Page 1 65.99897-8098A Operation and Maintenance Manual Diesel Engine DV11 PS-MMG0717-E1B Downloaded from www.Manualslib.com manuals search engine.
Page 2 DV11 Operation and Maintenance 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.
Page 3 DV11 Operation and Maintenance CONTENTS 1. Safety regulations & engine specifications 1.1. Safety regulations 1.2. Engine specifications 1.3. Engine power 1.4. Performance curve 1.5. Engine assembly 2. Technical information 2.1. Engine model and serial number 2.2. Diagnostic tool (SCAN-200) 2.3. Engine characteristic 2.4.
Page 4 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.
Page 5 DV11 Operation and Maintenance (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.
Page 32 DV11 Operation and Maintenance 2.3.16. Fuel injection system 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.
Page 33 DV11 Operation and Maintenance 2.3.18. Injector & high pressure connector Be careful to mix the foreign matter High pressure fuel into the injector and inside of the Injector harness connector nut connector connector for connecting the high O-ring Injector pressure at disassembly and check.
Page 34 DV11 Operation and Maintenance 2.3.20. Turbo charger The turbocharger needs not any specific maintenance. Every time of engine replacement, a leakage or clogging of oil pipes should be inspected. Air cleaner should be maintained carefully for nut or foreign material not to get in.
Page 35 DV11 Operation and Maintenance 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. Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add coolant if necessary When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and then clean them with cleaning solution.
Page 36 For the improper control might give the fatal damage to the cooling water pump and cylinder liners, detail care is needed. Since DV11 engine cylinder liner is wet type, particularly the cooling water control should be applied thoroughly. Technical Information Printed in Mar.
Page 37 Operation and Maintenance The density of anti-freezing solution and additive for rust prevention is able to be confirmed by the cooling water test kit. (Fleetguard CC2602M or DOOSAN 60.99901-0038) How to use the cooling water test kit °C, loosen (1) When the cooling water temp. of engine is in the range of 10 ～.
Page 38 DV11 Operation and Maintenance Amount of Anti-freeze in winter Ambient Cooling water (%) Anti-freeze (%) Temperature (°C) Over –10 2.3.24. Valve clearance adjust procedure After letting the #1 cylinder’s piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances.
Page 39 DV11 Operation and Maintenance 1) Rotating the engine, let #6 cylinder overlap. 2) In time that #1 cylinder become the state of top dead center, adjust the valve clearance corresponding to ”.
Page 40 DV11 Operation and Maintenance Adjusting of valves (Type 1) Cylinder No Valve adjusting Exhaust Intake Exhaust Intake Exhaust Intake Intake Exhaust Intake Exhaust Intake Exhaust #1 cylinder top dead center ◎ ◎ ◎ ◎ ◎ (#5 cylinder valve overlap) Crankshaft 90° rotation ◉.
Page 41 DV11 Operation and Maintenance 2.3.25. Battery Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of poor condition. Inspect for amount of electrolytic solution, and replenish if insufficient. Measure the gravity of electrolytic solution, if less than specified value (1.12 ～.
Page 42 DV11 Operation and Maintenance 2.3.26. Alternator a) Alternator (24Vx60A) The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alternator body interior limits the alternator voltage. The alternator should not be operated except with the regulator and battery connected in circuit to avoid damage to the rectifier and regulator.
Page 43 DV11 Operation and Maintenance b) Alternator (24Vx150A) 24V x 150A Regulator connector: AMP 250 Regulator connector — N terminal : cut off the charging lamp with detect the voltage by regulator. — A terminal : switching the regulator on sensing the output voltage.
Page 44 DV11 Operation and Maintenance 2.3.27. Starting motor 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.
Page 45: Diagnosis And Remedy
Page 55: Engine Inspection
Page 59: Engine Disassembly
3 minutes until the engine oil by-passes to the oil pan, then take off the filter. Unscrew the oil filter head fixing bolts and take off the oil filter head 3.1.20.
Page 65 DV11 Operation and Maintenance 3.1.22. Fuel pump housing cover Remove the fuel pump housing Fixing bolt cover fixing bolts and take off the Fuel pump housing fuel pump housing cover. cover Fuel pump housing cove and cylinder block should be handled as a set because they are tooled in pairs.
Page 66 DV11 Operation and Maintenance 3.1.25. Electric control unit Remove the electric control unit fixing bolts, then take off the electric control unit and bracket. Rubber cushion Bracket Electric control unit 3.1.26. Cylinder head cover Remove cylinder head cover fixing bolts and take off the cylinder head cover.
Page 67 DV11 Operation and Maintenance 3.1.28. Rocker arm Remove the rocker arm bracket fixing bolts and take out the rocker arm. Pull out the push rod. 3.1.29. Injector Remove the fuel high pressure Injector connecter fixing nuts and take off Injector bush the fuel high pressure connecter.
Page 68 DV11 Operation and Maintenance 3.1.30. Cylinder head Loosen the cylinder head fixing Cylinder head bolt bolts in the reverse order of assembling, and remove them all Disassembly order no. and then take the cylinder head out. Remove the cylinder head gasket and scrap it.
Page 69 DV11 Operation and Maintenance 3.1.33. Piston Remove the connecting rod cap bolts in the reverse order of assembling. Tapping the upper and lower of connecting rod caps lightly with an urethane hammer, separate them and take the bearings out. By pushing the piston assembly.
Page 70 DV11 Operation and Maintenance Remove the flywheel ring gear. Heat the ring gear evenly with a gas burner (up to 200 °C) to invite volumetric expansion. Tapping around the edges of the ring gear with a hammer and brass bar to remove it.
Page 71 DV11 Operation and Maintenance NOTES: Do not mingle with the metal bearings bearing caps randomly. prevent mixing, temporarily assemble the metal bearings corresponding bearing caps in turn. 3.1.38. Cam shaft & tappet Pull out the tappets from the cylinder block.
Page 72 DV11 Operation and Maintenance 3.2. Measurement and Inspection of Major Parts 3.2.1. Cleaning and inspection of cylinder block 1) Clean the cylinder block and inspect it for any crack or damage. 2) If there is any crack or severe damage, replace it and if there is minor one, correct it.
Page 73 DV11 Operation and Maintenance Pull out the intake and exhaust valves. 2) Inspection and measurement of cylinder head a) Damage check Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly. Then be careful for the valve seat not to be damaged.
Page 74 DV11 Operation and Maintenance 3) Inspection and measurement of valve and valve guide a) Valve After cleaning the valves with clean diesel oil, measure the valve stem’s outside diameter at upper, middle, and lower to Valve stem determine the wears and if.
Page 75 DV11 Operation and Maintenance b) Valve guide Insert the valve into valve guide and measure the clearance between valve and valve guide Measuring 측정위치 by the shaking degree of valve. point clearance bigger, measure the valve and then replace the more worn valve guide.
Page 76 DV11 Operation and Maintenance Standard Limit Intake (A) 0.38 ∼ 0.42 mm 0.7 mm Valve Exhaust (A) 0.38 ∼ 0.42 mm 0.8 mm Valve seat Intake (B) Exhaust (B) The disassembly of valve seat.
Page 77 DV11 Operation and Maintenance d) Valve spring Inspect the outlook of valve spring and if necessary replace By means of spring tester, measure the tension and free length. Free length Standard Intake Inside 62.5 mm Inside 62.0 mm Exhaust Outside 62.5 mm.
Page 78 DV11 Operation and Maintenance Standard Limit Valve spring Less than 1.6 2.0 mm inclination 4) Cylinder head assembling Clean the cylinder head thoroughly. Coat the valve stems and valve guides with engine oil and assemble the valves. Replace the valve stem seals.
Page 79 DV11 Operation and Maintenance 3.2.4. Rocker arm ass`y 1) Rocker arm disassembling Remove the snap rings in of rocker arm with a pair of pliers. Tear down washer, rocker arm. Disassemble the rocker arm bush by means of a press.
Page 80 DV11 Operation and Maintenance b) Tappet & push rod means outside micrometer, measure clearance of the tappet and tappet holes of the cylinder block. If the value is beyond the specified limit, replace tappets. φ19.944 ∼ φ19.965 mm Standard .
Page 81 DV11 Operation and Maintenance 3.2.5. Cam shaft 1) Axial end play Push the camshaft toward the crankshaft pulley side. Place a dial gauge onto the camshaft gear. Measure the camshaft’s axial end play, moving the camshaft gear by means of a driver.
Page 82 DV11 Operation and Maintenance Camshaft bearing diameter Measure the camshaft bush inside diameter with a cylinder gauge. Standard Limit φ70.07 ∼ φ70.09 mm Thrust bush Cam bush inside φ70.00 ∼ φ70.03 mm φ70.06 mm diameter.
Page 83 DV11 Operation and Maintenance Camshaft run-out With placing the camshaft on the 2ea of V-blocks, and inspect the run-out of the camshaft, adjust or replace the severe one. Standard Limit 0.05 mm 0.1 mm 3.2.6. Crank shaft.
Page 84 DV11 Operation and Maintenance Standard Journal φ103.98∼ φ104.00 mm diameter φ89.98 ∼ φ90.00 mm Pin diameter In case that pin’s wear is more than the limit value, grind the crankshaft journal and crank pin, and use the undersized bearings.
Page 85 DV11 Operation and Maintenance b) Run out of crankshaft Place the crankshaft on the V- block. Turn the crankshaft with a dial Indicator on the surface plate and measure the run out of crankshaft, replace or correct the camshaft bearing if the measured value is beyond the limit.
Page 86 DV11 Operation and Maintenance Assemble the bearing at the Section A-B bigger end of connecting rod (bigger end) tightening bearing cap at the specified torque, measure inside diameter. Torque 10 kg.m + 90 Connecting rod φ89.98 ∼ φ90.00 mm bearing.
Page 87 DV11 Operation and Maintenance The spread of journal bearing connecting bearing should measured with special tool as a figure, but measure it under condition of assembling below Spread = φA — φB convenience of working in the field. Journal bearing.
Page 88 DV11 Operation and Maintenance d) Crank shaft end play Assemble the crankshaft to the cylinder block with a dial gauge, measure crankshaft end play. Standard Limit 0.190 ∼ 0.322 mm 0.452 mm 3.2.7. Piston.
Page 89 DV11 Operation and Maintenance 2) Check and measurement With naked eyes, inspect the piston for any wear, crack and scratch and particularly inspect carefully at the ring grooves for any wear. With outside micrometer, measure piston’s outside diameter the measuring position is 71.5mm from the piston lower end.
Page 90 DV11 Operation and Maintenance c) Piston ring and ring groove In case of piston ring’s wear, damage or engine overhaul, replace piston rings. d) Piston ring cut part clearance Measure the piston ring cut part. Insert the piston ring at the.
Page 91 DV11 Operation and Maintenance f) Piston pin Measure the amount of wear on the piston pin at the points as shown. The measured values are beyond the limit replace the pin. Standard Limit φ 45.994 ∼ φ 46.0 mm φ 44.983 mm or less.
Page 92 DV11 Operation and Maintenance Standard Limit 0.02 mm 0.1 mm Assemble the connecting rod to the crankshaft and measure connecting rod big end side clearance using a feeler gauge. Standard Limit 0.175 mm
0.321mm Assemble the connecting rod to.
Page 93 DV11 Operation and Maintenance 3.3. Engine Reassembly 3.3.1. Preparation and precaution before and after engine reassembly Clean all the parts thoroughly and also clean thoroughly by blowing into each passage of oil and cooling water. Disposition the various special and general tools for assembling in order.
Page 94 DV11 Operation and Maintenance 3.3.3. Oil spray nozzle Tighten the oil injection nozzle flange with hollow screws. Assemble the oil injection nozzle with the fixing bolts. Hollow screw 7 kg.m Torque Fixing bolt 1.2 kg.m 3.3.4. Crank shaft Put the wear ring into the heater to heat it up to 150 ∼.
Page 95: Reassembly
0.45 mm Attach a gasket at the surface of the oil pump where the oil suction pipe is to be installed, and install the oil suction pipe by tightening the fixing bolts.
Page 103 DV11 Operation and Maintenance 3.3.13. Oil pan Clean thoroughly the gasket that is projecting at the junction parts of front oil seal holder and flywheel housing of cylinder block’s lower face with a scraper. In the process of gasket removal, be careful for the gasket pieces not to get into the engine inside.
Page 104 DV11 Operation and Maintenance Assemble a gasket fitting with the fixing pin of cylinder block. Position cylinder head assembly on the cylinder block aligning with its dowel pin. (Take care not to damage the head gasket.) Part no. Coat the cylinder head bolts with.
Page 105 DV11 Operation and Maintenance 3.3.16. Injector Clean all the parts thoroughly and Injector Fixing bolt be careful not to fall into the foreign Injector bush material. Fuel high pressure Especially take deeper care on fuel connecter line from common rail up to injector.
Page 106 DV11 Operation and Maintenance 2) Clean the holes which an injector and a high pressure connector will be put into before they are assembled. Engine oil and fuel that might went into during disassembly should be wiped out especially for the holes where a fuel high pressure connector &.
Page 107 DV11 Operation and Maintenance 7) The injector and high pressure connector should be assembled correctly by the following order. Finally tighten the fixing bolt of injector up to the specified torque while the high pressure connector is still pre-tightened. Finally assemble the high pressure connector. Tighten the fixing nut of high pressure connector according to the specified torque by the torque wrench.
Page 108 DV11 Operation and Maintenance Torque 6.2 kg.m Adjust the valve clearance as reference of major maintenance part. 3.3.18. Engine brake Put the engine brake on the rocker arm of the cylinder head, then assemble the engine brake. Adjust the clearance of the slave.
Page 109 DV11 Operation and Maintenance 3.3.20. Fuel high pressure pump Assemble the gear of the fuel high pressure pump by using specified tool. Gear nut torque 11±0.5 kg.m Driving gear Fuel high pressure pump Install the fuel high pressure pump on the backside of the fly wheel housing.
Page 110 DV11 Operation and Maintenance 3.3.22. Common rail & high pressure pipe Assemble the common rail on the cylinder block. Install the fuel high pressure pipe between the common rail and the fuel high pressure connector, then tighten the cylinder by cylinder with specified torque.
Page 111 DV11 Operation and Maintenance 3.2.24. Exhaust manifold Attach a new gasket to the exhaust manifold. Fix the pipe that is connected exhaust manifold by tightening the fixing bolts. Assemble both sides in the same method as above. Torque 8.0 kg.m 3.3.25.
Page 112 DV11 Operation and Maintenance Refer to the chapter of 3.4 about relation of the common rail system Rubber cushion and the electric control unit. Bracket Electric control unit 3.3.26. Crankshaft speed sensor Measure the clearance of the Crankshaft speed sensor.
Page 113 DV11 Operation and Maintenance Torque 4.4 kg.m 3.3.29. Starter Install stud bolts at the bolt holes flywheel housing installing the starter. Insert the starter into the flywheel housing and tighten the fixing nuts. Torque 8.0 kg.m 3.3.30. Air compressor Assemble the piston assembly into air compressor cylinder liner before installing it to the flywheel housing.
Page 114 DV11 Operation and Maintenance Connecting rod bolt 3.5 kg.m Torque Liner fixing bolt 4 kg.m Head bolt 3 kg.m 3.3.31. Power steering pump Assemble the power steering pump to the fly wheel housing. Set the power steering pump to the driving coupling carefully to prevent from damage of the O-ring.
Page 115 DV11 Operation and Maintenance 3.3.33. Oil filter Insert greased O-rings into the oil port of the oil filter head. (Prevent the O-ring from slipping out.) Install the filter head on the cylinder block tighten bolts diagonal sequence. Install the oil filter element in the oil filter assembly.
Page 116 DV11 Operation and Maintenance 3.3.35. Thermostat Put the thermostat into the water Thermostat pump with gasket. Water pump Put the O-ring into the thermostat, then assemble cooling water pipe by tightening the fixing bolt. Torque 2.2 kg.m 2.3.36. Turbo charger.
Page 117 DV11 Operation and Maintenance Install the air pipe, then connect Rubber hose rubber hose into turbocharger and assemble with clamping. Rubber hose Torque (*mark) 2.2 kg.m Air pipe Take care for the direction of assembly when install the air heater.
Page 118 DV11 Operation and Maintenance Put the belt into the crankshaft pulley, alternator pulley, water pump con pulley connecting. Do not adjust the tension of the auto tensioner. Poly belt will be properly tensioned if the deflection force “F” is applied midway between the belt’s tangent.
Page 119 DV11 Operation and Maintenance 3.3.42. Others Assemble by connecting the other sensor, harness, oil and fuel line. Engine Reassembly Printed in Mar. 2005 PS-MMA0608-E1A Downloaded from www.Manualslib.com manuals search engine.
Page 120: Fuel Injection System
Page 134: Electrical System
Page 147: Engine Brake
Page 158: Engine Diagnostic
Page 169: Preparations
Page 171: Inspections After Starting
3 kg/cm at idling and 3
4.9 bar) 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.
Page 173: Operation In Winter Time
85°C) after continuous operation, examine the thermostat or the other cooling lines.
Page 176: Maintenance And Care
Page 179: Cooling System
Page 181: Adjustment Of Valve Clearance
Page 183: Tightening The Cylinder Head Bolts
Page 185: Cooling System
Page 189: Lubrication System
Page 192: Turbo Charger
3.0 kg/cm abnormal wear or stuck may be At full load : 3.0
5.5 kg/cm caused.
Page 197 DV11 Operation and Maintenance 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.
Page 198 DV11 Operation and Maintenance (1) Rotor axial direction end play Turbine wheel chamber Magnitic vise Move the turbine shaft in axial Dial direction gauge Standard : 0.117
0.20mm Limit of wear : 0.24mm (2) Rotor radial direction end play Dial Magnetic vise.
Page 199 DV11 Operation and Maintenance (1) Lubricating system 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. 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.
Page 200 DV11 Operation and Maintenance 5.3.7. Diagnostics and troubleshooting Complaints Possible causes Corrections 1. Excessive black smoke 1) Air cleaner element clogged Replace or clean 2) Restrictions in air duct Check and correct 3) Leakage at intake manifold Check and correct.
Page 201: Air Cleaner
Page 203: Belt
Page 206: Special Tool List
Page 208: Special Tool List
φ128.010 φ128.122 cylinder liner the rim of the upper side Liner’s roundness &. Page 212 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use 2nd ring 0.80
0.95 inside diameter : φ128 Oil ring 0.40
0.70 Top ring 0.105
0.155 0.20 Piston ring Limit for use is if. Page 213 DV11 Operation and Maintenance (unit: mm) Stand value Limit Group Part Inspection item Correction Remark for assembly for use Measure in Major Radial run-out of journal Correct 0.01 horizontal and and pin with a grinder moving vertical directions parts Outside diameter of Use under sized φ103.98
φ104.00.
Page 214 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use Torque value of Clean out foreign Coat the bolt connecting rod bearing 10kg.m + 90 objects on joining with engine oil cap bolt (kg.m)
Page 215 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use Valve seat φ43.50
φ43.75 Intake assembly part’s inner diameter of φ41.50
φ41.75 Exhaust cylinder head φ43.554
φ43.570 Intake Diameter of valve seat Exhaust φ41.554
φ41.570 Valve seat assembly part’s depth of. Page 216 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use Clearance between Replace bush rocker arm shaft & 0.031
0.073 0.14 or shaft rocker arm bush Replace or Run-out of push rod correct Tappet assembly part’s inner diameter of φ20.000
φ20.021. Page 217 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use Damage of oil filter Clean or element replace By-pass valve pressure 1.8
2.4 Oil filter (kg/cm Oil filter control valve 4.3
4.7 pressure (kg/cm Radiator &. Page 218 DV11 Operation and Maintenance Stand value Limit Group Part Inspection item Correction Remark for assembly for use Projection height of nozzle from the Replace 2.4
2.9 cylinder head surface(mm) sealing B grade φ90.000
