Doosan DV11 User manual

PS-MMG0717-E1B
Operation and
Maintenance Manual
Diesel Engine
DV11
65.99897-8098A

DV11
Operation and Maintenance
Printed in Mar. 2005 PS-MMA0608-E1A
FOREWORD
This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here
after DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN's DV11 Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for the overland transport
or industrial purpose. That meets all the requirements such as low noise, fuel economy, high
engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools of manufacturer's
Directional indication Lubricate with oil
Inspection Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental
damage;
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.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
Apr. 2005

DV11
Operation and Maintenance
Printed in Mar. 2005 PS-MMA0608-E1A
CONTENTS
1. Safety regulations & engine specifications
1.1. Safety regulations 1
1.2. Engine specifications 6
1.3. Engine power 8
1.4. Performance curve 9
1.5. Engine assembly 14
2. Technical information
2.1. Engine model and serial number 18
2.2. Diagnostic tool (SCAN-200) 18
2.3. Engine characteristic 19
2.4. Diagnosis and remedy 42
2.5. Engine inspection 52
3. Maintenance
3.1. Engine disassembly 54
3.2. Measurement and inspection on major parts 69
3.3. Reassembly 90
3.4. Fuel injection system 115
3.5. Electrical system 129
3.6. Engine brake 142
3.7. Engine diagnostic 153
3.8. Engine control unit (ECU) 158
4. Commissioning and operation
4.1. Preparations 179
4.2. Operation of a new engine (Break-in) 179
4.3. Inspections after Starting 166
4.4. Operation in winter time 168
4.5. Tuning the engine 170
4.6. Maintenance and care 171
4.7. Cooling system 173
4.8. Adjustment of valve clearance 176
4.9. Tightening the cylinder head bolts 178
5. Maintenance of major components
5.1. Cooling system 180
5.2. Lubrication system 184
5.3. Turbo charger 187
5.4. Air cleaner 196
5.5. Belt 198
6. Special tool list 203
●Appendix
●Worldwide network

DV11
Operation and Maintenance
1Safety regulations & specifications
Printed in Mar. 2005 PS-MMA0608-E1A
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.

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Operation and Maintenance
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(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.

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Operation and Maintenance
3Safety regulations & specifications
Printed in Mar. 2005 PS-MMA0608-E1A
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.

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Operation and Maintenance
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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.
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.

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Operation and Maintenance
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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 SCAN-200. (past about 5 minutes after engine stop)

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Operation and Maintenance
6Safety regulations & specifications
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1.2. Engine Specifications
Enginemodel
Items DV11
Engine type Water-cooled, 4 cycle V-type 90°, Turbo charged &
intercooled
Combustion chamber type Direct injection type
Cylinder liner type Wet type
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder-bore x stroke (mm) 6 – 128 × 142
Total piston displacement (cc) 10,964
Compression ratio 17.1 : 1
Engine dimension
(length x width x height) (mm) 1,206 x 1,031 x 1,070
Engine weight (kg) 904
Rotating direction (from flywheel) Counter clockwise
Firing order 1 – 4 – 2 – 5 – 3 - 6
Fuel high pressure pump type Bosch CP3.4 fuel high pressure pump type
Engine control type Electric control type(ECU)
Injector type Multi-hole(8 x φ0.197 Bosch DLLA146)
Fuelinjectionpressure (kg/cm
2) 250bar (operating pressure 1,600bar)
Intake valve 0.4
Exhaust valve 0.5
Valve clearance
Jake brake 1.5
Open at 24°(B.T.D.C)
Intake valve Close at 30°(A.B.D.C)
Open at 52.5°(B.B.D.C)
Exhaust valve Close at 14.5°(A.T.D.C)
Fuel filter type Full-flow (cartridge)
at idle speed 1.0 ~ 3.0Oil pressure
(kg/cm2) 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 Full-flow, paper element type(double)
Lubricating oil capacity (max./min.) (lit) Bus : 34/ 26 , Truck : 32/ 26
Oil cooler type Water cooled
Oil pressure indicator Oil pressure unit
Water pump Belt driven centrifugal type
Cooling method Pressurized circulation
Cooling water capacity(engine only) (lit) 14.3

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Enginemodel
Items DV11
Type Wax pallet type (79 ∼94 °C)
Open at (°C) 83 °C
Open wide at (°C) 95 °C
Thermostat
Valve lift (mm) 8
Water temperature indicator Water temperature sensor mounted
Type Water cooled
Capacity (cc/rev) 550 (275 × 2 each)
Air compressor
Revolution ratio 1 : 1.265 (Engine speed : Air compressor speed)
Type Gear driven, vane type
Capacity (l/min) 16 / 18 / 25
Adjusting pressure
(kg/cm2) 125 / 150
Power steering
pump
Revolution ratio 1 : 1.265 (engine speed : pump speed)
Turbo charger Exhaust gas driven type (waste gate)
Engine stop system Fuel feeding shut-off by ECU
Engine brake Control by ECU
Alternator (voltage – capacity) (V - A) 24 - 60 or 24 – 150
Starting motor(voltage – output) (V-kW) 24 – 6.0
Air heater capacity (V – A) 24V – 2.64 kW
Battery capacity (V - AH) 20 - 150

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Operation and Maintenance
8Safety regulations & specifications
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1.3. Engine Power
tolerance : ±5%
Engine model Performance
Model Suffix Power
(PS / rpm)
Torque
(kg.m / rpm)
Low idle
(rpm)
High idle
(rpm)
Remark
EUJBA W/ Jake brake
EUJBE
380 / 1,800 173 / 1,200 600 2,120↓
W/o Jake brake
EUJBB W/ Jake brake
EUJBF
340 / 1,800 145 / 1,200 600 2,120↓
W/o Jake brake
EUJBC W/ Jake brake
EUJBG
360 / 1,800 160 / 1,200 600 2,120↓
W/o Jake brake
EUJBD W/ Jake brake
EUJBH W/o Jake brake
EUJBL
400 / 1,800 173 / 1,200 600 2,120↓
W/ Retarder
EUJBI W/ Retarder
EUJBJ W/ Jake brake
EUJBK
420 / 1,800 187 / 1,200 600 2,120↓
W/o Jake brake
EUJCA
EUJCB 420 / 1,800 187 / 1,200 600 2,120↓W/ Jake brake
EUJCC W/o Jake brake
EUJCI
380 / 1,800 160 / 1,200 600 2,120↓
W/ Jake brake
EUJCD W/o Jake brake
EUJCJ
345 / 1,800 145 / 1,200 600 2,120↓
W/ Jake brake
EUJCF W/ Jake brake
EUJCH
420 / 1,800 187 / 1,200 600 2,120↓
W/ Jake brake
EUJXA W/o Jake brake
DV11
EUJXB
380 / 1,800 160 / 1,200 600 2,120↓
W/ Jake brake
* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)

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Operation and Maintenance
9Safety regulations & specifications
Printed in Mar. 2005 PS-MMA0608-E1A
1.4. Engine Performance Curve
1.4.1. Performance curve (340PS)
Performance ISO 1585 (SAE J1349)
Output (max.) 250 kW (340PS) / 1,800 rpm
Torque (max) 1,423 N.m (145 kg.m) / 1,200 rpm
Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)
Revolution (rpm)
Output (PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

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1.4.2. Performance curve (360PS)
Performance ISO 1585 (SAE J1349)
Output (max.) 265 kW (360PS) / 1,800 rpm
Torque (max) 1,570 N.m (160 kg.m) / 1,200 rpm
Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)
Revolution (rpm)
Output (PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

DV11
Operation and Maintenance
11 Safety regulations & specifications
Printed in Mar. 2005 PS-MMA0608-E1A
1.4.3. Performance curve (380PS)
Performance ISO 1585 (SAE J1349)
Output (max.) 280 kW (380PS) / 1,800 rpm
Torque (max) 1,570 N.m (160 kg.m) / 1,200 rpm
Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)
Revolution (rpm)
Output (PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

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1.4.4. Performance curve (400PS)
Performance ISO 1585 (SAE J1349)
Output (max.) 294 kW (400PS) / 1,800 rpm
Torque (max) 1,697 N.m (173 kg.m) / 1,200 rpm
Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)
Revolution (rpm)
Output (PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

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Operation and Maintenance
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1.4.5. Performance curve (420PS)
Performance ISO 1585 (SAE J1349)
Output (max.) 309 kW (420PS) / 1,800 rpm
Torque (max) 1,834 N.m (187 kg.m) / 1,200 rpm
Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)
Revolution (rpm)
Output (PS)
Torque (kg.m)
Fuel consumption (g/ps.h)

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Operation and Maintenance
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1.5. Engine Assembly
1.5.1. Engine sectional view (longitudinal)
1 Vibration damper 7 Power steering pump
2 Thermostat 8 Oil seal
3 Exhaust valve 9 Fly wheel
4 Push rod 10 Crank shaft
5 Tappet 11 Oil pump
6 Air compressor
1
2
3 4 5
6
7
8
9
10 11

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1.5.2. Engine sectional view (cross)
1 Starting motor 8 Injector
2 Oil cooler 9 Oil spray nozzle
3 Cylinder block 10 Connecting rod
4 Cylinder head 11 Electric control unit (E.C.U)
5 Engine brake 12 Oil drain plug
6 Fuel high pressure pump 13 Oil suction pipe
7 Common rail
1
2
3
4
5
6 7
8
9
10
11
12 13

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1.5.3. Engine assembly (Bus engine)
1 Crank shaft pulley 9 Exhaust manifold 18 Air pipe
2 Oil filter 10 Mounting bracket (rear) ( turbocharger to intercooler
3 Water pump pulley 11 Flywheel housing 19 Air heater
4 Idle pulley 12 Mounting bracket (front) 20 Air pipe
5 Water outlet 13 Oil pan 21 Cylinder head cover
6 Fuel filter 14 Electric control unit (ECU) 22 Oil filler cap
7 Air pipe 15 Power steering pump 23 Water inlet
(Air cleaner to turbocharger) 16 Air compressor 24 Starting motor
8 Breather 17 Turbocharger 25 Oil cooler
15
16
6
17
111
18 19 20
21
22
23
2524
12 13 14
11
10
9
8
6
5
4
3
2
1
7

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Operation and Maintenance
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1.5.4. Engine assembly (Truck engine)
1 Power steering pump 9 Fan guide 18 2nd fuel filter
2 Air compressor 10 Cooling fan 19 Air pipe
3 Exhaust outlet 11 Starter (Air filter to intake manifold)
4 Turbo charger 12 Exhaust manifold 20 Breather
5 Oil filler cap 13 Water inlet 21 Crank shaft speed sensor
6 Intake manifold 14 Oil filter 22 Exhaust manifold
7 Air heater 15 Primary fuel filter 23 Air con compressor
8 Air pipe 16 Boost pressure sensor 24 Alternator
(Air cleaner to Turbocharger) 17 Fuel priming pump 25 Electric control unit(ECU)
1
2
3
4 5 6 7
8
9
10
11 12 13
14
15
16
17
18
19
20
21
22
23 24 25