Doosan DL06 User manual

DL06Diesel Engine
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly
D110S-5, D130S-5, D160S-5
SB4228E01
Sep. 2011

1
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.
Read and understand all safety precautions and warnings before operating or performing
lubrication, maintenance and repair on this product.
Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual.
Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance
publication.
Specific safety warnings for all these publications are provided in the description of operations where
hazards exist. WARNING labels have also been put on the product to provide instructions and to
identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur
to you or other persons. Warnings in this publication and on the product labels are identified by the
following symbol.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by DOOSAN is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These changes can affect the
service given to the product. Obtain the complete and most current information before starting any job.
DOOSAN dealers have the most current information available.
WARNING

DL06 Diesel Engine Index
3
INDEX
1. Safety Regulations &
Specifications
1.1. Safety Regulations................................5
1.2. Engine Specifications..........................10
1.3. Engine Power .....................................12
1.4. Engine Performance Curve.................13
1.5. Engine Assembly ................................15
2. Technical Information
2.1. Engine Model and Serial Number........18
2.2. Diagnostic tool (EDIA).........................19
2.3. Engine character.................................19
2.4. Diagnosis and Remedy.......................42
2.5. Engine Inspection ...............................52
3. Disassembly and Reassembly of
Major Components
3.1. Engine Disassembly............................54
3.2. Inspection and Measurement on Major
Parts...................................................70
3.3. Reassembly........................................94
3.4. Fuel injection System........................120
3.5. Electrical System ..............................134
3.6. Engine Diagnostic............................146
3.7. Operating condition of the ECU......... 152
4. Commissioning and Operation
4.1. Preparations .....................................156
4.2. Breaking-In.......................................156
4.3. Inspections after Starting...................158
4.4. Operation in winter time....................160
4.5. Engine components check after long time
running .............................................162
4.6. Maintenance and Care......................163
4.7. Cooling System.................................166
5. Maintenance of Major Components
5.1. Cooling System.................................168
5.2. Lubrication system.............................172
5.3. Turbo Charger...................................175
5.4. Air cleaner.........................................185
5.5. Belt....................................................187
6. Special Tool List..........................190
7. Engine assembly DL06 – EUTFC
......................................................204

4

DL06 Diesel Engine Safety Regulations & Specifications
5
1. Safety Regulations & Specifications
1.1. Safety Regulations
1.1.1. General notes
zDay-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.
zThis summary is a compilation of the most important regulations, These are
broken down into main sections which contain the information necessary for
preventing injury to persons, damage to property and pollution. In addition to
these regulations those dictated by the type of engine and its site are to be
observed also.
IMPORTANT:
If despite all precautions, an accident occurs, in particular through contact
with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc, consult a doctor immediately.
1.1.2. To prevent accidents with injury to persons
(1) Engine starting and operation
zBefore putting the engine into operation for the first time, read the operating
instructions carefully and familiarize yourself with the “critical” points. If you
are unsure, ask your DOOSAN representative or service man.
zFor reason of safety we recommend you attach a notice to the door of the
engine room prohibiting the access of unauthorized persons and that you
draw the attention of the operating personal to the fact that they are
responsible for the safety of person who enter the engine room.
zThe engine must be started and operated only by authorized personnel.
zEnsure that the engine cannot be started by unauthorized person.
zWhen the engine is running, do not get too close to the rotating parts.
zDo not touch the engine with bare hands when it is warm from operation risk
of bums.
zExhaust gases are toxic. If it is necessary to run an engine in an enclosed
area, remove the exhaust gases from the area with an exhaust pipe
extension.

DL06 Diesel Engine Safety Regulations & Specifications
6
(2) Maintenance and care
zAlways 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.
zChange 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.
zTake into account the amount of oil in the sump. Use a vessel of sufficient
size to ensure that the oil will not overflow.
zIf change or refill the cooling water, disassemble the drain plug when the
engine has cooled down. Heated cooling water has the risk of scalding and
safety accidents.
zNeither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit
and any additional hydraulic oil circuit) during the operation. The fluids which
flow out can cause injury.
zFuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank
must be filled only when the engine is switched off.
zKeep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
zComply with the manufacturer's instructions when handling batteries.
CAUTION:
Accumulator acid is toxic and caustic. Battery gases are explosive.
Therefore it should be done by an expert of the handling professionally.
(3) When carrying out checking, setting and repair work
zChecking, setting and repair work must be carried out by authorized
personnel only.
zUse only tools which are in satisfactory condition. Slip caused by the worn
open-end wrench could lead to injury.

DL06 Diesel Engine Safety Regulations & Specifications
7
zWhen the engine is hanging on a crane, no-one must be allowed to stand or
pass under it. Keep lifting gear in good condition.
zWhen do electric weld, stop the engine, power off, then remove the wire
harness’ connector which is connected to the ECU.
zDo not weld the electric control unit (ECU) absolutely, and do not damage on
it by electrical or mechanical shock.
zWhen working on the electrical system disconnect the battery earth cable
first. Connect it up again last in prevent short circuits.
1.1.3. To prevent damage to engine and premature wear
(1) Never demand more of the engine than it was designed to yield for its intended
purpose.
Detailed information on this can be found in the sales literature. Engine control
unit must not be adjusted without prior written permission of DOOSAN.
(2) If faults occur, find the cause immediately and have it eliminated in order to
prevent more serious of damage.
(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility
for damage resulting from the installation of other parts which are supposedly
"just as good”.
(4) In addition to the above, note the following points.
zNever let the engine run when dry, i.e. without lube oil or coolant.
zPay attention to cleanliness. The Diesel fuel must be free of water.
zUse only DOOSAN approved service products (engine oil, anti-freeze and
anticorrosion agent)
zRefer to the subjects of recommendation of the fuel.
zHave the engine maintained at the specified intervals.
zDo not switch off the engine immediately when it is warm, but let it run without
load for about 5 minutes so that temperature equalization can take place.
zNever put cold coolant into an overheated engine.
zDo not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Do not exceed the maximum permissible tilt of the engine.
zAlways ensure that the testing and monitoring equipment (for battery charge,
oil pressure, coolant temperature) function satisfactorily.
zDo not let the raw water pump run dry, If there is a risk of frost, drain the
pump when the engine is switched off.

DL06 Diesel Engine Safety Regulations & Specifications
8
1.1.4. To prevent pollution
(1) Engine oil, filter elements, fuel filters
zTake old oil only to an oil collection point.
zTake strict precautions to ensure that oil does not get into the drains or into
the ground. The drinking water supply could be contaminated.
zFilter elements are classed as dangerous waste and must be treated as such.
(2) Coolant
zTreat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
zWhen disposing of spent coolant comply with the regulations of the relevant
local authorities.
1.1.5. Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and any kind of engine oil
decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal
experiments. If the basic rules of hygiene and health and safety at work are
observed, health risks are not to the expected as a result of handling used engine oil
.
< Health precautions >
zAvoid prolonged or repeated skin contact with used engine oil.
zProtect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
zClean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
zAfter washing apply a fatty skin cream to the skin.
zChange oil-soaked clothing and shoes.
zDo not put oily rags into your pockets.

DL06 Diesel Engine Safety Regulations & Specifications
9
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. Before performing service operation, disconnect the grounding cable from the
battery for reducing the chance of cable damage and burning due to short-
circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient
and reliable service operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should
be discarded and new ones should be prepared for installation as normal function
of the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separate is very important as they
vary in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has
been done property.
13. Work the fuel line after the common rail pressure and engine temperature is
checked with the EDIA. (past about 5 minutes after engine stop)

DL06 Diesel Engine Safety Regulations & Specifications
10
1.2. Engine Specifications
Items Enginemodel DL06
Engine type Water-cooled, 4 cycle, In-line,
Turbo charged & inter-cooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder-bore x stroke (mm) 6 – 100 ×125
Total piston displacement (cc) 5,890
Compression ratio 17.4 : 1
Engine dimension
(length x width x height) (mm) 1,069 x 815 x 1,164
Rotating direction (from flywheel) Counter clockwise
Engine weight (kg) 560
Firing order 1 – 5 – 3 – 6 – 2 - 4
Fuel high pressure pump type Bosch CP3.3 fuel high pressure pump type
Engine control type Electric control type (ECU)
Injector type Multi – hole (8 x Ø0.136)
Fuel injection pressure (kg/cm2) 250bar(operating pressure 1,600bar)
Valve clearance Intake valve 0.3
Exhaust valve 0.4
Intake valve Open at
2
1°(B.T.D.C)
Close at
3
3°(A.B.D.C)
Exhaust valve Open at
5
6.2°(B.B.D.C)
Close at
2
2.2°(A.T.D.C)
Fuel filter type Full-flow (cartridge)
Oil pressure
(kg/cm2) at idle speed 1.5 ~ 3.0
at rated speed 3.0 ~ 5.5
Using lubrication oil ACEA-E5(API CI-4 class)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Oil filter type Cartridge type
Lubricating oil capacity (max./min.) (lit) 27 / 17 , 22 / 16
Oil cooler type Water cooled
Hydraulic indicator Oil pressure unit
Water pump Belt driven centrifugal type
Cooling method Pressurized circulation
Cooling water capacity(engine only) (lit) 10.6
Thermostat
Type Wax pallet type
Open at (°C) 71°C (82°C)
Open wide at (°C) 90°C (95°C)
Valve lift (mm) 10 (10)

DL06 Diesel Engine Safety Regulations & Specifications
11
Items Enginemodel DL06
Water temperature indicator Water temperature sensor mounted
Air compressor
(if equipped)
Type Water cooled
Capacity (cc/rev) 305
Revolution ratio 1 : 0.93 (engine speed : air compressor speed)
Power steering
pump
Type Gear driven, vane type
Capacity (l/min) 18
Adjusting pressure
(kg/cm2) 125 (Pump speed 1,300 rpm)
Revolution ratio 1 : 1.303 (engine speed : pump speed)
Turbo charger Exhaust gas driven type (waste gate)
Engine stop system Fuel feeding shut-off by ECU
Alternator (voltage – capacity) (V - A) 24 - 60
Starting motor(voltage–output) (V - kW) 24 – 4.5
Air heater capacity (V – A) 12V – 1.3kW x 2ea
Battery capacity (V - AH) 24 - 150

DL06 Diesel Engine Safety Regulations & Specifications
12
1.3. Engine Power tolerance : ±5%
Engine model Performance
Remark
Model Suffix Power
(PS / rpm)
Torque
(kg.m /
rpm)
Low idle
(rpm) High idle (rpm)
DL06
EUTFA 160/2,100 67/1,400 750 2,420 Tier-2
EUTFB 140/2,100 59/1,400 750 2,420 Tier-2
EUTFC 160/2,100 67/1,400 750 2,420 Tier-3
EUTFD 140/2,100 59/1,400 750 2,420 Tier-3
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)

DL06 Diesel Engine Safety Regulations & Specifications
13
1.4. Engine Performance Curve
1.4.1. Performance curve (140 PS) – D110/130S-5
Performance ISO 1585 (SAE J1349)
Output (max.) 103 kW (140 PS) / 2,100 rpm
Torque (max) 579 N.m (59 kg.m) / 1,400 rpm
Fuel consumption (min.) 224 g/kW.h (165 g / PS.h)
Revolution (rpm)
Outpu
t
(PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

DL06 Diesel Engine Safety Regulations & Specifications
14
1.4.2. Performance curve (160 PS) – D160S-5
Performance ISO 1585 (SAE J1349)
Output (max.) 118kW(160PS)/2,100rpm
Torque (max) 657 N.m (67 kg.m) / 1,400 rpm
Fuel consumption (min.) 224 g/kW.h (165 g / PS.h)
Revolution (rpm)
Outpu
t
(PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

DL06 Diesel Engine Safety Regulations & Specifications
15
1.5. Engine Assembly
1.5.1. Sectional drawing (longitudinal)
1 Cooling water pump 8 Cylinder head
2 Thermostat 9 Push rod
3 Injector 10 Tappet
4 Piston 11 Vibration damper
5 Piston pin 12 Oil suction pipe
6 Oil filler cap 13 Crank shaft
7 Intermediate cover 14 Cam shaft
1
2 3 4 5 67
8
9
10
11 12
13 14

DL06 Diesel Engine Safety Regulations & Specifications
16
1.5.2. Sectional drawing
1 Oil spray nozzle 8 Rocker arm
2 Oil cooler 9 Valve
3 Connecting rod 10 Cylinder block
4 Fuel high pressure pipe 11 Oil pump
5 Common rail 12 Oil level gauge
6 High pressure connector 13 Drain plug
7 Caliper
1
2
3
4 56789
10
11
12
13

DL06 Diesel Engine Safety Regulations & Specifications
17
1.5.3. Engine assembly
(1) DL06 (Fork lift)
1 Flywheel housing 10 Fuel high pressure pump 18 Air pipe
2 Air compressor
(if equipped) 11 Engine control unit(ECU) (intercooler to intake manifold)
12 Oil filter 19 Oil filler cap
3 Lifting hook (rear) 13 Crank shaft pulley 20 Exhaust manifold
4 Cylinder head cover 14 Cooling water pump 21 Turbo charger
5 Cooling water outlet 15 Alternator 22 Starter
6 Breather (CCV) 16 Lifting hook (front) 23 Oil pan
7 Intake manifold 17 Air pipe
8 Fuel filter (turbocharger to intercooler)
9 Oil level gauge
1
2
3
45
6
7
8
9
10
11
12
13
14
15
16
19 20
21
22
23
18
17

DL06 Diesel Engine Technical Information
18
2. Technical Information
2.1. Engine Model and Serial Number
zThe engine model and serial
number is located on the engine as
illustrated.
zThese numbers are required when
requesting warranty and ordering
parts.They are also referred to as
engine model and serial number
because of their location.
zEngine serial No. (example 2 : DL06 Fork lift)
DL06 6 00001 FA
Engine model suffix (EUTFA)
Serial no.
Production year (2006)
Engine model
Engine number
(located the
cylinder block)