 M16x1.5 M18 M18x1.5 M20 M20x1.5 M22 M22x1.5 M24 M24x1.5 3.6 (4A) 4.6 (4D) 4.8 (4S) 20 24 32 0.15 0.28 0.43 0.7 0.73 1.35 1.5 2.4 2.55 3.7 4.1 5.6 6.2 7.8 9.1 11.5 12.8 15.5 17 20.5 23 0.16 0.30 0.46 0.75 0.8 1.4 1.6 2.5 2.7 3.9 4.3 6 6.5 8.3 9.5 12 13.5 16 18.5 21.5 25 0.25 0.45 0.7 1.1 1.2 2.2 2.5 3.7 4 6 6.6 9 9.7 12.
z Engine assembly tolerance (unit : mm) Group Part Inspection item Inside diameter of cylinder liner Cylinde r block & liner Cylinde r block Cylinde r head & valve Piston ring Correction φ104.4 0.03 ~ 0.08 - 0.08 - Correct with a surface grinder 4 - Replace if leaky Valve seat Intake depression Exhaust 0.35 ~ 0.65 0.85 0.35 ~ 0.65 0.85 Cylinder head height 104.9~105.1 104.4 Replace cylinder head 0.15 0.3 Replace cylinder head 1.215~1.285 - 4 - Replace if leaky φ99.93~φ99.
Group Part Inspection item Piston ring side clearance Oil ring Top ring 2nd ring Oil ring Direction of ring gap Piston pin Outer diameter of piston pin Clearance between piston pin and its bush DL06 Diesel Engine Stand value for assembly 0.25~0.45 0.05~0.09 0.03~0.07 Limit for use 1.5 0.15 0.15 Correction Replace ring or piston φ108 Limit for use is if for standard clearance. Cross Install by 120° - - φ39.994~φ40.000 φ39.94 Replace piston pin 0.006~0.020 0.
(Unit : mm) Group Stand value for assembly Limit for use - 0.01 Outside diameter of journal φ79.905~φ79.925 φ78.905 Outside diameter of pin φ68.924~φ68.944 φ67.92 4 33.99 ~ 34.03 33.94 0.007 0.025 0.02 0.03 0.02 0.03 0.06↓ 0.1↓ Adjust by a press Measure #4 journal (journal #1, #7 support) 0.045~0.110 0.15 Replace bearings Measure at crown part 0.14~0.33 0.
Group Part Inspection item Con-rod bearing cap bolt (kg.m) Cam shaft Timing gear Inner diameter of hall of cylinder block camshaft Diameter of camshaft journal Clearance between cam shaft and cam bush Valve system Valve and valve guide Limit for use Correction Remark 9.75+0.25 - Coat the bolt with engine oil Clean out foreign objects on joining surface. φ56.000 ~ φ56.030 - φ55.92~φ55.95 φ55.65 0.03 ~ 0.09 0.18 Replace cam bush End play of camshaft 0.280 ~ 0.430 0.
Group Part Inspection item Outer diameter of valve seat Intake Exhaust Valve seat assembly part’s depth of cylinder head Inner diameter of valve guide Valve guide assembly part’s inner diameter of cylinder head Diameter of valve guide Clearance between valve guide and cylinder head installing hole Concentricity between valve seat and valve guide Free length Intake and exhaust valve spring 7.9 ~ 8.1 - Remark - φ7.000~φ7.015 - φ13.000~φ13.0 18 - φ13.028~φ13.
Group Stand value for assembly Limit for use - - Oil pressure (at normal speed) 2 kg/cm 3.0 ~ 5.5 - Oil pressure 2 (idling) kg/cm 1.5 ~ 3.0 - - 105 Part Inspection item Tappet face in contact with cam Engine oil Lubrica ting system Oil pump Oil temperature (°C) Permissible oil temperature in short time (°C) By-pass valve for oil filter 2 (kg/cm ) Operating pressure Spray nozzle Nozzle diameter Delivery volume l/min - Pump speed: 3,333rpm - Oil temperature: 80°C 2 - pressure: 4.
Group Inspection item Stand value for assembly Limit for use Correction Delivery volume l/min - Pump speed 2,500rpm - Water temp. 80°C - Back pressure 0.5 kg/cm2 200 or more - Check the water passage Part Water pump Diameter Pulley side of water pump Impeller side shaft Clearance of bearing Clearance between impeller & housing Squareness of pulley Fan belt depression Cooling water temp Thermo stat Operating temperature (permissible temp.
Group Part Inspection item D grade Piston ring #1, #2 ring gap #2, #4 ring Drive system Gear back lash Cam shaft gear & idle gear Fuel high pressure pump gear & idle gear Crankshaft gear & oil pump driving gear Air compressor (PTO) gear & cam gear DL06 Diesel Engine Stand value for assembly φ89.930~φ89.9 40 0.2 ~ 0.45 Limit for use Correction Remark - 0.2 ~ 0.4 0.074 ~ 0.163 - 0.103 ~ 0.182 - 0.073 ~ 0.239 - 0.074 ~ 0.
7.
