service repair manual

1. GENERAL INSTRUCTIONS
SHOP MANUAL
Ch 0 page 1
Manufacturer: Dealer:
Printed in Norway
Doosan Infracore Norway AS
N - 6440 Elnesvågen - NORWAY
SHOP MANUAL

2. SHOP MANUAL
GENERAL INSTRUCTIONSCh 0 page 2
Contents
0 General
1 Engine
2 Transmission
3 Driveline
4 Lubrication
5 Hydraulic
6 Electrical system
7 Front frame
8 Rear frame
9 Option
10 Error codes list

3. GENERAL INSTRUCTIONS
SHOP MANUAL
Ch 0 page 3
Chapter 0
General instructions
Index
Foreword............................................................................................... 4
Torque limit table.................................................................................. 5
Types of sealing-/locking compounds and lubricants...................... 6
Safety in workshop............................................................................... 7
Working on machine............................................................................ 8
Personal Protective Equipment (PPE).............................................. 11
Vibration.............................................................................................. 12
Injurious noise.................................................................................... 13
Organic solvent.................................................................................. 14
Fueling................................................................................................. 15
Fire and Explosion Prevention.......................................................... 15
Fire and explosion risks.................................................................... 17
In case of Fire..................................................................................... 18
Coolant................................................................................................ 19
Refrigerant.......................................................................................... 20
Air pollution........................................................................................ 21
Operation in extreme conditions...................................................... 22
Liquid or gas under high pressure................................................... 26
Asbestos............................................................................................. 27
Lead..................................................................................................... 27
Battery hazard prevention................................................................. 28
Disposal of hazardous materials...................................................... 30
Jacked up vehicle or bodywork........................................................ 31
Crushing and Cutting Danger........................................................... 31
Heavy units......................................................................................... 32
More than one person working with the same object..................... 33
Involuntary start of electric motors etc............................................ 33
Rotating parts..................................................................................... 34
Splinters, flying object When using certain tools............................ 35
Springs under load............................................................................. 36
Precautions for disassembly and assembly.................................... 37

4. SHOP MANUAL
GENERAL INSTRUCTIONSCh 0 page 4
The Shop Manual is prepared as an aid to performing quality repairs by giving the service personnel an under-
standing of the dump truck, and showing the correct way perform repairs and make judgements.
Make sure that you understand the manual and use it at every available opportunity. The manual will also serve
as a useful guide to office personnel and other persons who are involved with the dump truck in one way or
another.
Foreword
How to use the SHOP MANUAL:
The main index give an view of the chapters index page no.
The manual is divided into the following chapters:
In the chapters index you will find the page no. for the description of each part.
Each part will describe:
Structure and function:
This section explains how the components are built and how they work.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be
done at the completion of the checks and repairs.
Disassemly and assembly:
This section describes how to remove, install, disassemble, repair and assemble components, and the work
order. Special tools are listed at the end of each chapter. The special tools are an excellent aid in the work shop.
By using special tools, the job will be easier to perform and in some cases a special tool is required to carry out
the work. List of all special tools for the complete truck are listed in the “Special Tool Guide”.
Maintenance standard:
This section gives the judgement standards when inspecting disassembled parts.
Troubleshooting:
When a fault is detected, this section is used as before the practical fault finding starts. A skilled and trained
mechanic together with the Shop Manual is the best combination for troubleshooting when repair instruction is
needed.
At the end of each chapters are the main Troubleshooting
This manual is valid for the serial nos. listed on the first page.
Distributing and updating:
Subscribed Shop Manuals will automatically be updated at revisions.
This manual is originally produced by Doosan Infracore Norway AS, 6440 Elnesvågen, Norway, and must not
be reproduced, translated or made available to a third party, fully or partly, without our written permission.
Because of the different variants the parts and images which are contained in this book can be different
from the current model of dump truck . For the spare parts please used the parts catalogue for current
model.
Chapter 1: Engine
Chapter 2: Transmission
Chapter 3: Drive line
Chapter 4: Lubrication
Chapter 5: Hydraulic system
Chapter 6: Electric system
Chapter 7: Front frame
Chapter 8: Rear frame
Chapter 9: Option
Chapter 10: Error codes list
NOTE

5. GENERAL INSTRUCTIONS
SHOP MANUAL
Ch 0 page 5
This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions. The
torques are valid for screws on the outside of the components.
Bolt quality marking
Strength marking on screws consists of two numerals that may be separated by a point (.). The numerals indi-
cate tensile and yield limits of material in N/mm².
- Numeral 1 denotes a hundreths of the tensile limit in N/mm².
- Numeral 1 x numeral 2 denotes a tenth of the yield limit in N/mm².
A bolt designated 8.8 thus has tensile limit 800 N/mm² and yield limit 640 N/mm².
Nut quality marking
The designation for nuts consists of one numeral. The numeral denotes that the nut is of equal strength to a bolt
with the same first number.
A nut of strength class 8 is thus equally strong to a bolt of class 8.8.
Torque limit table
:ssalcytilauQ
noisnemiD
8.8
)mN(M
9.01
)mN(M
9.21
)mN(M
8M
01M
21M
42
74
18
33
56
411
04
97
631
41M
61M
81M
821
791
572
181
772
683
712
333
364
02M
22M
42M
583
815
566
145
827
539
946
478
0211
72M
03M
33M
63M
169
0131
0771
0822
0531
0481
0842
0123
0261
0122
0892
0583
:ssalcytilauQ
noisnemiD
8.8
)mN(M
9.01
)mN(M
9.21
)mN(M
1x8M
52,1x01M
1x01M
52
84
94
53
86
07
24
18
48
5,1x21M
52,1x21M
5,1x41M
38
58
531
711
021
091
041
441
882
5,1x61M
5,1x81M
5,1x02M
402
492
804
782
314
475
443
694
886
5,1x22M
2x42M
2x72M
645
696
0001
867
979
0141
129
0711
0961
2x03M
2x33M
2x63M
0931
0681
0532
0591
0162
0133
0432
0313
0793
:ssalcytilauQ
noisnemiD
8.8
)mN(M
9.01
)mN(M
9.21
)mN(M
FNU"8/3
FNU"61/7
FNU"2/1
14
66
99
95
39
141
37
511
571
FNU"61/9
FNU"8/5
FNU"4/3
241
791
443
102
972
684
052
743
606
FNU"8/7
FNU"1
FNU"8/11
745
418
0711
277
0511
0661
369
0341
0602
FNU"4/11
FNU"8/31
FNU"2/11
0261
0712
0482
0922
0703
0004
0582
0283
0005
:ssalcytilauQ
noisnemiD
8.8
)mN(M
9.01
)mN(M
9.21
)mN(M
CNU"8/3
CNU"61/7
CNU"2/1
83
16
39
45
78
131
86
801
361
CNU"61/9
CNU"8/5
CNU"4/3
331
381
223
781
952
554
432
323
865
CNU"8/7
CNU"1
CNU"8/11
615
277
0901
927
0901
0551
909
0631
0391
CNU"4/11
CNU"8/31
CNU"2/11
0351
0202
0562
0612
0582
0573
0962
0553
0864

6. SHOP MANUAL
GENERAL INSTRUCTIONSCh 0 page 6
Loctite 242/243: Middle strength (for locking of screws, bolts and nuts).
Loctite 270/2701: High strength (for locking of screws, bolts and nuts).
Loctite 603: High strength (for locking of bearings bushings, etc.).
Loctite 638: Extra high strength (for locking of bearings, bushings, etc.).
Loctite 574: Master gasket as floating gasket.
Loctite 7063: For cleaning of surfaces prior to lubrication or glueing.
Molycote 321R*: Anti-obstruction and running in lubricant.
Wurth 210/Loctite 8201: Anti-corrosion spray for electrical wires and components.
Types of sealing-/locking compounds and lubricants

7. GENERAL INSTRUCTIONS
SHOP MANUAL
Ch 0 page 7
Purpose
This section is intended as general information about dangers of various types of workshop activities.
Follow the workshop manual
The workshop manual provides instructions about work methods and equipment that reduces the risk of acci-
dents.
Mechanical skill
This is a very important factor. The Doosan-mechanic is skilled and well trained for his job.
Without these qualities, risks are much greater and more difficult to anticipate.
Common sense
This characteristic should form the basis of activities in the workshop.
Negligence and carelessness cannot be allowed.
Work with a safety margin
Always expect that something can go wrong during the work.
Always work with a safety margin where there are risks.
Legislation and local rules
In most countries there are legislation and local practices that apply to safety at work. Follow them at all times.
Warnings (parts or packages)
Always read and follow warnings and instructions.
Do not trust your own knowledge of the risks. The properties of a part or the chemical composition of a product
could have been changed during transit.
You have to know where the risks are
In this way you can avoid them. In many cases, risks are so obvious that you do not have to search for them,
e.g. carbon monoxide - true it is invisible, but you know that it is lethal. Therefore protect yourself.
The hidden dangers
Dangers are found in all work environments and the most serious danger is in not being aware of them.
The three demands of safety
* Knowledge:You have to know your job and also where the risks are.
* Apprehension:You must be aware that you are exposed to risks, or at least to suspect that you are.
* Caution:You have to protect yourself, do not take chances.
Incidents are warning signals
An incident is an unforeseen event without injury or damage.
The next time the consequence of the same event may be worse.
An incident demonstrates that there is a risk. Every incident must be taken as a warning signal - exactly as if
there had been an accident or someone had been taken ill.
Look out
Do not trust others to point out the hazards. It is difficult to remember all pointers and exhortations. New and
unexpected risks may also occur.
Therefore; look out!
As a guide, a number of examples follow.They are not to be regarded as a comprehensive listing.
Safety in workshop

8. SHOP MANUAL
GENERAL INSTRUCTIONSCh 0 page 8
Working on machine
When performing maintenance operations on
machine, prevent tripping and falling by keeping
area around your feet clean and free of objects and
debris. Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying around.
• Watch your step when walking.
• Never jump down from machine. When getting
on or off machine, use steps and handrails, and
maintan a three-point contact (both feet and one
hand or both hands and one foot) to support
yourself.
• If job requires it, wear protective clothing.
• To prevent injury from slipping or falling, when
working on hood or covers, never stand or walk
on areas except areas equipped with nonslip
pads.
• If it is necessary to work under raised equipment
or the machine, support work equipment and
machine securely with blocks and stands strong
enough to support weight of work equipment
and machine.
• Do not work under the machine if machine is
lifted off ground and the machine is supported
only with work equipment. If any control levers
are moved, or there is damage to hydraulic
system, work equipment or the machine will sud-
denly drop causing death or serious injury.
• Never service DOOSAN equipment without
instructions.
• Always lower lift arm and attachment to ground
before doing any maintenance.
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and Main-
tenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct func-
tion after adjustments repairs or service. Untrained opera-
tors and failure to follow instructions can cause death or
serious injury.
WARNING

9. GENERAL INSTRUCTIONS
SHOP MANUAL
Ch 0 page 9
• Use correct procedure to lift and support machine.
• Cleaning and maintenance are required daily.
• Welding or grinding painted parts must be done in well
ventilated areas.
• Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Vent exhaust to outside when engine must be running for
service.
• Exhaust system must be tightly sealed. Exhaust fumes are
hazardous and can cause death or serious injury.
• Stop and allow engine to cool and clean engine of flam-
mable materials before checking fluids.
• Never service or adjust machine with engine running unless
instructed to do so in this manual.
• Avoid contact with leaking hydraulic fluid or diesel fuel under
pressure. It can penetrate skin or eyes.
• Never fill fuel tank while engine running, while smoking, or
when near an open flame or sparks.
• Keep body, jewelry and clothing away from moving parts,
electrical componets, hot parts and exhaust.
• Wear eye protection to guard from battery acid, com-
pressed springs, fluids under pressure and flying debris
when engines is running or tools are used. Use eye protec-
tion approved for welding.
• Lead-acid batteries produce flammable and explosive
gases.
• Keep arcs, sparks, flames and lighted tobacco away from
batteries.
• Batteries contain acid which burns eyes or skin on contact.
• Wear protective clothing. If acid contacts body, flush well
with water. For eye contact flush well and get immediate
medical attention from a physician familiar with this injury.
• The maintenance procedures which are given in this man-
ual can be performed by the owner or operator without any
specific technical training. Maintenance procedures which
are not in this manual must be performed ONLY BY QUALI-
FIED SERVICE PERSONNEL. Always use genuine DOO-
SAN replacement parts.
• Only authorized personnel should service and repair the
machine. Do not allow unauthorized personnel access to
the machine or into work area.

10. Engine
SHOP MANUAL
Ch 1 page 1
Chapter 1
Engine

11. SHOP MANUAL
EngineCh 1 page 2
Chapter 1
Engine
Index
Engine identification............................................................................... 7
Removal of engine assembly............................................................... 11
Lifting the engine..........................................................................................................................17
XPI Fuel system DA30/40..................................................................... 18
Route of the fuel on 9 and 13 litre engines..................................................................................19
Fuel filter and water separation....................................................................................................20
Overflow valve..............................................................................................................................21
Fuel system components.............................................................................................................22
Schematic diagram of the fuel system:........................................................................................22
Important information about the fuel...........................................................................................23
Exhaust system XPI.............................................................................. 24
Introduction System overview......................................................................................................24
Control system for exhaust gas aftertreatment............................................................................25
Control unit EEC3........................................................................................................................33
System overview for mechanics...................................................................................................34
System overview for electrics.......................................................................................................35
Ad blue filter change....................................................................................................................36
Reductant doser...........................................................................................................................37
Reductant pump, function............................................................................................................39
Start-up instruction for new SCR Pump.......................................................................................40
Fuel system Tier2 (PDE)...................................................................... 42
Schematic diagram of the fuel system Tier2................................................................................42
Overflow valve..............................................................................................................................42
General........................................................................................................................................43
FUEL............................................................................................................................................43
Temperature dEpendency of the Fuel..........................................................................................44
Fuel filter......................................................................................................................................45
Changing the fuel filter.................................................................................................................45
Water separating prefilter XPI.....................................................................................................46
changing the water separating fuel filter......................................................................................46
Bleeding the fuel system..............................................................................................................47
Feed pump...................................................................................................................................49
Diagnostic prosedure........................................................................... 50
Use of diagnostic kit, Tier 2.........................................................................................................50
Connection point Can pc VCU + Testman ...................................................................................50
Can bus overview........................................................................................................................50
Connection point SDP3 Scania dagnostic...................................................................................51
Renewing the control unit.............................................................................................................52
Removing the ECU wiring Tier2.................................................................................................53
Cylinder head - PDE System Tier2...................................................... 57
Cylinder head, parts view. PDE Tier2..........................................................................................57
Special tools.................................................................................................................................58
Valve mechanism.........................................................................................................................59
Dismantling .................................................................................................................................64
Renewing the valve stem seal......................................................................................................64
Replacement of valve seats.........................................................................................................65
Machining the valve seats insert..................................................................................................66
Renewing the valve guides.........................................................................................................68
Renewing PDE unit injector sleeves............................................................................................69
Assembly .....................................................................................................................................70
Fitting...........................................................................................................................................70
Common rail Injectors Tier4/XPI.......................................................... 71
Cylinder head - XPI system Tier4......................................................... 72
Cylinder head, parts view. XPI system Tier4................................................................................72
Continuation next page

12. Engine
SHOP MANUAL
Ch 1 page 3
Injector Scania XPI................................................................................ 73
Valve adjustment DC13 with XPI.......................................................... 75
Order of adjustment for 13 litre engines.......................................................................................75
Cylinder configuration, 6 cylinder engines...................................................................................76
Valve adjustment DC9 with XPI............................................................ 77
Cylinder configuration, 5 cylinder engines...................................................................................78
Valve adjustment DC13 with PDE........................................................ 79
Adjusting unit injectors.................................................................................................................79
Adjusting the valve clearance and unit injectors..........................................................................81
Checking, adjusting the PDE injector and rocker arms................................................................82
Valve adjustment DC9 with PDE.......................................................... 83
Checking, adjusting the PDE32 injector and rocker arms (I)......................................................83
Turbocharger......................................................................................... 84
General .......................................................................................................................................85
Changing oil filter.........................................................................................................................86
Oil analysis...................................................................................................................................87
Checking oil level.........................................................................................................................87
Changing the oil...........................................................................................................................88
Special tools.................................................................................................................................89
Measuring radial clearance and axial clearance .........................................................................90
Renewing the turbocharger..........................................................................................................92
Pistons and cylinder liners................................................................... 93
Special tools.................................................................................................................................94
Connecting rods...........................................................................................................................95
Removing and dismantling connecting rods and pistons.............................................................96
Renewal of bearing bushing in connecting rod............................................................................98
Pistons.......................................................................................................................................100
Assembling piston and connecting rod......................................................................................102
Cylinderblock....................................................................................... 103
Cylinder liner..............................................................................................................................103
Removing the cylinder liners......................................................................................................105
Measuring the cylinder liner height............................................................................................106
Measuring the cylinder wear ridge and cylinder bore................................................................106
Fitting the cylinder liners............................................................................................................107
Fitting the piston and connecting rod.........................................................................................108
Flywheel and flywheel housing......................................................... 110
Special tools...............................................................................................................................111
Removing the flywheel...............................................................................................................111
Renewing the rear crankshaft seal.............................................................................................113
Removing the flywheel housing.................................................................................................113
Fitting flywheel housing..............................................................................................................114
Fitting the flywheel.....................................................................................................................116
Timing gear, 13 litre with unit injector............................................... 117
Gear drive..................................................................................................................................117
Belt drive collant pump, generator and AC compressor.............................................................118
Checking the Drive Belt..............................................................................................................119
Check for leaks...........................................................................................................................120
Renewing the seal in the front cover..........................................................................................121
Crankshaft damper.....................................................................................................................122
Timing gear, view exploded........................................................................................................123
Continuation next page

13. SHOP MANUAL
EngineCh 1 page 4
Special tools........................................................................................ 124
Intermediate gear ......................................................................................................................125
Camshaft gear ...........................................................................................................................128
Crankshaft gear .........................................................................................................................129
Camshaft ............................................................................................. 130
Replacement of camshaft bearing.............................................................................................131
Crankshaft .......................................................................................... 138
Removal.....................................................................................................................................139
Fitting.........................................................................................................................................142
Adjust - Machining the crankshaft..............................................................................................143
Lubrication system............................................................................. 144
Oil pump.....................................................................................................................................144
Lubrication oilways ...................................................................................................................145
Oil pressure................................................................................................................................146
Oil cooler, engine ......................................................................................................................147
Oil cooler view Se 010009 ......................................................................................................148
Renewing seals and leakage testing..........................................................................................149
Oil filter.......................................................................................................................................150
Centrifugal oil cleaner ........................................................................ 151
Dismantling and assembly.........................................................................................................152
Oil mist separator................................................................................ 156
General......................................................................................................................................156
High levels of oil carryover.........................................................................................................156
Crankcase pressure measurement............................................................................................158
Oil mist separator exploded view...............................................................................................159
Oil mist separator disassemble..................................................................................................160
Check - Rotational speed on oil mist separator.........................................................................162
Alternator 100 A.................................................................................. 163
Check.........................................................................................................................................163
Output test..................................................................................................................................164
Renewal - Bearing and carbon brushes.....................................................................................167
Oil pump, brake cooling circulate (DA40)......................................... 171
Exploded view............................................................................................................................171
Disassemble and overhaul the oil pump....................................................................................172
Checking and renewing parts.....................................................................................................174
Oil circulate pump assemble......................................................................................................175
Renewing the gasket..................................................................................................................178
Cooling fan.......................................................................................... 179
View of the radiator system DA40.............................................................................................179
Cooling system................................................................................... 180
Principal view of the cooling system..........................................................................................180
Circulation..................................................................................................................................181
Coolant.......................................................................................................................................182
Checking Coolant Level.............................................................................................................183
Checking the Antifreeze Level....................................................................................................184
Changing Coolant......................................................................................................................184
Cleaning the Cooling System.....................................................................................................186
Disassemble the cooling unit.....................................................................................................187
Thermostat and thermostat housing..........................................................................................189
Thermostat.................................................................................................................................190
Coolant pump.............................................................................................................................191
External cleaning.......................................................................................................................195
Internal cleaning.........................................................................................................................195
Technical data DC13 with XPI............................................................ 196
General data..............................................................................................................................196

14. Engine
SHOP MANUAL
Ch 1 page 5
Technical data DC9 with XPI.............................................................. 198
General data..............................................................................................................................198
Technical data DC13 with PDE........................................................... 200
General data..............................................................................................................................200
Technical data DC9 with PDE............................................................. 202
General data..............................................................................................................................202
Troubleshooting ECOM / Canbus...................................................... 205
To do: .........................................................................................................................................205
Troubleshooting, -basic info........................................................................................................205
Troubleshooting fuel system............................................................. 206
Troubleshooting Guide...............................................................................................................206
Troubleshooting Manual..................................................................... 224
White smoke..............................................................................................................................225
White smoke, water vapour........................................................................................................225
White smoke, water vapour........................................................................................................226
Black smoke on starting.............................................................................................................226
Blue smoke................................................................................................................................227
Fuel in the oil..............................................................................................................................227
Oil in coolant..............................................................................................................................228
Coolant/water in oil.....................................................................................................................228
Low oil pressure.........................................................................................................................229
High oil pressure (engine warmed up).......................................................................................231
Abnormal wear (liner, piston rings, etc.) ....................................................................................231
Vibration, no driven components engaged ................................................................................232
Vibration when the clutch or reverse gear is engaged ..............................................................233
Vibration when alternator is in operation ...................................................................................233
Engine speed hunting - single-speed engines with RQ governor .............................................234
Engine speed hunting - single-speed engines with RSV governor............................................234
Delivery pipe fractures ..............................................................................................................235
External corrosion on cylinder liner............................................................................................235
Engine difficult to start ............................................................................................................236
Fluid stroke.................................................................................................................................237
Knocking/noise...........................................................................................................................238
High oil consumption..................................................................................................................239
High fuel consumption................................................................................................................240
Low compression.......................................................................................................................240
Low engine output......................................................................................................................241
Hot engine..................................................................................................................................242
Cold engine ...............................................................................................................................243
Coolant loss...............................................................................................................................243
Polluted coolant..........................................................................................................................243
Polluted coolant..........................................................................................................................244
High oil temperature...................................................................................................................244
High exhaust temperature..........................................................................................................244
Low charge air pressure.............................................................................................................245
Low fuel pressure.......................................................................................................................245
Low system voltage....................................................................................................................245
High system voltage...................................................................................................................246
External oil leakage ...................................................................................................................246
External fuel leakage.................................................................................................................246
External coolant leakage ...........................................................................................................247
Oil pressed out via crankcase ventilation...................................................................................247
Turbocharger breakdown...........................................................................................................247
Compressed air system.............................................................................................................248

15. SHOP MANUAL
EngineCh 1 page 6
Important information on industrial safety
Generally, the persons repairing Doosan product-sets are responsible on their own for the industrial safety.
The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to per-
sons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.
The proper repair of these Doosan-products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.
The following safety references are used in the present Repair Manual:
Serves as reference to special working procedures, methods, information,
the use of auxiliaries etc..
This word is used for precautions that must be taken to
avoid actions which could shorten the life of the dump truck.
This word denotes safety messages for hazards which could
result in minor or moderate injury if the hazard is not avoided.
This word might also be used for hazards where the only
result could be damage to the dump truck.
Illustrations, drawings and parts do not always represent the original;
the working procedure is shown. The illustrations, drawings, and
parts are not drawn to scale; conclusions regarding size and weight
must not be drawn (not even within one representation).
The works must be performed according to the description.
REFERENCE: Prior to starting the checks and repair works, thoroughly
study the present instructions.
This word denotes safety messages where there is a high
probability of serious injury or death if the hazard is not avoided.
These safety messages usually describe precautions that
must be taken to avoid the hazard. Failure to avoid this hazard
may result in serious damage to the dump truck.
Is used, if lacking care can lead to personal injury or danger to life.
REFERENCE: After the repair works and the checks, the expert staff must
convince itself that the product is properly functioning again.
DANGER
CAUTION
NOTE
Structure of the Repair Manual

16. Engine
SHOP MANUAL
Ch 1 page 7
Engine identification
DC13 77A
6690537
368 2100
Stamped number on
top of the block
The engine designation indicates, in the form of a code, the type
of engine, its size and applications, etc.
The type designation and engine serial number are indicated on a
type plate affixed to the right-hand side of the engine.
The engine number is also stamped on the engine block
Refer to the figure 1.
Type
DC Supercharged diesel engine with air-cooled charge air cooler.
Displacement in whole dm3
Performance and certification code
Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.
Application
A For general industrial use
Variant 00 -99
DC kW A368 08313 00
Because of the different engine variants the parts and images which are contained in this book can be dif-
ferent from the current model of engine or dump truck . For the spare parts please used the parts catalogue
for current model.
NOTE
Figure 1
Figure 2

17. SHOP MANUAL
EngineCh 1 page 8
PREPARING THE ENGINE FOR STORAGE
If the engine is not to be used for an extended period its cooling
system, fuel system and combustion chamber must be protected
against rust. This also applies to the external shell of the engine.
An alternative to preparing the engine for long-term storage is to
start the engine and warm it up every 6 months.
Handling the Engine
The engine can normally stand idle for up to six months without
preparation for storage. For longer periods of downtime, the
following measures should be taken. These measures provide
protection for approximately 4 years.
Preparations for storage:
• Thoroughly clean the engine.
• Run the engine for a specific period using special
preservative fuel, oil and coolant.
• Also prepare other aspects of the engine for storage (filter
renewal, lubrication, etc.).
Preservative Coolant
If the engine is to be stored with a full cooling system, use
coolant containing 50 percent glycol by volume. Glycol without
nitrite based inhibitor should be used.
Ethylene glycol is highly dangerous if imbibed. Avoid contact with
the skin.
WARNING
Preservative Oil
Suitable preservative oils are supplied by most oil companies.

18. Engine
SHOP MANUAL
Ch 1 page 9
1. Drain and flush the cooling system. Top up with
preservative coolant.
2. Warm up the engine on regular fuel. Stop the engine and
drain the oil.
3. Renew the fuel filter.
4. Fill the engine with preservative oil up to the minimum level
on the dipstick.
5. Mix preservative fuel in a can. Detach the fuel pipe at the
feed pump suction line and connect a hose from the can.
6. Detach the fuel pipe at the overflow valve and connect a
return hose to the can.
7. Start the engine and run it at about 1,000 rpm for 20-25
minutes.
8. Stop the engine, remove the hoses and connect the
normal fuel pipes.
9. Remove the rocker covers and lubricate the valve
mechanisms with plenty of preservative oil. Refit the rocker
covers.
10. Drain the preservative oil from the engine. Fill with new
engine oil immediately or when the engine is to be reused. (For
fluid type and specifications, refer to the DOOSAN Operating &
Maintenance Manual Chapter 6)
11. Drain the coolant if the engine is not to be stored with
coolant in the system. Plug and tape all coolant
connections if the engine is to be stored without a cooling
system.
12. Air cleaner: clean or renew the filter element.
13. Cover air intakes and exhaust pipes.
14. Alternator and starter motor: Spray with water-repellent
anticorrosive oil.
15. Spray the outside of bright engine parts, first with
penetrating preservative oil such as Dinitrol 25B and then
with Dinitrol 112 or the equivalent.
Clearly mark the engine with the storage preparation date, and
state that the engine must not be started or cranked.
Preparations for Storage
Use a container to avoid spills when draining the oil and coolant. Dispose
of used fluids through an authorized waste disposal contractor.
NOTE
Do not remove the injectors.
NOTE

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20. SHOP MANUAL
EngineCh 1 page 10
Batteries
Remove the batteries for trickle charging at a charging station
(this does not apply to batteries which are maintenance-free
according to the manufacturer).
The same applies to short-term storage, even if the engine has
not been prepared for storage as above.
Wear gloves and protective goggles when charging and handling bat-
teries. The batteries contain a highly corrosive acid.
Storage
After the preparations, the engine should be stored in a dry and
warm place (room temperature).
When the Engine is to be Taken Into Operation Again
• Remove plugs and tape from coolant connections, air
intakes and exhaust pipes.
• Fill the cooling system with coolant. For more information
refer to Inspections.
• Check the oil level in the engine or top up with fresh engine
oil.
• Lubricate the valve mechanisms and their pushrods and
valve tappets as well as the injector mechanisms with
plenty of oil.
• Drain the preservative fuel from the fuel manifold and fuel
filter.
• Connect and bleed the fuel system. For more information
refer to the section headed Inspection.
• Wash off any preservative oil on the outside using white
spirit.
WARNING
Checks After Long-term Parking
• All oil and fluid levels.
• Tension of all belts.
• Air pressure.
• Air cleaner.
• Batteries and electrical connections.
• Lubricate all greasing points.
• Wipe off grease from piston rods.
• Inspect for signs of nests (i.e. birds, rodents, etc.)

21. Engine
SHOP MANUAL
Ch 1 page 11
Removal of engine assembly
Place the dump truck on level ground and apply parking brake.
Apply articulation lock.
Turn off main switch in battery case.
Raise the dump body and lock it with the safety support.
Raise the tiltable cab and lock it with the safety support.
Remove bonnet.
Drain engine coolant.
Look in OPERATION & MAINTENANCE MANUAL chapter 2 for instructions.
Take away the cab bolt, left and right hand side.
M46 mm
Bolt torque: 277Nm
Turn the direction valve on the pump
in lifting up position.
With the handle, pump and raise the
cab.
Place wheel chocks to the front wheel
DANGER
Figure 3
Figure 4
Never turn off battery main switch when engine is running
Never turn off battery mainSwitch when ignition is on
Leave battery main switch on for atleast 3 minutes before engine has stopped
Figure 5
WARNING

22. SHOP MANUAL
EngineCh 1 page 12
1
2
3
4
Left side:
1.
Disassemble the cab pump unit from the air filter stand.
2.
Remove the water hose from the pipe socket.
3.
Remove the fuel hoses (3 pcs) and
4.
Disassemble hydraulic hoses
Right side:
1.
Unscrew the hose clamps and remove the pipe bend,
filter - turbo
2.
Disconnect the oil hose from engine brake cylinder and bracket
disassemble the other end at left side on the magnetic valve
3.
Hook up the filter stand in lifting device.
4.
Screw off the fastening bolt for filter stand,
left and right hand side
7
1
1
4
3
5.
Disassemble outlet pipe bend from turbo
6.
Unmount hoses attached to cooling water expansion tank
7.
Disconnect the exhaust pipe from the turbo pipe bend.
2
5
6
Figure 6
Figure 7
Figure 8