Doosan DL06 User manual

DL06Diesel Engine
(interim Tier Ⅳ)
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly
D110S-5, D130S-5, D160S-5
SB4391E00
Aug. 2012

DL06K Interim Tire-4 Diesel Engine Foreword
1
FOREWORD
This Operation & Maintenance Manual is designed to provide the information on engine operation and
maintenance manual to customers and service technicians of the DL06K industrial electronic control
diesel engine provided by DOOSAN.
The DL06K industrial electronic control diesel engine is designed and manufactured to satisfy all
requirements, such as low noise, economical power consumption, high-speed, and durability by
applying DOOSAN's latest technologies in order to provide the best engine to its customers, and meet
interim Tier-4 emission regulation.
It is important to use precise operation and maintenance procedures to keep the engine in the best
possible condition and ensure the best possible long term performance. This Operation &
Maintenance Manual provides the specification, defined values, fault diagnosis, parts configuration
diagrams, and figures, that allow users to understand, manage, and take actions conveniently and
accurately.
Please read this Operation & Maintenance Manual carefully before handling the engine, to ensure that
the highest quality maintenance procedures can be applied and the technician's safety can be
protected through the use of proper work methods and operating procedures as recommended by
DOOSAN and compiled here within.
We are continually developing and investing in creating products with the best performance and
quality, as well as the improvement of maintenance procedures. We are not obliged to reflect all
design changes for product improvement in this Operation & Maintenance Manual, and this manual is
subject to change without prior notice.
We are always working to satisfy customer requirements and provide more convenient and safe
maintenance procedures to its customers.
If you find any incorrect information in this manual or have any inquiry, please contact our head office,
dealers or authorized service shops near by your location for any services.
Doosan industrial vehicle Co., Ltd.
* All contents in this Operation & Maintenance Manual are the property of DOOSAN.

DL06K Interim Tire-4 Diesel Engine Foreword
2

DL06K Interim Tire-4 Diesel Engine Important Safety information
3
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

DL06K Interim Tire-4 Diesel Engine Important Safety information
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DL06K Interim Tire-4 Diesel Engine Index
5
INDEX
1. Safety Regulations &
Specifications.................................8
1.1. Safety Regulations................................8
1.2. Engine Specifications..........................13
1.3. Engine Power .....................................14
1.4. Engine Performance Curve.................15
1.5. Engine Assembly ................................17
2. Technical Information...................20
2.1. Engine Model and Serial Number........20
2.2. Diagnostic tool ....................................21
2.3. Engine character.................................21
2.4. Diagnosis and Remedy.......................42
2.5. Engine Inspection ...............................53
3. Disassembly and Reassembly of
Major Components.......................54
3.1. Engine Disassembly............................54
3.2. Inspection and Measurement on Major
Parts...................................................69
3.3. Engine Reassembly. ...........................90
3.4. Fuel Injection System........................ 114
3.5. Electrical System ..............................126
3.6. Exhaust Gas Reduction System........133
3.7. Engine Diagnostic............................. 149
3.8. Operating Condition of the ECU........ 161
4. Commissioning and Operation....163
4.1. Preparations ..................................... 163
4.2. Breaking-In.......................................163
4.3. Inspections after Starting................... 165
4.4. Operation in Winter Time...................166
4.5. Engine Components Check after Long
Time Running ...................................167
4.6. Maintenance and Care......................168
4.7. Cooling System.................................170
4.8. Adjustment of Valve Clearance..........171
5. Maintenance of Major Components
......................................................174
5.1. Cooling System.................................174
5.2. Lubrication system.............................178
5.3. Turbo Charger...................................181
5.4. Air cleaner.........................................193
5.5. Belt....................................................195
6. Special Tool List..........................197
zAppendix

DL06K Interim Tire-4 Diesel Engine Index
6
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DL06K Interim Tire-4 Diesel Engine General Instructions
7
0. General Instructions
This Operation & Maintenance Manual is a manual designed for officially qualified professional
service technicians. If maintenance procedures is performed by unqualified personnel, or without
the specified tools and facilities, workers or others may be injured or their life can be threatened,
or an error may occur that could fatally affect engineperformance.
Regular checkups and management are required to keep the engine in optimal condition and
performing at its best. If any part needs to be replaced, the genuine part supplied by DOOSAN
and specified in the Parts Book should be used. Use of uncertified, similar parts, or recycled
parts may cause serious damage to the engine. If such a part is used, DOOSAN will bear no
responsibility.
Please note that the work procedures described in this Operation & Maintenance Manual are
the safest and most efficient work procedures, and you may be required to use special tools
for some work items.
Please contact us for genuine parts and special tools.
This Operation & Maintenance Manual uses the following symbols to explain maintenance
procedures, so that workers can make preparations and understand work items in advance.
Removal Adjustment
Installation Cleaning
Disassembly Paycloseattention-Importants
Reassembly Tightentospecifiedtorque
Alginthemarks Usespecialtoolsofmanuafacturer's
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement.
Please follow the instructions listed below to prevent environmental pollution during engine
maintenance.
zTake old oil to an old oil disposal point only.
zEnsure without fail that oil and diesel fuel will not get into the sea or rivers and canals
or the ground.
zTreat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges
as special waste.
zThe regulations of the relevant local authorities are to be observed for the disposal of
spent coolants and special waste.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
8
1. Safety Regulations & Specifications.
1.1. Safety Regulations
1.1.1. General notes
zYou should read this manual carefully and follow routine and regular check
methods to use the engine as safely as possible and minimize problems.
zSafety rules can be divided into three parts - injury to people, damage to property,
and pollution. In addition, users must comply with the regulations which apply to
each particular engine model, and the regulations regarding its place of use.
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
zPlease read "Caution" in the manual carefully before starting an engine. If you
don't understand anything, please contact Doosan.
zPlease attach the "Authorized personnel only" warning sign on the engine for safety,
and remind the engine driver that the driver is responsible for safety in the engine
room.
zOnly authorized personnel should start and run the engine. Unauthorized personnel
should not start the engine.
zDo not access the engine parts when the engine is running.
zDo not touch the engine with bare hands while the engine is running, because
the engine is hot and dangerous.
zExhaust fumes are toxic. Check ventilation when the engine is running in an enclosed
space.
(2) Maintenance and care
zThe engine must be stopped before performing maintenance procedures. If the
engine should be maintained during operation, please take additional caution as
to the danger of burns or accidents. Refrain from doing maintenance when the
engine is running as much as possible. Do not get too close to rotating parts, if
maintenance works are inevitable during operation.
zReplace engine oil when it is hot after operation, when the engine is stopped.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
9
CAUTION:
Do not replace or disassemble pipes or hoses (engine fuel circuit, engine oil
circuit, coolant circuit, and compressed air circuit) while the engine is running.
Fluid spattering may cause injury.
zCheck the amount of oil in the oil pan, and use a container large enough to hold
engine oil when replacing it.
zWhen replacing or replenishing engine coolant, cool down the engine and
disassemble the drain plug. The heated coolant may cause burns and safety
accident.
zDo not fasten or open pipes or hoses (engine oil circuit, coolant circuit, and
compressed air circuit) while the engine is running. Fluid spattering may cause injury.
zFuel is a highly combustible substance. Do not smoke or use fire around the
engine. Refuel the engine only when the engine is stopped.
zDo not mix engine maintenance materials (coolant, engine oil, fuel, battery fluid,
etc.) with drinking water containers.
zFollow the instructions of the manufacturer when checking or handling the battery.
CAUTION:
Battery fluid is toxic, corrosive, and explosive. Therefore, the battery should
be handled by a specialized technician only.
(3) When carrying out checking, setting and repair work
zEngine maintenance should be performed by authorized personnel only.
zOnly tools suitable for the purpose should be used. If a wrench with a worn-out
edge is used, safety accidents may occur due to sliding.
zWhen an engine is lifted by a crane, nobody should stand below it, or pass by it.
Please check the safety conditions of the crane first.
zFor electric welding, turn off the engine, block the power supply, and remove the
vehicle side wire harness connector that is connected to the ECU (electronic
control unit).
zNever weld the electric device or ECU, or apply electric or mechanical shock.
zDisconnect the battery ground wire first when working with electric devices.
Connect the ground wire again when other work is completed, in order to prevent
a short circuit.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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1.1.3. To prevent damage to engine and premature wear
(1) Do not use the engine any purpose other than original design.
For more details, please refer to reference data from sales. Never calibrate the
ECU without the approval of DOOSAN.
(2) If any fault is found in the engine, the cause should be found and fixed immediately
to prevent serious damages to the engine.
(3) Please use genuine spare and maintenance parts recommended by DOOSAN.
DOOSAN will bear no responsibility for damage due to the use of unauthorized
parts.
(4) Keep the following points in mind, in addition to the above instructions.
zUse normal and clean diesel fuel only. Do not use bio-diesel. Please refer to the
recommendations on fuel. Diesel fuel should not contain any moisture.
zDo not run the engine without lubricant and coolant. Use the service products
(engine oil, coolant, and anticorrosion agent) recommended by DOOSAN only.
zKeep the surroundings of the engine clean
zRefer to the recommendations about fuel in the handling manual.
zMaintain the engine at a regular interval, using the engine checklist.
zDo not stop the engine abruptly if the engine is hot. Instead, run the engine in the
idle state for 5 minutes without load to reduce engine temperature.
zDo not refill the coolant if the engine is overheated.
zDo not refill engine oil to a level higher than those marked on the level gauge.
Keep the maximum allowable slant of the engine during maintenance works.
zCheck whether equipment gauges (battery, oil pressure, coolant temperature)
work properly (normally).
zDo not run the engine without coolant. If coolant freezing is expected in winter,
drain off coolant.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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1.1.4. To prevent pollution
(1) Engine oil filter elements, fuel filters
zPour used oil into the oil collection drum.
zPay special attention not to spill oil on the ground or into the ocean. Leaked oil
can pollute sources of drinking water.
zSeparate oil and oil filter cartridge as wastes of environmental pollution, and
dispose them according to the prescribed regulations.
(2) Coolant
zTreat non-diluted anticorrosive agents and coolants as dangerous waste.
zComply with the relevant regulations of the related government office, when
disposing used coolant.
1.1.5. Notes on safety in handling used engine oil
If the skin is in contact with engine oil repetitively or for a long period of time, the skin
can contract or gets dry, and become inflamed.
As used engine oil contains hazardous substances, follow basic safety rules at the
work site when handling engine oil.
< Cautions for your health >
zDo not touch used engine oil repetitively or for a long time.
zApply skin protection cream or wear gloves.
zClean the skin if contacted with engine oil.
zUse soap and water when washing your skin.
zDo not use gasoline, diesel fuel, thinner, or solvent as an abstergent.
zApply an oily cream to your skin after washing your skin.
zReplace your clothes or shoes if they have been soaked with oil.
zDo not put oil-stained rags into your pocket.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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CAUTION:
Please check whether used engine oil is processed properly.
Wrongly processed engine oil can contaminate drinking water.
Therefore, do not pour out engine oil on the ground, waterway, drain, or sewer. You
may be punished if you don't obey these handling regulations. Be careful when
disposing engine oil. Please contact the seller, supplier, or related agency,
regarding engine oil collection methods.
1.1.6. General repair instructions
1. Disconnect the battery ground wire first for maintenance, in order to prevent wire
damage due to a short circuit.
2. Use the cover not to damage or pollute disassembled parts.
3. Handle engine oil and coolant with care, as they can do damage to paintings.
4. It is recommended to use the proper tools and special tools for maintenance of the
specified parts, considering efficiency and reliability of the maintenance work.
5. Make sure to use the genuine Doosan replacement parts.
6. Use the new cotter pin, gasket, O-ring, sealing, oil seal, lock washer, and self lock
nut when maintaining these parts. If you use the existing parts without change,
normal function cannot be maintained.
7. Keep disassembled parts by group for smooth reassembly. In particular, bolts and
nuts with different strength and shape are used, depending on the assembly
position. Therefore, you should separate bolts and nuts clearly.
8. Clean all parts before inspection or re-assembly. In addition, clean the oil hole
using compressed air to prevent the presence of foreign objects.
9. Spray oil or grease on the rotation or sliding part thinly before assembly.
10. If necessary, apply adhesives to the gasket to prevent an oil or water leak.
11. Assemble parts, using pre-defined bolts and net fastening torque.
12. Please check the engine again, when maintenance is completed.
13. Check common rail pressures and engine temperature using the laptop diagnosis
device before working with fuel lines, and start work 5 minutes after the engine has
stopped.

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
13
1.2. Engine Specifications
Enginemodel
Items DL06K
LDF00/LDF01
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) 1,264 x 848 x 1,124
weight (kg) 644
Rotating direction (from flywheel) Counter clockwise
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 Multiple hole type
Fuel injection operating pressure (bar) 1,800
Valve clearance (cold)
(mm) Intake valve 0.3
Exhaust valve 0.4
Intake valve Open at 21°(B.T.D.C)
Close at 33°(A.B.D.C)
Exhaust valve Open at 56.2°(B.B.D.C)
Close at 22.2°(A.T.D.C)
Fuel filter type Current type (cartridge type)
Oil pressure
(kg/cm2) At idle speed 1.5 or more
At rated speed 3.0 ~ 6.0
Using lubrication oil SAE 15W40 (over API CJ-4 orACEA-E9 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.) 1
)
(lit) 27 / 17
Oil cooler type Water cooled
Oil pressure indicator Hydraulic indicator
Water pump Belt-driven centrifugal type
Cooling method Pressurized circulation
Oil separator OCV
Cooling water capacity (engine only) (lit) 13
1) With 2.0 liters in the engine

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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Enginemodel
Items DL06K
LDF00/LDF01
Thermostat
Type Wax pallet type
Open at (°C) 75
Open wide at (°C) 90
Valve lift (mm) 9.5
Water temperature indicator Water temperature sensor mounted
Turbo charger Exhaust gas driven type
Engine stop system Fuel feeding shut-off by ECU
Alternator (voltage – capacity) (V–A) 24 - 50
Starting motor(voltage–output) (V–kW) 24 – 4.5
Air heater (V–A) 24 – 2.1
1.3. Engine Power tolerance : ±5%
Engine model Performance1)
Model Suffix Power
(PS / rpm) Torque (kg.m / rpm) Low idle (rpm) High idle (rpm)
DL06K LDF00 140/2,100 65/1,400 850±10 2,400±25
LDF01 160/2,100 74/1,400 850±10 2,400±25
* Note1) :All data are based on operation without cooling fan.
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DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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1.4. Engine Performance Curve
1.4.1. Performance curve
DL06 – LDF00
Performance KS-R 1004
Output (rating) 140PS/2,100rpm
Torque (max) 65 kgf·m / 1,400 rpm
EL4OM001
80
100
120
140
150
160
170
70
60
50
1000 1500 2000
Revolution

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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DL06 – LDF01
Performance KS-R 1004
Output (rating) 160PS/2,100rpm
Torque (max) 74 kgf·m / 1,400 rpm
EL4OM002
Revolution
100
120
140
160
150
160
170
70
60
50
1000 1500 2000

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
17
1.5. Engine Assembly
1.5.1. Sectional drawing
1 Cooling water pump 8 Cylinder head
2 Thermostat 9 Vibration damper
3 Exhaust valve 10 Oil pan
4 Intake valve 11 Oil suction pipe
5 Piston 12 Connecting rod
6 Cylinder head cover 13 Camshaft
7 Intermediate cover 14 Tappet
9 10 11 121314
123 45 6 7 8
EL4OM003

DL06K Interim Tire-4 Diesel Engine Safety Regulations & Specifications
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1.5.2. Sectional drawing
1 Fuel filter 8 Cylinder block
2 Oil spray nozzle 9 Cylinder liner
3 Oil cooler 10 Crankshaft
4 Caliper 11 Oil level gauge
5 Rocker arm 12 Oil drain valve
6 Fuel high pressure connector 13 Oil pump
7 Fuel high pressure pipe
EL4OM004
7
8
9
10
131211
456
2
3
1