65.

99897-8098A

Operation and
Maintenance Manual

Diesel Engine

DV11

PS-MMG0717-E1B

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 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. 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;
z Take old oil to an old oil disposal point only.
z Ensure without fail that oil and diesel fuel will not get into the sea or rivers and
canals or the ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.
z 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.

Apr. 2005

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 DV11
Operation and Maintenance

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

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 DV11
Operation and Maintenance

1. Safety Regulations & Specifications

1.1. Safety Regulations

1.1.1. General notes
z 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.
z 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
z 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.
z 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.
z The engine must be started and operated only by authorized personnel.
z Ensure that the engine cannot be started by unauthorized person.
z When the engine is running, do not get too close to the rotating parts.
z Do not touch the engine with bare hands when it is warm from operation risk
of bums.
z 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.

1 Safety regulations & specifications

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 DV11
Operation and Maintenance

(2) Maintenance and care

z 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.
z Change 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.

z Take into account the amount of oil in the sump. Use a vessel of sufficient
size to ensure that the oil will not overflow.
z If 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.
z Neither 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.
z Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank
must be filled only when the engine is switched off.
z Keep service products (anti-freeze) only in containers which can not be
confused with drinks containers.
z Comply 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

z Checking, setting and repair work must be carried out by authorized
personnel only.
z Use only tools which are in satisfactory condition. Slip caused by the worn
open-end wrench could lead to injury.

2 Safety regulations & specifications

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 DV11
Operation and Maintenance

z When the engine is hanging on a crane, no-one must be allowed to stand or

pass under it. Keep lifting gear in good condition.
z When do electric weld, stop the engine, power off, then remove the wire
harness’ connector which is connected to the ECU.
z Do not weld the electric control unit (ECU) absolutely, and do not damage on
it by electrical or mechanical shock.
z When 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.
z Never let the engine run when dry, i.e. without lube oil or coolant.
z Pay attention to cleanliness. The Diesel fuel must be free of water.
z Use only DOOSAN approved service products (engine oil, anti-freeze and
anticorrosion agent)
z Refer to the subjects of recommendation of the fuel.
z Have the engine maintained at the specified intervals.
z Do 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.
z Never put cold coolant into an overheated engine.
z Do 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.
z Always ensure that the testing and monitoring equipment (for battery charge,
oil pressure, coolant temperature) function satisfactorily.

3 Safety regulations & specifications

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 DV11
Operation and Maintenance

z Do 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
z Take old oil only to an oil collection point.
z Take strict precautions to ensure that oil does not get into the drains or into
the ground. The drinking water supply could be contaminated.
z Filter elements are classed as dangerous waste and must be treated as such.

(2) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When 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 >
z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean 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.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.

4 Safety regulations & specifications

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 DV11
Operation and Maintenance

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)

5 Safety regulations & specifications

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 DV11
Operation and Maintenance

1.2. Engine Specifications

Engine model
Items DV11

Water-cooled, 4 cycle V-type 90°, Turbo charged &

Engine type
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
1,206 x 1,031 x 1,070
(length x width x height) (mm)
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)
Fuel injection pressure (kg/cm2) 250bar (operating pressure 1,600bar)
Intake valve 0.4
Valve clearance Exhaust valve 0.5
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)
Oil pressure at idle speed 1.0 ~ 3.0
(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

6 Safety regulations & specifications

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 DV11
Operation and Maintenance

Engine model
DV11
Items
Type Wax pallet type (79 ∼ 94 °C)
Open at (°C) 83 °C
Thermostat
Open wide at (°C) 95 °C
Valve lift (mm) 8
Water temperature indicator Water temperature sensor mounted
Type Water cooled
Air compressor Capacity (cc/rev) 550 (275 × 2 each)
Revolution ratio 1 : 1.265 (Engine speed : Air compressor speed)
Type Gear driven, vane type
Capacity (l/min) 16 / 18 / 25
Power steering
pump Adjusting pressure
125 / 150
(kg/cm2)
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

7 Safety regulations & specifications

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