Doosan DL06 Excavator Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DL06 Excavator Shop Manual – PDF DOWNLOAD
- DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.
- It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine’s package.
- Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item
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 DL06 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
- During engine maintenance, please observe following instructions to prevent environmental damage;
- ? Take old oil to an old oil disposal point only.
- ? Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
- ? Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
- ? The 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.
1. Safety Regulations & Specifications
1.1. Safety Regulations
.1.1. General notes
- 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
- This 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
- Before 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.
- For 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.
- The engine must be started and operated only by authorized personnel.
- Ensure that the engine cannot be started by unauthorized person.
- When the engine is running, do not get too close to the rotating parts.
- Do not touch the engine with bare hands when it is warm from operation risk of bums.
- Exhaust 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
(2) Maintenance and care
? 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. ? Change the oil when the engine is warm from operation
General repair instructions
- Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to shortcircuiting.
- Use covers for preventing the components from damage or pollution.
- Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage
- The use of proper tools and special tools where specified is important to efficient and reliable service operation.
- Use genuine DOOSAN parts necessarily.
- 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.
- 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.
- Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions.
- Lubricate rotating and sliding faces of parts with oil or grease before installation.
- When necessary, use a sealer on gaskets to prevent leakage.
- Carefully observe all specifications for bolts and nuts torques.
- When service operation is completed, make a final check to be sure service has been done property.
- 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)
TABLE OF CONTENTS:
Doosan DL06 Excavator Shop Manual – PDF DOWNLOAD
1. Safety regulations & engine specifications
1.1. Safety regulations 1
1.2. Engine specifications 6
1.3. Engine power 8
1.4. Engine performance curve 9
1.5. Engine assembly 14
2. Technical information
2.1. Engine model and serial number 19
2.2. Diagnostic tool (SCAN-200) 20
2.3. Engine character 20
2.4. Diagnosis and remedy 44
2.5. Engine inspection 54
3. Maintenance
3.1. Engine disassembly 56
3.2. Measurement and inspection on major parts 72
3.3. Reassembly 96
3.4. Fuel injection system 122
3.5. Electrical system 136
3.6. Engine diagnostic 149
3.7. Engine control unit (ECU) 155
4. Commissioning and operation
4.1. Preparations 159
4.2. Operation of a new engine (Break-in) 159
4.3. Inspections after Starting 161
4.4. Operation in winter time 163
4.5. Tuning the engine 165
4.6. Maintenance and care 166
4.7. Cooling system 169
5. Maintenance of major components
5.1. Cooling system 171
5.2. Lubrication system 175
5.3. Turbo charger 178
5.4. Air cleaner 188
5.5. Belt 190
6. Special tool list 193
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S.M