Doosan DP158L Series Manual

950106-037009EN
DP158L, DP180L, DP222L
DIESEL GENERATOR ENGINE
Operation &
Maintenance Manual

Forward
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Doosan Infracore's DP 158L/DP 180L/DP 222L diesel engine.
To provide the best engine to our customers, the DP 158L/DP 180L/DP 222L diesel engine is designed to satisfy all require-
ments for low noise, economic fuel consumption, high speed and durability with the latest technology and quality.
Exact operation and proper maintenance are essential for operating engines for an extended time with optimum conditions and
best performance. This Operation and Maintenance Manual provides detailed descriptions of specifications, specified values,
defect diagnosis, component diagrams, and drawings for easier and more precise understanding of the product and for proper
maintenance and troubleshooting.
With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety of
workers can be ensured. Please read and understand this manual before working with our engines.
To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's best to
continuously develop and invest. The design of our product may be changed without prior notice and Doosan shall not be held
liable for the failure of this manual to contain all the design changes made to improve the product.
We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the requirements
of our customers. If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate
to contact us.
Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you.
2020.06
950106-037009EN
Doosan Infracore
*Items exempted from warranty coverage
• Malfunctions resulting from failing to comply with the proper handling instructions, regular inspections, and machine
storage techniques specified in the user manual
• Malfunctions resulting from failing to have the machine repaired at a designated dealer or center, or resulting from the
use of non-genuine parts
• Malfunctions resulting from unauthorized modifications, changes, or external hardware
• Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural disasters
*The contents of this operation and maintenance manual are the exclusive property of Doosan Infracore. Any unauthorized
reproduction, printing and distribution thereof are strictly prohibited.

Table of contents
1. General introduction .................................................................................................................1
General information ................................................................................................................................... 3
Danger, warning, caution, and note ........................................................................................................... 4
Engine maintenance .................................................................................................................................. 8
2. Operation and maintenance .....................................................................................................9
Starting and stopping of the engine ......................................................................................................... 11
Break-in period of the engine ................................................................................................................... 13
Operation in winter ................................................................................................................................... 15
Inspection and repair of the engine .......................................................................................................... 16
3. Performance and specifications ............................................................................................17
Engine specifications and performance ................................................................................................... 19
Exterior view drawing of the engine ......................................................................................................... 29
Engine identification number .................................................................................................................... 38
4. Regular inspection ..................................................................................................................39
General information ................................................................................................................................. 41
Regular inspection table .......................................................................................................................... 42
Cooling system ........................................................................................................................................ 44
Lubrication system ................................................................................................................................... 49
Fuel system .............................................................................................................................................. 52
Intake/exhaust system ............................................................................................................................. 59
Cylinder block/head ................................................................................................................................. 62
Electric system ......................................................................................................................................... 65
Others/driving system .............................................................................................................................. 66
5. About the engine .....................................................................................................................69
Marking system of units ........................................................................................................................... 71
Tightening torque ..................................................................................................................................... 72
Engine Disassembly ................................................................................................................................ 76
Engine Assembly ..................................................................................................................................... 89
6. Cooling system ......................................................................................................................107
General information ............................................................................................................................... 109
Thermostat ............................................................................................................................................. 113

7. Lubrication system ...............................................................................................................115
General information ............................................................................................................................... 117
8. Fuel system ............................................................................................................................121
General information ............................................................................................................................... 123
Fuel injection pump ................................................................................................................................ 127
9. Intake/exhaust system ..........................................................................................................135
General information ............................................................................................................................... 137
General information ............................................................................................................................... 139
10. Cylinder block/head ..............................................................................................................149
General information ............................................................................................................................... 151
Cylinder block ........................................................................................................................................ 153
Cylinder head ......................................................................................................................................... 154
Valve ...................................................................................................................................................... 156
Rocker arm ............................................................................................................................................ 159
Tappet and push rod .............................................................................................................................. 160
Camshaft ................................................................................................................................................ 161
11. Electric system ......................................................................................................................165
General information ............................................................................................................................... 167
Switches and sensors ............................................................................................................................ 169
Starter .................................................................................................................................................... 171
Alternator ............................................................................................................................................... 174
12. Others/driving system ..........................................................................................................179
General information ............................................................................................................................... 181
Crankshaft .............................................................................................................................................. 182
Piston ..................................................................................................................................................... 185
Connecting rod ....................................................................................................................................... 188
Others .................................................................................................................................................... 189

1
1. General introduction
General information ...................................................................................................................3
General Information .......................................................................................................................................... 3
Danger, warning, caution, and note ...........................................................................................4
General Information .......................................................................................................................................... 4
General Instructions.......................................................................................................................................... 4
Precautions in Starting the Engine.................................................................................................................... 5
Cautions for Inspection and Repair................................................................................................................... 5
General Repair.................................................................................................................................................. 6
Other Safety Instructions and Environmental Pollution..................................................................................... 6
Use of Genuine Parts........................................................................................................................................ 7
Engine maintenance ..................................................................................................................8
Prevention of damage and abrasion ................................................................................................................. 8
Prevention of Pollution ...................................................................................................................................... 8
Handling of Engine Oil ...................................................................................................................................... 8

2

1. General introduction
3
General information
General Information
This Operation and Maintenance Manual provides the most
efficient methods for engine maintenance as well as quick,
efficient methods to determine the cause of engine faults to
ensure that any actions taken by authorized skilled techni-
cians are done in the most efficient and efficient way
possible. If maintenance is performed by unskilled techni-
cians, or maintenance without the specified tools and facili-
ties, serious bodily injury or critical faults in engine
performance may occur.
Regular inspection and maintenance are required to main-
tain long-term optimal engine conditions and best perfor-
mance. In the event that a part must be replaced, only
genuine parts as defined by the parts the list (PARTS BOOK)
should be used. Doosan shall not be held liable for any crit-
ical damage or faults which may be caused by the use of
unauthorized or remanufactured parts.
The maintenance methods stated in this Operation and
Maintenance Manual are the most efficient and safest work
procedures. Some work procedures require special tools.
For questions about genuine parts and special tools, please
contact us.
This Operation and Maintenance Manual includes 'Danger,'
'Warning,' and 'Caution' in order to reduce possible injuries
and engine faults which may occur while performing mainte-
nance. If workers do not follow the instructions, critical faults
in engine performance and operation or serious bodily injury
may occurred. 'Danger,' 'Warning,' and 'Caution' instructions
must be followed. However, we inform you that it is not
possible to describe all possible and unexpected dangers
which may arise while performing engine maintenance.

1. General introduction
4
Danger, warning, caution, and note
General Information
This Operation & Maintenance manual divides maintenance
operations such as performing engine checks, trouble-
shooting, or diagnosing faults into three categories,
"Danger," "Warning," and "Caution." In addition, Note) is
used to provide additional descriptions and information
required for maintenance technicians to successfully operate
Doosan engines. The recommended repair methods and
'Danger,' 'Warning,' and 'Caution' can enhance the degree of
completion of engine maintenance and prevent bodily injury
which may occur to workers. However, this manual cannot
predict all possible risks.
Note) Indicates additional description, information, and
references for workers' easy understanding.
General Instructions
1. In order to maintain the best long term performance and
safety, please read and understand this manual and
execute routine inspections and regular inspections.
2. We have divided the content of this manual into causes
of bodily injury and damage to assets and causes of
pollution.
DANGER
Workers MUST observe instructions, otherwise fatal or
serious injuries to workers and other persons may
occur.
WARNING
Workers must follow this instruction as failing to do?
so may result in the death or serious bodily harm? of
workers or others.
CAUTION
Workers must observe this instruction since failing to
do so may cause critical faults which can have impact
on the engine performance and operation.
WARNING
When a safety accident, such as skin contact with
corrosive acids or fuel, burns with hot oil, exposure of
eyes to fuel or antifreeze, occurs while starting,
inspecting, or repairing an engine, see a doctor imme-
diately.
WARNING
When a safety accident, such as skin contact with
corrosive acids or fuel, burns with hot oil, exposure of
eyes to fuel or antifreeze, occurs while starting,
inspecting, or repairing an engine, see a doctor imme-
diately.
WARNING
During operating the engine, be careful not to touch the
safety guard of cooling fan. Otherwise, it can cause
serious injuries such as a cutting of fingers to you by
the rotating cooling fan.
WARNING
During operating the engine, be careful not to touch the
safety guard of v-belt. Otherwise, it can cause serious
injuries such as a cutting of fingers to you by the
rotating v-belt.
WARNING
V-belt safety guard is an optional item for customers. In
order to prevent accidents, you should install a v-belt
safety guard. If v-belt safety guard is not installed, you
should not access to the engine in operating. The
engine maker won't be responsible for an accidents or
injury arising without an installation of v-belt safety
guard.

1. General introduction
5
Precautions in Starting the Engine
1. Before starting the engine, please read this manual care-
fully and fully understand 'Danger,' 'Warning,' and
'Caution'. If you cannot fully understand it or have any
question, please contact us.
2. For safety reasons, attach "Warning" signs around
engines in operation to keep people other than workers
from accessing the engines. Let engine operators know
that they are responsible for the safety of the engine
room.
3. Only authorized people may start and operate engines.
Unauthorized people should not be allowed to handle
engines.
4. Do not get close moving or rotating parts while the engine
is in operation.
5. Do not touch the hot engine during operation since.
6. Exhaust gas is poisonous. Fully ventilate before starting
engine. If the space is enclosed, ensure that it is well
ventilated.
7. Keep vicinity of engine, ladders and stairways free of oil
and grease. Accidents caused by slipping can have
serious consequences.
Cautions for Inspection and Repair
1. Inspection and repair of engine should be performed only
when the engine is stopped.
2. If it is inevitable to perform inspection or repair on the
operating engine, do not get close to the rotating parts.
3. Use an engine oil drain container that is large enough to
prevent the overflow of engine oil while draining engine
oil.
4. Open the engine coolant cap after fully cooling the engine
to exchange or replenish coolant.
5. Fuel is highly flammable. Smoking or use of fire around
an engine may cause fire.
6. Mark and separately manage the containers for storing
coolant from beverage bottle for avoiding confusion. See
a doctor immediately in case of drinking coolant.
WARNING
Immediately after stopping the engine or during
driving, be careful not to touch a part of turbocharger.
Otherwise, it can cause you to severe burns due to a
hot turbocharger. If you need to contact the turbo-
charger for maintenance, you should wait until the
temperature of the turbocharger will be lower suffi-
ciently.
WARNING
Immediately after stopping the engine or during
driving, be careful not to touch a part of exhaust mani-
fold or heat screen. Otherwise, it can cause severe
burns to you due to the hot exhaust manifold or heat
screen. In particular, be careful not to touch the heat
screen installed on the exhaust manifold because it has
also a high temperature.
WARNING
If you need an emergency engine stop, use an elec-
tronic emergency stop device installed on a generator
at first instead of mechanical emergency stop of
engine. It is difficult to operate a mechanical emer-
gency stop device mounted on a fuel pump and it can
cause serious burns to you by contact with the exhaust
manifold. The operator is requested to install the sepa-
rate cable for operating the mechanical emergency
stop. The engine maker won’t be responsible for an
accidents or injury arising without an installation of
separate auxiliary cable.
DANGER
When accessories such as necklaces, rings, watches,
or gloves become stuck in rotating parts while the
engine is running, serious bodily injury may occur.
WARNING
Do not exchange or disassemble a pipe or horse (from
the engine fuel circuit, engine oil circuit, coolant circuit,
or compressed air circuit) while the engine is running.
The leaked liquid may cause bodily injuries.
WARNING
If the coolant cap is opened while the engine is still hot,
hot water will spurt out and may cause burns. Open the
engine coolant cap after fully cooling the engine.
WARNING
Only refuel when the engine is stopped.

1. General introduction
6
7. Follow the instructions provided by the battery manufac-
turer when checking or handling batteries.
8. Only authorized skilled technicians should repair and
maintain engines.
9. Only appropriate tools should be used. If the jaws of a
wrench are worn out, the wrench might slip during use,
causing safety accidents.
10. Do not allow other persons to stay or pass under an
engine when lifting the engine with a crane. Before lifting
the engine, ensure that there is no one around the engine
and to secure enough safety space.
11. Before inspecting or replacing the electrical apparatus,
disconnect the battery ground wire first. Connect the
battery ground wire after completing all required work for
checking or replacing the electrical apparatus in order to
prevent a short circuit.
12. Before performing electric welding works, turn off engine,
block the power supply to the engine, and remove the
wire harness connector.
13. Do not give any electric or mechanical shocks or perform
welding works on the electrical apparatus or the ECU.
General Repair
1. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
2. Disconnect the battery ground wire from to prevent
damage of wires and sensors caused by a short circuit.
3. Engine oil and coolant may damage paint and should be
stored in a separate container and marked for safe
management.
4. Store the disassembled parts in a specified space to
avoid damage or pollution.
5. Use specified and special tools for efficient and safe
repair.
6. If parts need to be replaced, use only genuine parts for
replacement. Using unauthorized or remanufactured
parts may cause critical damage and faults in engine
performance.
7. Replace parts such as cotter pins, gaskets, O-rings, seal
rings, oil seals, and washers with new ones during
repairs. Reuse of parts may be the cause of engine faults
and engine may not operate properly.
8. Group and store disassembled parts in disassembling
order. Due to the fact that bolts and nuts vary in strength,
shape and torque according to their assembly position.
Please divide and store them accordingly to these char-
acteristics.
9. Clean disassembled parts to remove foreign substances
before inspecting or reassembling parts. Use
compressed air to clean the oil holes or holes.
10. Thinly spread oil or grease on rotating parts or parts
requiring lubrication, before assembling them.
11. If required, use a specified adhesive to assemble gaskets
to prevent water or oil from leaking.
12. Assemble bolts and nuts with the specified tightening
torque.
13. After completing repairs, conduct a final inspection and
perform a test operation to check if all works have been
successfully completed.
Other Safety Instructions and Environmental
Pollution
Observe the following instructions to protect workers from
danger and to prevent the environmental pollution while
performing engine repairs.
1. Good ventilation and low humidity should be maintained
in the work space.
2. The workspace should be clean, in good order, and no
flammables are allowed in the workshop.
3. Smoking is strictly forbidden in the workshop.
4. Workers should wear working clothes, protective
goggles, and safety shoes.
5. Workers are not allowed to wear accessories such as
necklaces, rings, watches, and earrings.
6. Start the engine in a well-ventilated space and fully venti-
late the space before starting engine to prevent carbon
monoxide poisoning.
7. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
8. Do not work on rotating or running parts once the engine
has been started.
9. Discard oil according to the regulations set forth by the
relevant authorities.
10. If engine oil or fuel leaks on the floor or is improperly
discharged, serious environmental pollution of sea, river
or underground water may occur.
WARNING
Battery fluid is corrosive and dangerous because of its
explosiveness and toxicity. Therefore, it should only be
handled by a skilled technician who specializes in
battery fluid.

1. General introduction
7
11. Discard the undiluted anticorrosive agent, antifreeze,
filter elements, and cartridges as special wastes.
12. Discard coolant and special waste according to the regu-
lations of the appropriate authorities.
Use of Genuine Parts
An engine consists of many parts which are mechanically
harmonized. To prevent engine faults in advance and use
engines with best performance for a long period, mainte-
nance and replacement of expendable parts should be
conducted regularly.
Use of genuine parts is recommended. Using unauthorized
or remanufactured parts may cause critical damage and
faults to engine for which Doosan shall not be held liable.
WARNING
Failure to observe the regulations of the relevant
authorities violates environmental pollution regula-
tions and may be subject to legal penalties.

1. General introduction
8
Engine maintenance
Prevention of damage and abrasion
Using an engine for any purposes other than the designed
purpose may cause critical faults to the engine for which
Doosan shall not be held liable. For details concerning the
usage and purpose of the engine, please direct questions to
Doosan Sales Team. Do not adjust, convert, or change the
ECU without Doosan authorization.
If a problem is found in an engine, figure out and solve the
cause to prevent the critical faults in advance.
Use of genuine parts is recommended. Using unauthorized
or remanufactured parts may cause critical damage and
faults to engine for which Doosan shall not be held liable.
Consider the following while managing engines.
1. Use clean, specified, and qualified fuel only. Use fuel
recommended in this Operation and Maintenance
Manual.
2. Do not operate an engine without lubrication oil or
coolant. Use only the products (engine oil, cooling water,
anticorrosive agent, and etc) recommended by Doosan.
3. Always keep surroundings of the engine clean.
4. Use fuel recommended in this Operation & Maintenance
manual.
5. Conduct inspections and exchanges regularly according
to the regular inspection table.
6. If the engine is overheated, do not stop it immediately,
but operate it at idle status for five minutes or more to
lower the engine temperature to the proper level.
7. Check the engine oil level on a flat surface. Do not
exceed the maximum of the oil level gauge.
8. If there are gauges for battery, oil pressure and coolant
and temperature, check if they indicate a normal status.
9. Do not operate engine without coolant.
Prevention of Pollution
Consider the following to manage engine without causing
environmental pollution.
1. Discharge oil and coolant using collection containers.
2. Discard oil and coolant according to the regulations of the
relevant authorities.
3. Be careful not to let discharged oil and cooling water flow
into the ground or the sewer. Otherwise, serious pollution
of the drinking water source may occur.
4. Classify the oil, filters, and filter cartridges as environ-
mental pollution wastes and discards them according to
regulations.
5. Classify the antifreeze, cooling water, and anticorrosive
agent as hazardous wastes and discards them by
observing the regulations.
Handling of Engine Oil
Prolonged and repeated contact of skin with engine oil may
cause skin to dry out and contract, causing dermatitis.
Engine oil includes substances toxic to the human body.
Handle engine oil by observing the following safety rules:
1. Do not expose skin to used engine oil for a long time.
2. Always wear working clothes and gloves.
3. If skin comes in contact with engine oil, immediately wipe
it off with water, soap or hand cleaners.
4. Do not clean skin with gasoline, fuel, thinner, or solvent.
5. Apply a skin care cream after cleaning from oil.
6. Do not put oil-stained gloves or cloth in ones pocket.
CAUTION
Using inappropriate or unspecified fuel may cause crit-
ical damage and faults in engine performance.
WARNING
If the radiator cap is opened while the engine is still hot,
hot water will spurt out and may cause burns.
CAUTION
Immediately replenish engine oil when the engine oil
level is below the lower limit of the engine oil gauge.
CAUTION
Always use coolant mixed with antifreeze. If coolant
without antifreeze is used, the coolant may freeze
causing the coolant passage in the cylinder block to
freeze and damaging the engine.
WARNING
Discard oil according to the regulations set forth by the
relevant authorities. Disposing of discharged oil into
the ground, sewers, drains, rivers, or the sea will cause
serious environmental pollution. Violation of regula-
tions regarding discard of engine oil without observing
the handling regulations, will be punished.

9
2. Operation and maintenance
Starting and stopping of the engine .........................................................................................11
Preparing for Start........................................................................................................................................... 11
Starting the Engine ......................................................................................................................................... 11
Running in....................................................................................................................................................... 11
During Operation............................................................................................................................................. 11
Stopping the Engine........................................................................................................................................ 12
Break-in period of the engine...................................................................................................13
General Information ........................................................................................................................................ 13
Break-in Period of a New Engine.................................................................................................................... 13
Check Points................................................................................................................................................... 13
Cold Start Operation ....................................................................................................................................... 13
Inspection after Starting the Engine................................................................................................................ 13
Operation in winter...................................................................................................................15
Cold Start ........................................................................................................................................................ 15
Preventing Coolant from Freezing .................................................................................................................. 15
Preventing Over cooling of the Engine ........................................................................................................... 15
Engine Oil ....................................................................................................................................................... 15
Inspection and repair of the engine..........................................................................................16
Checking Engine Parts after Prolonged Operation ......................................................................................... 16
Inspection and Repair of Turbocharger .......................................................................................................... 16
Intake System ................................................................................................................................................. 16
Exhaust System .............................................................................................................................................. 16
Lubrication System ......................................................................................................................................... 16

10

2. Operation and maintenance
11
Starting and stopping of the engine
Preparing for Start
Check the following before starting the engine for the first
time after purchase.
1. Before starting an engine, check the levels of fuel,
coolant, and oil and replenish those fluids if required.
2. Check if engine oil level is between the upper and lower
limit of the oil level gauge. The upper and lower limit of
the oil level gauge indicate the maximum and minimum of
the engine oil level.
3. Be careful not to mix foreign substances in fuel, engine
oil, or coolant while adding the fluid, and keep the fluid
clean while it is not in use. Use fuel, oil, and coolant
recommended by Doosan. Otherwise, critical damage to
the engine may occur
Starting the Engine
Observe the following when starting the engine.
1. Insert key in starting lock.
2. Moving control lever to idle speed.
3. Key switch rotate clockwise.
4. Do not operate for longer than 10 seconds at a time.
5. After ignition of the engine, take-off the hands in key
switch.
6. and adjust control lever for desired speed.
7. If engine fails to start, release the key, wait about 1
minute, then operate starter again.
8. Avoid running the cold engine for any length of time since
in any internal combustion engine this is liable to cause
increased wear due to corrosion. Prolonged idling is
harmful to the environment.
9. Keep no-load operation to a minimum. During no-load
operation combustion chamber temperatures drop to the
point where fuel does not burn completely, causing slob-
bering and white smoke. Always have some load
connected when the gen set is run for long periods.
Running in
It is recommended that new or overhauled engines should
not be operated at a load higher than about 75% minimum
load during the first few hours of operation. Initial run-in
should be at varying speeds or load. After this initial run-in,
the engine should be brought up to fuel output gradually.
During Operation
1. Oil pressure
1) During operation the oil pressure in the engine lubrication
system must be monitored. if the monitoring devices
register a drop in the lube oil pressure, switch off the
engine immediately.
2. Coolant temperature
1) Operating an engine with too low coolant temperature
increases fuel consumption, abrasion of the cylinder
liner, and shortens the engine's life span.
3. Alternator
In order to avoid damage to the alternator, observe the
following instructions while the engine is running.
CAUTION
• When replenishing engine oil, do not exceed the
maximum on the oil level gauge. Too much oil may
cause damage to the engine.
• The oil required to fill the oil filters and pipes
depends upon the engine equipment and use and
must be determined individually at the time of initial
commissioning. Make a note of the determined
quantity.
CAUTION
• On initial start of an overhauled engine or after long
periods without use, press shutdown lever in “stop”
position and operate starter motor for a few
seconds (max. 10) until oil pressure is indicated.
• Ensure that the engine can not be started by unau-
thorized persons.
CAUTION
Do not overload the engine. Do not exceed the
maximum permissible engine tilt. if faults occur, find
their cause immediately and have them eliminated in
order to prevent more serious damage.

2. Operation and maintenance
12
1) Do not switch off the main battery.
2) Do not disconnect the battery or pole terminals or the
cables.
3) If during operation the battery charge lamp suddenly
lights up, stop the engine immediately and remedy the
fault in the electrical system.
4) Do not short-circuit the connections of the alternator with
those of the regulator or said connection with ground, not
even by briefly bringing the connections into contact.
5) Do not operate th alternator without battery connection of
the alternator with those of the regulator or said connec-
tions with ground, not even by briefly bringing the
connections into contact.
6) Do not operate the alternator without battery connection.
Stopping the Engine
Cut off the main circuit breaker of the generator control panel
but do not stop the engine immediately.
Keep running the engine at idle speed for about 5minutes
before stopping the engine.

2. Operation and maintenance
13
Break-in period of the engine
General Information
Doosan engines are subjected to a final approval test to
ensure the provision of high quality engines before being
shipped. However, engines are not operated for a long
period of time in this test. Therefore, new engines require a
break-in period of during the initial 50 hours after delivery. By
properly breaking-in an engine, the highest levels of engine
performance can be maintained long-term.
Break-in Period of a New Engine
If the engine's bearings are not properly broken in, they may
be easily damaged and the lifetime of the engine may be
shortened by overloading or high speeds. In order to prevent
this, please follow the guidelines below for the initial 50 hours
after delivery of new engine.
1. Fully warm up the engine until the engine temperature
reaches the normal operation condition, before starting
operation of the engine.
2. Do not overload the engine or operate it at too high RPM.
3. Do not operate the engine with high speed at idle.
4. Do not rapidly start up or stop the engine.
5. Operate the engine with less than 70 % of the engine
load.
6. Inspection, check, and repair of engines should be
managed by officially-certified technicians at certified
service centers in compliance with corresponding rules.
Check Points
check the following during the break-in period of a new
engine.
1. Periodically check if the engine oil level is between the
minimum and maximum limit of the oil level gauge.
2. If the oil indicator lamp on the apparatus is turned on or
blinks, the oil pressure may be insufficient. In this case,
check the oil level and replenish oil if required. When
replenishing engine oil, do not exceed the maximum on
the oil level gauge. If the oil level is normal, check other
related parts such as the oil pressure sensor, oil pump, or
oil line.
3. Check the coolant level to check if the coolant circulates
properly. If the coolant in the radiator is not enough, the
coolant level indicated may not be accurate.
4. Exchange engine oil and oil filter after the break-in
period.
Cold Start Operation
Slowly warm up the engine in case of starting up in cold
weather or in areas with cold climate. Do not rapidly raise the
rpm or load before the engine has not been warmed up. The
engine may consume oil until its piston ring is in position.
Please check the engine oil level frequently for the initial 50
hours of the break-in period.
Inspection after Starting the Engine
Check the pressure of the engine lubrication system by using
the engine oil pressure gauge mounted on the apparatus
while the engine is in operation. If pressure decreases on oil
pressure gauge, immediately stop the engine. In addition,
make sure that the recharge alarm indicator lamp of the alter-
nator is turned off while the engine is operating.
1. Tightly connect the +/- terminals to prevent gaps between
them. The sheath of battery connection cables should not
be damaged or broken.
2. If the recharge alarm indicator lamp suddenly turns on or
blinks during engine operation and the engine stops, fix
the fault of the electric apparatus.
CAUTION
If you cannot accurately check the oil level through the
oil level gauge, rotate the oil level gauge to 180 degree,
put it in the guide tube, and then pick it out again to
check.
CAUTION
The oil pressure may increase with high rpm and
decrease with low rpm. In addition, the pressure of cold
oil may be higher at a specific rpm than that of warm oil.
This phenomenon may occur when the engine operates
properly.
CAUTION
If engine oil and oil filter need to be replaced, use only
genuine engine oil and parts recommended by Doosan.

2. Operation and maintenance
14
3. If color or odor of exhaust gas is unusual during opera-
tion, stop the engine, diagnose the cause and fix the fault.
4. Check the engine status through the alarm indicator lamp
and gauges mounted on the apparatus during operation.