Doosan DP158LCF Manual

950106-01352
GENERATOR DIESEL ENGINE

3. Performance and specifications
21
Engine specifications and performance
Engine Specifications
Item
DP158L
Remarks
DP158LCS DP158LCF DP158LDS DP158LDF10
General Information
Engine types Water-cooled, 4cycle, V-type, Turbo charger & inter cooled (air to
air)
Cylinder liner type Wet type liner
No. of cylinder - bore x stroke
(mm) 8 - 128 X 142
Total displacement(cc) 14,618
Compression ratio 15 : 1
Rotation Counter clockwise viewed from flywheel
Firing order 1-5-7-2-6-3-4-8
Injection timing (°) (BTDC) 23°±1°18°±1°23°±1°18°±1°
Dry weight (kg) 1,155 With fan
Dimension (L x W x H) (mm) 1,274 X 1,138 X 1,207 With fan
Flywheel housing SAE NO.1M
Flywheel Clutch NO.14M
No. of teeth on flywheel 160
Cooling System
Cooling method Fresh water forced circulation
Coolant capac-
ity (L)
Engine only Approx. 20
With radiator Approx. 79 (Air on 43°C) / Approx 90 (Air on 52°C)
Coolant flow rate (L /min) 660 550 660 550
Pressure cap (kPa) Max. 49
Water tempera-
ture (°C)
Max. for stand
by and prime 103
Before start of
full load 40
Water pump Centrifugal type driven by belt
Thermostat
Type Wax-pellet type
Opening temp.
(°C) 71
Full open temp.
(°C) 85

3. Performance and specifications
22
Cooling fan
Type Blow Type
Diameter -
blades 915mm - 7 blades
Lubrication System
Lubrication method Fully forced pressure feed type
Oil pump
Type Gear type
Driving type Driven by crankshaft gear
Oil filter Full flow, Cartridge type
Oil capacity (L)
Max. 22
Min. 13
Lubrication oil
pressure (kPa)
Idle speed Min. 100
Governed
speed Min. 250
Max. oil temperature (°)120
Oil specification
Oil class Above API CD
SAE 15W/40
Fuel System
Injection pump Bosch in-line "P" type
Governor Electric type
Fuel feed
pump
Type Mechanical type injection pump
Capacity (L/hr) 315
Injection nozzle
Type Multi hole type
Opening pres-
sure (MPa) 28
Fuel filter Full flow, Cartridge type with water drain valve
Fuel Used Diesel fuel oil
Intake/Exhaust System
Max. back pressure (kPa) 5.9
Max. intake air
restriction (kPa)
With clean filter
element 2.16
With dirty filter
element 6.23
Cylinder block/head
Valve system type Overhead valve type
Item
DP158L
Remarks
DP158LCS DP158LCF DP158LDS DP158LDF10

3. Performance and specifications
23
No. of valve
(per cylinder)
Intake 1
Exhaust 1
Valve lashes
(at cold) (mm)
Intake 0.25
Exhaust 0.35
Intake valve (°)
Opening 24°(BTDC)
Close 36°(ABDC)
Exhaust valve
(°)
Opening 63°(BBDC)
Close 27°(ATDC)
Electrical System
Alternator voltage - capacity (V -
A) 27.5 - 45
Voltage regulator Built-in type IC regulator
Starting motor voltage - capacity
(V - kW) 24 - 7.0
Battery capacity 2-200Ah (recommended)
Item
DP180L
Remarks
DP180LBS DP180LBF DP180LAS DP180LAF
General Information
Engine types Water-cooled, 4cycle, V-type, Turbo charger & inter cooled (air to
air)
Cylinder liner type Wet type liner
No. of cylinder - bore x stroke
(mm) 10 - 128 X 142
Total displacement(cc) 18,273
Compression ratio 15 : 1
Rotation Counter clockwise viewed from flywheel
Firing order 1-6-5-10-2-7-3-8-4-9
Injection timing (°) (BTDC) 21°±1°19°±1°21°±1°19°±1°
Dry weight (kg) 1,250 With fan
Dimension (L x W x H) (mm) 1,592 x 1,389 x 1,223 With fan
Flywheel housing SAE NO.1M
Flywheel Clutch NO.14M
No. of teeth on flywheel 160
Cooling System
Item
DP158L
Remarks
DP158LCS DP158LCF DP158LDS DP158LDF10

3. Performance and specifications
29
Gross Engine Output
Engine Model
Performance
RemarkPrime Stand by
PS kWm PS kWm
DP158L
DP158LCS 60Hz
(1,800rpm) 634 466 697 513
DP158LCF 50Hz
(1,500rpm) 555 408 610 449
DP158LDS 60Hz
(1,800rpm) 687 505 756 556
DP158LDF 50Hz
(1,500rpm) 630 464 693 510
180L
DP180LBS 60Hz
(1,800rpm) 817 601 899 661
DP180LAS 60Hz
(1,800rpm) 760 559 836 615
DP180LBF 50Hz
(1,500rpm) 756 556 832 612
DP180LAF 50Hz
(1,500rpm) 682 502 750 552
DP222L
DP222LCS 60Hz
(1,800rpm) 1,023 753 1,126 828
DP222LCF 50Hz
(1,500rpm 894 657 983 723
DP222LBB 60Hz
(1,800rpm) 967 711 1,063 782
DP222LBF 50Hz
(1,500rpm) 821 604 903 664
DP222LAS 60Hz
(1,800rpm) 911 670 1,002 737

3. Performance and specifications
30
Exterior view drawing of the engine
Front/Rear(DP158L)
DV2213001A
1. Fuel Filter 6. Crankshaft Pulley 11. Engine Oil Supply Pipe
2. Breather 7. Cooling Fan Pulley 12. Flywheel Housing
3. Coolant Pump 8. Idle Pulley 13. Flywheel
4. Alternator 9. Engine Oil Return Pipe 14. Oil Pan
5. Engine Oil Drain Plug 10. Turbocharger 15. Oil Filter
1
2
3
4
5
6
7
8
9
10
11
15
14
13
12

3. Performance and specifications
31
Left/Right(DP158L)
DV2213002A
1. Cooling Fan 6. Turbocharger 11. Flywheel Housing
2. Oil Pan 7. Breather 12. Oil Filter
3. Engine Oil Drain Plug 8. Fuel Filter 13. Alternator
4. Starter 9. Oil Cooler 14. Oil Cap
5. Exhaust Manifold 10. Tacho Sensor
1
87
5
4
2
14
13
12
11
10
9
3
6

3. Performance and specifications
http://www.brizmotors.ru/equipment/ctm/400/
Top(DP158L)
DV2213003A
1. Injector 4. Fuel Injection Pump 7. Oil Filler Cap
2. Fuel Injection Pipe 5. Intake Manifold 8. Inlet Pipe
3. Fuel Pre-Filter/Priming Pump 6. Intake Stake
1
2
3
4
5
67 8

3. Performance and specifications
39
Engine identification number
Engine Code and Manufacturing Number
The engine code and manufacturing number are
engraved in the position marked (A) in the drawing.
These numbers are necessary to request quality assur-
ance or to order parts.
DV2213007A
Engine number engraving
• Type 1
• Type 2
• Type 3
• Type 4
• Type 5
• Type 6
A

41
4. Regular inspection
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Routine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Regular inspection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Use of Genuine Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Coolant standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Capacity of coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Measurement of Coolant Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Discharging the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Charging the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inter cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine oil standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking the Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replacement of Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacement of Engine Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Water draining from fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacing fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Preventing fuel contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cleaning the fuel pre-filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air bleeding in the fuel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Injector maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal of nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Note for cleaning nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking the injection timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Adjusting injection timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Intake/exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

42
Disassembly of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cleaning of the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Changing the air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Routine check and serving the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly and cleaning a turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cylinder block/head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Tightening Cylinder Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cylinder Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electric system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Others/driving system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4. Regular inspection
43
General information
General Information
As time passes after purchasing an engine, each of the
engines parts age and initial engine performance cannot
be maintained.
Regular inspection and replacement according to the
recommended regular inspection table allows you to
maintain an engine with the optimum conditions and best
performance for a long period and prevent unexpected
accidents in advance.
Users are responsible for the proper operation and main-
tenance of engines. Engines should be inspected and
replaced by officially-certified technicians in a workspace
with the specified tools and facilities. Observe the
following instructions to perform inspections.
1. Perform inspections on a flat floor without a slope.
2. Excluding extreme circumstances, only perform
inspection while the engine is stopped.
3. Disconnect the '-' terminal of the battery before
performing an inspection.
4. Perform inspection in a well ventilated space.
5. Use a wooden prop or lift when working under the
engine.
Routine Inspection
Routine inspection is an inspection performed by an
engine operator before operating the engine. It should be
performed to protect operator's safety, as well as the
engine.
The following is a minimal check list.
1. Check whether the engine smoothly starts and the
levels of fuel, oil, and coolant are within the normal
range.
2. Check if any discharged emissions are colored and if
the exhaust contains toxic gas elements.
3. Check whether abnormal noise occurs after starting
an engine or not.
4. Check whether oil or water is leaking.
DANGER
• Wait until the engine is sufficiently cooled before
starting inspection after operating the engine.
Otherwise, you may be burned.
• You may be poisoned by the emission when
starting an engine in a closed space. Perform
inspection at the well-ventilate space.
• Unless absolutely compelled, do not perform
inspection under an engine.
• Do not be close to fire when inspecting an
engine. Fuel, oil, or batteries may generate gas,
causing fire.
• If inspecting the engine while it is running, do
not wear accessories such as necklaces, rings,
watches or gloves. Such accessories may
become stuck in rotating parts while the engine
is running and may cause serious bodily injury.
CAUTION
• Incorrect inspection methods may cause of
engine faults.
• Cleaning an engine with liquids such as water or
wax may cause breakdown of electrical parts.
• Be careful when handling batteries, cables, and
electrical wirings because current flows through
those parts.
• Do not put heavy things or apply excessive force
or impact on the fuel-related units.
• Make sure that you connect the battery terminal
('+' and '-') to the right terminal. Connecting the
'+' and '-' terminals to the wrong terminal may
cause damage to the electrical unit parts and fire.

4. Regular inspection
44
Regular inspection table
General Conditions
Regular inspection and replacement according to the
recommended regular inspection table allows you to
maintain the engine with optimum conditionsand best
performance for a long period and prevent unexpected
accidents in advance.
(○:Inspection and Adjustment, ●: Replacement)
Check Points Daily
Inspection interval (Hours)
Remark
First 50 200 400 800 1,600 3,200 1Year 2Year
Coolant system
Check of coolant level ○
V-belt tension, adjusting if neces-
sary ○
Check of coolant hose & clamp ○
Concentration of antifreeze solution ○
Replace V-belt ●●
Cleaning of water jacket and radia-
tor ○
Change of coolant ●
Replace of coolant hose & clamp ●
Lubrication system
Check of engine oil level ○
Engine exterior for loss of oil ○
Oil Separator for oil leaks ○
Change of Engine oila●● ●
Change of Oil Filtera●● ●
Replace Oil Hoses, Clamps ●
Intake/Exhaust system
Check of exhaust gas color ○
Check of air or gas leak ○
Check of air cleaner indicator ○
Clean of air filter element ○
Replace air filter element ●
Replace Air hoses, Clamps ●
Fuel System

4. Regular inspection
45
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 unautho-
rized or remanufactured parts may cause critical damage
and faults to engine for which Doosan shall not be held
liable.
Fuel lines for leaks ○
Drain Fuel filter / Water separator ○
Check of fuel stop lever ○
Engine Clean fuel pre-filter ○○
Replace Fuel filter ●●
Replace Water separator filter ●●
Drain Water & Sediment from fuel
tank ○
Check of Injectors, replace if nec-
essarya○
Replace Fuel Hoses, Clamps ●
Electrical system
Engine alarms ○
Check of battery charging ○
Magnetic pick up and adjust ○
Cylinder head
Cylinder head valve and valve
seats ○
Check of valve clearance If neces-
sary
a. If the sulfur content of fuel is > 0.02wt%, the changer or check intervals should be halved.
Check Points Daily
Inspection interval (Hours)
Remark
First 50 200 400 800 1,600 3,200 1Year 2Year

4. Regular inspection
46
Cooling system
General Information
The coolant should be replaced according to the cycle
specified in the inspection interval table. If the coolant
gets dirty, the engine is overheated, and the coolant over-
flows in the thermal expansion tank.
Coolant standards
We recommend you to inject the antifreeze about
40~50% of the entire coolant. The antifreeze prevents the
freezing and corrosion of the system, and increases the
boiling point of water. In winter, you may need to change
the amount of antifreeze per ambient temperature as
shown in the table below. The freezing point per anti-
freeze ratio shown in the table may differ slightly
depending on the antifreeze type. For more information,
see the specifications provided by the manufacturer.
Whenever you add coolant(water) to replenish the amount
reduced by engine operation, the antifreeze portion is
decreased. So, you need to increase the antifreeze level
to the proper level after replenishing the coolant.
• concentration of antifreeze during winter
Capacity of coolant
Checking the Coolant
1. For the engine coolant, you should use clean tap
water.
2. To the engine coolant add 40% of antifreeze, and
3~5% of additive(DCA4) to prevent corrosion.
3. Periodically check coolant to maintain the concentra-
tion of antifreeze and additives.
4. The engine cylinder liner is of a wet type which
specially requires good coolant flow.
5. You can check the concentration of antifreeze and
corrosion inhibitor using the coolant test sheet.
Ambient tem-
perature (°C) Coolant (°C) Antifreeze (%)
Above -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
Engine Mode
Coolant capacity ( ℓ)
Inside engine With radiator
DP 158L About 20
About 79
(Air on 43°c)
About 90
(Air on 52°c)
DP180L About 21
About 91
(Air on 43°c)
About 114
(Air on 43°c)
DP 222L About 23
About 114
(Air on 43°c)
About 125
(Air on 52°c)
DANGER
If the radiator cap is opened to exchange or
replenish coolant while the engine is overheated, hot
water will spurt out and may cause serious burns.
If it is absolutely necessary to open the radiator cap
while the engine is overheated, wrap the radiator cap
with a cloth and slowly open the cap in two steps
until the steam pressure has been released from the
inside. After the steam pressure has been completely
released, remove the radiator cap.
DANGER
If you keep the antifreeze and corrosion inhibitor at
a proper level, you can prevent the corrosion of
engine effectively and keep the quality of the engine.
Be careful that, if managed improperly, it can give a
fatal impact on the coolant pump and cylinder liner.
Engine Mode
Coolant capacity ( ℓ)
Inside engine With radiator

4. Regular inspection
47
Measurement of Coolant Concentration
• Special Tools
The coolant concentration can be measured as follows.
1. If the engine coolant temperature is within a range of
10 ~ 55°C, drain the coolant and fill half a plastic cup
with it.
2. Soak the test sheet in the coolant and take it out after
3 ~ 5 seconds. Shake the sheet to remove the
remaining coolant.
3. Wait for about 45 seconds until the test sheet
changes its color.
4. Check the color on test sheet.
EDL0213002A
1) Compare the color of part A on the test sheet to the
color of GLYCOL/FREEZEPOINT (End pad) of the
standard color table.
2) Compare the color of the test sheet (B) to the color
of MOLYBDATE (Middle pad) of the standard color
table.
3) Compare the color of the test sheet (C) to the color
of NITRITE of the standard color table.
5. Compare and confirm the parts with identical colors
on the test sheet and the standard color table.
EDL022154A
1) Compare the changed pink color part A of the test
sheet with the GLYOOL/FREEZEPOINT (End pad) of
the standard color table on top of the container and
confirm the concentration. The concentration indication
has to be within the color scope of 33~50%.
2) The state of additives for anticorrosion is shown on
the point where the color of MOLYBDATE (Middle
pad) on the standard color table (which is identical
with the Middle (B) of the test sheet) is crossed with
the color of NITRITE on the standard color table
(which is identical with the (C) of the test sheet). It
should be maintained at the optimum range, in the
green section between 0.3 to 0.8.
Figure Product Number/Name
60.99901-0038 CC2602M
Coolant test sheet
CAUTION
When taking out a sample of coolant from the
supplementary tank, it is difficult to measure the
precise concentration. Always take out sample by
opening the drain plug of coolant.
CAUTION
Measurement time should not exceed 75 seconds.
The color changes as time passes.
C) B) A)
TESTTEST
SERVICESERVICE
PRE CHARGEPRE CHARGE

4. Regular inspection
48
3) If the measurement result is below 0.3, replenish anti-
corrosion additives (DCA4). If it is above 0.8 or, drain
alittle coolant and then add clean tap water to adjust
the concentration.
Discharging the coolant
The coolant can be discharged as follows.
1. Make sure that engine and radiator are cooled.
2. Open the radiator cap.
3. Loosen the drain valve which is located under the
radiator to discharge the coolant.
DV2213011A_E
4. Disassemble the coolant discharge plug of the cylinder
block, and discharge it to a container.
DV2213012A
5. Drain cooling water in the oil cooler.
DV2213167A
1) Loosen the drain plug(A) of the oil cooler cover and
then drain cooling water.
CAUTION
• If the color on the test sheet does not match the
color of the standard color table, find a middle
color on the standard color table. For example, if
the color of (C) of the test sheet matches D and
Fon the NITRITE of the standard color table,
select E.
• To prevent corrosion inside of the engine cooling
unit, drain the coolant and replace it with new
coolant once a year.
DANGER
• Never open the radiator cap while the engine is
overheated. If the radiator cap is opened while
the engine is overheated, hot water will spurt out
and may cause serious burns. Open the radiator
cap after ensuring that the engine has been
cooled sufficiently.
• Mark and separately manage the containers for
storing coolant from beverage containers to avoid
confusion. If coolant is ingested, see a doctor
immediately.
Drain valve
A

4. Regular inspection
49
Charging the Coolant
1. Make sure that engine is coolant.
2. Open the radiator cap.
3. Put in the coolant slowly.
4. Be sure that the air is gone out from cooling system.
5. After checking the coolant level when the engine is
warmed up, replenish coolant if necessary.
Cleaning the cooling circuit
If the internal coolant circuit is contaminated by corrosion
or foreign substance, the cooling effect is reduced. The
resistance in the coolant circuit may damage the mechan-
ical seal of the coolant pump.
The negative impact on the cooling circuit may be caused
by use of improper antifreeze or corrosion inhibitor, or by
use of coolant without such ingredients. If the coolant
pump leaks or the coolant is severely contaminated within
short period of time (6 months) after start of using the
operation (e.g., the coolant color becomes muddy - prob-
ably brown, gray or black depending on the degree of
contamination), before removing the coolant pump, clean
the cooling system in the following way.
1. Discharge the coolant.
2. If you want to clean the cooling circuit swiftly, remove
the thermostat.
3. Mix water and 1.5% of cleaning solution and fill the
cooling circuit with this liquid.
4. Load the engine. When the coolant temperature
reaches 60°C, run the engine for about 15 minutes.
5. Discharge the cleansing solution.
6. Repeat the step 3 and 4 above.
7. Fill the cooling circuit with hot water.
8. While running the engine at idle speed for 30 minutes,
check if there is any leakage in the drain plug and
coolant line. If the coolant is insufficient, replenish it.
DANGER
• Never open the radiator cap while the engine is
overheated. If the radiator cap is opened while
the engine is overheated, hot water will spurt out
and may cause serious burns. Open the radiator
cap after ensuring that the engine has been
cooled sufficiently.
• Mark and separately manage the containers for
storing coolant from beverage containers to avoid
confusion. If coolant is ingested, see a doctor
immediately.
CAUTION
Be careful not to let foreign substances flow into the
engine when replenishing coolant.
DANGER
If the engine is hot, wrap the coolant pressure cap
with a cloth upon opening it so that the steam may
be discharged. This can prevent you from burning
by the hot steam coming out of the cap inlet.
CAUTION
• Do not mix antifreezes from different manufac-
turers.
• Do not mix the coolant with different concentra-
tions.
• Do not add antirust which is not recommended
by us.
• As insufficient coolant concentration may cause
corrosion or freezing, on the other hand, an
excessive concentration may degrade the cooling
performance. Mix coolant with 40% antifreeze and
3~5% additives (DCA4) to prevent corrosion.
WARNING
Discard exchanged coolant according to the regula-
tions set forth by the relevant authorities. Disposing
of exchanged coolant into the ground, sewers,
drains, rivers, or the sea will cause serious environ-
mental pollution. Violation of regulations regarding
discard of coolant without observing the handling
regulations, will be punished.
CAUTION
Clean the cooling circuit regularly with cleansing
solution.

4. Regular inspection
50
Inter cooler
The air cooler adopts an air cooling fan, which has suffi-
cient cooling capacity. The life and performance of an air
cooler greatly depends on the intake air conditions. Dirty
air may contaminate and clog the cooling pins. This
results in reduced engine power or engine failure. So,
always check the intake system for air leak, damage or
contamination of air filter.
DV2213205B
CAUTION
To keep the optimum performance of the air cooler,
clean it regularly.
Air/air intercooler
with downstream
radiator
(Combined radiator)
Cooling air
Hot charge air
from compressor
Recooled charge air
to intake pipe (max. 50 C)

4. Regular inspection
51
Lubrication system
General Information
Engine oil lubricates, cools, seals, prevents corrosion, and
cleans engines, enhancing engine performance and
extending the engine's lifetime. If a vehicle is continuously
driven while engine oil is insufficient, the moving parts of
the engine may get stuck, causing engine faults.
Engine oil should be checked through the oil level gauge
and replenished if required. Oil level should be checked
while the engine is stopped. To check the oil level,
turn off the engine while it is running and wait for 5 ~10
minutes to allow the engine oil to flow back into the oil
pan. The engine oil level should indicate between the
upper limit and the lower limit of the oil level gauge.
Engine oil should be periodically replaced based on the
regular inspection table and the oil filter and the cartridge
should be replaced as the engine oil is replaced.
Engine oil standards
Use the specified engine oil suitable for the environment
and conditions of the site where the engine will be used.
EDL0213001A
Please use the engine oil which satisfies the following recommended specifications.
Note) Use of Doosan genuine engine oil is recommended.
Engine Model and Product Code SAE Classification Oil Class
DP 158L SAE 15W40 API CD or above
DP180L SAE 15W40 API CD or above
DP 222L SAE 15W40 API CD or above
Engine Oil Viscosity by temperature
Ambient
temperature
This manual suits for next models
12
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