GENERATOR DIESEL ENGINE DP158LCF/LCS/LDF/LDS, DP180LBS/LAS/LBF/LAF, DP222LAS/LBF/LBS/LCF/LCS. Maintenance Manual

3. Performance and specifications

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)

±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 (

Max. for stand
by and prime

103

Before start of
full load

Water pump

Centrifugal type driven by belt

Thermostat

Type

Wax-pellet type

Opening temp.

(

Full open temp.

(

3. Performance and specifications

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.

Min.

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)

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

No. of valve
(per cylinder)

Intake

Exhaust

Valve lashes
(at cold) (mm)

Intake

0.25

Exhaust

0.35

Intake valve (

)

Opening

(BTDC)

(ABDC)

Exhaust valve

(

)

Opening

(BBDC)

(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)

±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

Gross Engine Output

Engine Model

Performance

Remark

Prime

Stand by

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

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

3. Performance and specifications

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

4. Regular inspection

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

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 oil

●

Change of Oil Filter

●

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

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-

essary

○

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

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 (

Coolant (

Antifreeze (%)

Above -10

-10

-15

-20

-25

-30

-40

Engine Mode

Coolant capacity (

ℓ

)

Inside engine

With radiator

DP 158L

About 20

About 79

(Air on 43

About 90

(Air on 52

DP180L

About 21

About 91

(Air on 43

About 114

(Air on 43

DP 222L

About 23

About 114

(Air on 43

About 125

(Air on 52

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

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.

TEST

SERVICE

PRE CHARGE

4. Regular inspection

3) If the measurement result is below 0.3, replenish anti-

corrosion additives (DCA4). If it is above 0.8 or, drain

a little 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

F on 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

4. Regular inspection

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

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

4. Regular inspection

Engine Oil Capacity

Please replenish the engine oil based on the following

recommended oil amount.

Checking the Engine Oil

Check the oil level everyday using an oil level gauge.

1. The oil level should be checked when the engine is

stopped and on an even level. If you started the

engine, wait for 5~10 minutes to allow the engine oil

to flow back into the oil pan.

2. Pull out the oil level gauge, and clean the indication

line of the oil level gauge with clean cloth.

DV2213163A

3. Insert the oil level gauge, and then pull it out to check

the engine oil level, viscosity, and contamination.

Replenish or replace the engine oil if required.

DV2213016A

1) Check the oil level everyday using an oil level gauge.

2) Check if the oil is smeared between the upper limit

(A) and the lower limit (B) of the oil level gauge.

3) If engine oil is smeared below the lower limit (B) or

not smeared on the gauge at all, replenish engine oil.

4) Check condition of engine oil. If it is polluted, replace

it with new oil.

Engine Model

Engine oil capacity (

ℓ

)

Max.

Min.

DP 158L

DP 180L

DP 222L

CAUTION

Cleaning the indication line of the oil level gauge

with dirty cloth allows the foreign substances to get

into the engine, causing damage to the engine.

Max

Min

CAUTION

•

Do not fill the engine oil above the upper limit.

Exceeding the upper limit may damage the

engine.

•

Be careful not to let foreign substances flow into

the engine when replenishing engine oil.

4. Regular inspection

Replacement of Engine Oil

Check the oil level using an oil level gauge and replenish

it if required. Replace the engine oil in the following steps

when the engine is warm by running it.

1. Pull out the oil level gauge.

2. Open the drain plug of the oil pan to discharge the

engine oil from the container.

DV2213017A

3. After discharging the engine oil, assemble the drain

plug of ghe oil pan again.

4. Fill the engine oil into the cartridge of the oil filter.

5. Through the oil filler cap, fill the engine oil.

6. Idle the engine for several minutes so that the oil

circulate through the lubrication system.

7. Then, stop the engine, wait for about 10 minutes,

check the oil level, and fill the oil if required.

Replacement of Engine Filter

Check the oil pressure and leakage, and replace the oil

filter if required. Whenever replacing the oil, the oil filter

cartridge should be replaced with a new on.

1. Using an oil filter wrench, loosen the cartridge by

turning it counterclockwise.

2. Wipe the oil filter head and cartridge contact thor-

oughly, and make sure that the oil filter cartridge is

positioned properly.

3. Apply a little bit of oil to the o-ring area of the

cartridge, assemble it until the O-ring surface may

contact, and turn it 3/4 or 1 turn using a wrench to

keep it air-tight.

DANGER

•

Prolonged and repeated contact of skin with

engine oil may lead to shrinking, dryness of skin

and even cause dermatitis.

•

Do not expose skin with exchanged engine oil for

a long period.

•

Always wear work clothes and gloves.

•

When skin is stained with engine oil, immediately

wash it with water, soap or hand cleaners.

•

Do not clean skin with gasoline, fuel, thinner, or

solvent.

•

Apply a skin protective cream after cleaning from

oil.

•

Do not put oil-stained gloves or cloth in pockets.

WARNING

Discard exchanged 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 regulations regarding discard

of engine oil without observing the handling regula-

tions, will be punished.

CAUTION

When replacing the oil filter cartridge, be sure to use

the genuine part of Doosan.

4. Regular inspection

Fuel system

General Information

The fuel injection pump and nozzle are composed of very

sophisticated components with high precision. If fuel is

mixed with foreign substance, it may clock the nozzle or

the fuel injection pump components may be seized. So,

be sure to keep the fuel system clean all the time.

Fuel Standards

The quality of fuel is very important to satisfy the engine

performance, extension of engine life and the allowable

exhaust gas level. Doosan engine engine is designed to

use diesel fuel available in the local market. If you want

the optimum engine performance, select the proper fuel

referring to the fuel selection table below.

•

Low Sulfur Diesel

Note) High sulphur content in diesel fuel Doosan diesel

engines can be operated with fuels whose sulphur

content is max. 0.05wt%. Fuels with a sulphur

content of > 0.05wt% are not permitted as they

result in increased corrosion and hence greatly

reduce the service life of engines. The oil change

intervals must be halves if the sulphur content is >

0.02wt%.

CAUTION

•

Use clean, certified and qualified fuel only. Using

irregular or unspecified fuel may cause critical

damage and faults to the engine.

•

Replenish fuel while the engine is stopped.

Fuel Ingredients

Unit

Standard

Product

Specific Gravity

(kg/lit)

0.83

Flash Point

(

> 40

47.8

Viscosity (40°C)

(cSt)

1.955

2.459

Sulfur content

(wt%)

< 0.05

0.038

Cloud point

(

-3

Pour Point

(

< -17.5

-27.2

Low temperature filter clogging point

(

< -12

-18

Color (ASTM)

< 2.5

0.7

Carbon Residue (10%) Distillation residue (wt)

(%)

< 0.15

0.08

Total acid value

(mg KOH/g)

< 0.40

0.03

Copper corrosion (100°C, 3 hrs)

< 1

1 - a

Ash content (wt)

(%)

< 0.01

0.001

Moisture and Precipitate

(vol. %)

< 0.01

0.005

Cetane Index

> 45

Distillation test tem-
perature

50% Distillation Point

(

264.4

90% Distillation Point

(

< 360

344.3

4. Regular inspection

Water draining from fuel filter

An oil filter has two functions: oil filtering and water sepa-

ration.

1. the water separation function of the fuel filter

discharges water and sediment from the water

separator.

2. Stop the engine, and loosen the drain plug for water

separation manually.

DV2213164B

3. Turn the drain plug (A) for water separation counter-

clockwise 2~3times until water is drained. Drain the

water in the cartridge until fuel is discharged.

4. Tighten the drain plug for water separation by turning

it clockwise.

Replacing fuel filter

DV2213019A

1. Clean the area around the fuel filter head(3).

2. Disassemble the cartridge(2) by turning it counter-

clockwise with a fuel filter wrench.

3. Remove the fuel filter screw adapter seal ring(4).

4. Clean the gasket contact of the fuel filter head(3).

5. Check the position of the new cartridge adapter seal

ring(4).

6. Apply thin coat of clean oil to the O-ring(5) area of

the cartridge, and fill the cartridge with fuel.

7. Assemble the cartridge to the fuel filter head.

8. Tighten the cartridge with hand until the O-ring

contacts the fuel filter head surface.

DANGER

Fuel may be drained when water is drained from the

fuel filter. Fuel is highly inflammable. Fire may occur

when you use fire near the engine when draining

water from the fuel filter.

CAUTION

•

Do not tighten the plug excessively because it

may damage the screw.

•

If you do not check the fuel filter regularly and

drain the water in the fuel filter, water flows into

the fuel system of the engine, causing serious

failure in the fuel system, etc., and decrease in

or damage to the fuel filter performance. Inflow

of water to the fuel system may stop the engine.

•

Use clean, specified, and qualified fuel only.

using irregular or unspecified fuel may result in

more water in the fuel filter.

CAUTION

Do not reuse the cartridge; replace them with new

ones.

4. Regular inspection

9. Turn it by 3/4 to 1 turn with a fuel filter wrench.

DV2213020A

Preventing fuel contamination

Most of the fuel contaminations encountered while using

the alternator engine are caused by water and propaga-

tion of microbes.

Usually, the contamination results from improper handling

of fuel. Propagation of microbes requires water contained

in the fuel. To prevent propagation of microbes, you have

to keep the water to the minimum level possible in the

storage tank.

Fuel injection pump

•

Check the fuel injection pump housing, and replace it

if crack or damage is found.

•

Check if the idle operaion and speed control lever’s

sealing device was not removed.

•

Chcek if the idling or speed control lever’s sealing line

is not damaged.

•

You should not modify the fuel injection pump if the

sealing line is damaged, such engine cannot receive

compensation.

•

if the fuel injection pump is found abnormal, autho-

rized personnel should handle it.

•

The adjustment and test of the fuel injection pump

must be conducted using a tester.

Cleaning the fuel pre-filter

The fuel pre-filter should be cleaned periodically through

disassembly. the fuel pre-filter is mounted individually for

easy maintenance. Open the cover of the pre-filter and

clean the element with compressed air first, and then

rinse it with diesel fuel to remove foreign substances.

DV2213021C

CAUTION

If you tighten the cartridge excessively, the screw

may be

distorted or O-ring damaged.

CAUTION

If you separate the parts where the seal ring (copper

seal ring, rubber coating seal ring, etc.) is assem-

bled, you should replace the seal ring with a new

one. Otherwise, leakage may occur in the fuel filter

connections, preventing normal functioning.

4. Regular inspection

Air bleeding in the fuel circuit

When the engine stops due to replacement of fuel filter,

fuel injection pump or insufficient fuel, you should perform

air bleeding.

1. Loosen the air bleeding plug (B) on the fuel filter.

2. Operate the priming pump by hand to bleed air inside

the fuel circuit.

3. Operate the priming pump until the air is discharged

completely through visual checking.

DV2213164B

Injector maintenance

•

The injectors are designed to spray the fuel delivered

by the injection pump directly into the spherical

combustion chamber in the piston crown.

•

The injector consists of the nozzle and the nozzle

holder.

•

A copper gasket fitted to the injector ensures gas-tight

seating and good heat dissipation.

•

The opening pressure of the nozzle is adjusted by

means of shims at the compression spring.

DV2213022A

Fuel injection nozzle

1. Install a nozzle to the nozzle tester.

DV2213023A

2. Check the fuel injection pressure. If the pressure does

not satisfy the reference value, adjust the injection

pressure of the nozzle using an adjustment shim.

DANGER

Fuel is highly inflammable. Fire may occur when you

use fire near the engine when air bleeding in the fuel

circuit from the priming pump.

CAUTION

If you separate the parts where the seal ring (copper

seal ring, rubber coating seal ring, etc.) is assem-

bled, you should replace the seal ring with a new

one. otherwise, leakage may occur in the fuel filter

connections, preventing normal functioning.

1. Rod type filter

7. Connect hole for fuel
delivery

2. Cap nut

8. Nozzle holder

3. Compression spring

9. Connect tube for overflow

4. Compression pin

10. Shim

5. Cap nut for fixed nozzle 11. Pin

6. Nozzle

12. Nozzle bush

4. Regular inspection

3. Check the nozzle spray status. If it is defective,

replace the nozzle.

DV2213165A

Removal of nozzle

1. Remove fuel injection pipe between nozzle holder and

injection pump.

2. Remove fuel return pipe.

3. loosen the Union screw(A) of nozzle holder with

Nozzle plug socket (EI.03004-0225)

4. Remove nozzle holder with sealing from the cylinder

head.

DV2213166B

CAUTION

•

As the nozzle injection nozzle is designed to

operate under high pressure, you should handle

it with special care.

•

Do not hold your hands under the fuel jet, as

there is a rise of injury. Do not inhale the atom-

ized oil fuel. If possible, work under an extraction

system.

abnormal

normal

Engine Model

Nozzle injec-

tion pressure

(Mpa)

DP158L

DP158LCS

DP158LCF

DP158LDS

DP158LDF

DP180L

DP180LBS

DP180LBF

DP180LAS

DP180LAF

DP222L

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

Sealing

Dust seal

Nozzle plug socket

4. Regular inspection

Installation nozzle

1. Clean seat in cylinder head.

2. Insert nozzle holder with new gasket.

3. Tighten union nut with 12 kgf•m.

4. Install injection lines free of constraint. Install leak fuel

lines, screw delivery pipe at nozzle holder and at the

injection pump.

Note for cleaning nozzle

•

Clean nozzle body externally from soot and carbon,

When cleaning several nozzles at the same time,

make sure nozzle bodies and needles are not mixed

up. Visually inspect needle and body.

•

Cleaning is useless if the seat of the needle is

indented or the pintle is damaged and the nozzle

should be replaced.

•

Clean annular groove with scraper over full circumfer-

ence. Wash out dislodged carbon deposits and dirt.

•

Scrape needle seat with cleaning cutter, Dip cutter in

test oil before use. The cutter can also be clamped

in a lathe.

•

Polish needle seat with wooden cleaning tool, prefer-

ably by chucking the needle in a lathe at the pintle

end.

•

Clean the spray holes of nozzles by chucking a

cleaning needle of suitable diameter in the collect. If

the carbon deposits in the spray holes cannot be

removed by rotating and pressing, have the needle

project only slightly from the collect and drive out the

carbon by lightly tapping on the tool.

•

Before reassembly thoroughly wash nozzle body and

needle in clean test oil.

•

Hold the needle at the pintle end only ; to avoid corro-

sion do not touch the lapped surfaces of the needle

with you fingers.

•

Thoroughly clean all other parts of the nozzle holder

with clean fuel.

•

Check nozzle discharge pressure in nozzle tester. The

edge-type filter should not be pressed into the nozzle

holder by more than about 5mm. If this depth is

exceeded the injector must be replaced.

Checking the injection timing

1. Remove the plug screw on the flywheel housing

cover.

Note) Some cases are needed to remove cover

assembly.

2. Turn the crank pulley so that the mark on pointer

provided on injection pump coincides with matching

mark(FB) on the flange surface of the drive gear.

DV2213164A_K

Torque

12kgf

CAUTION

•

The injection lines are designed for high oper-

ating pressure and should thus be handled with

particular core.

•

When mounting the pipes to the engine take care

of good fitness.

•

Do not bend pipes to permanent deformation.

(not for replacing the nozzles either)

•

Do not mount any heavily bent pipes.

•

Avoid bending the pipes at the ends by more

than 2 to 3 degrees.

•

In case of faults in the injection system which

might have resulted in excessive operating pres-

sures, not only the failed part but also the injec-

tion line has to be replaced.

Flange

Pointer

4. Regular inspection

3. Check the injection timing degree whether the V-type

edge of the flywheel housing sight hole coincides with

the engine injection timing degree marked on the

flywheel corresponding to fuel delivery position.

DV2213165A_K

Adjusting injection timing

If upper pre-checked injection timing degree is wrong,

follow as below.

1. Loosen the fixing bolts(M8) of the injection pump

driving gear in order to adjust the injection timing

slightly.

DV2213028A

2. Turn the crank pulley clockwise until V-groove of the

flywheel housing sight hole is aligned with the injection

timing degree of the engine.

3. Coincide the mark on pointer provided in injection

pump with the matching mark(FB) on the flange

surface of the drive gear by turning the flange in the

oblonog holes of the drive gear.

4. Tighten the bolt(M8) to specified torque, (2.2 kgf

not to move the drive gear.

5. After confirmation that fastening bolts are completely

tightened check the start point (injection timing

degree) of fuel delivery setting once more if not right

repeat it again as same as upper way.

Engine Model

Injection Tim-

ing (

)

DP158L

DP158LCS

DP158LCF

DP158LDS

DP158LDF

DP180L

DP180LBS

DP180LBF

DP180LAS

DP180LAF

DP222L

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

4. Regular inspection

Intake/exhaust system

General Information

The air filter purifies dust and foreign substances included

in the air and supplies clean air into the engine. The air

filter is directly related to engine lifetime, emissions, and

engine output. Please periodically check, clean, and

replace the air filter.

Air Filter

•

Air cleaner is mounted on the engine to purify the air

for combustion.

•

The intervals at which the air cleaner requires

servicing depend on the specific operating conditions

encountered.

•

Clogged air filters may cause black smoke and reduce

power.

•

A check should be made from time to time to see

that the fastening elements securing the air cleaner to

the intake manifold seal the connection tightly.

•

Any ingress of unfiltered air is liable to cause a high

rate of cylinder and piston wear.

Disassembly of air filter

1. Empty the dust bucket periodically. The dust should

not exceed the half of the dust bucket capacity.

2. You can disassemble the dust bucket by removing two

clamps. Remove the dust bucket cover and empty the

dust inside.

3. Assemble the cover and dust bucket accurately with

care.

4. For easy alignment, the cover has dent and the dust

collector has a protrusion. Here is the position where

a filter is mounted horizontally, check the “TOP” mark

on the air filter canister.

DV2213029A

CAUTION

•

Do not operate the engine when the air filter is

separated from the engine.

•

Use specified air filters only. Using unauthorized

or remanufactured air filters may result in critical

faults.

•

Foreign substances in the engine may cause

abrasion inside the engine.

•

Immediately exchange a damaged air filter with a

new one.

•

Be careful not to let foreign substances flow into

engine or damage the air filter

related electric

apparatus when replacing an air filter.

•

Be careful not let dust inside when assembling

the air filter.

DANGER

Allowed only when the engine is stopped.

1. Air cleaner ass'y

2. Air cleaner element

DV15

DV18/22

4. Regular inspection

Cleaning of the Air Filter Element

Clean the air filter element by using the most suitable

method for your work environment among the three

methods stated below.

1. Use compressed air to clean the air filter element.

EDL022155A

1) To clean, let sufficient compressed air reach the inside

bottom of the element at 90

direction with an air gun.

2) Move air gun up and down the element to blow air

from inside to outside until no more dust is coming

out from the element.

3) Do not use compressed air pressure exceeding 5

bars.

2. Clean the element by washing it.

EDL022156A

1) Before washing the element, clean the element by

using compressed air as described above.

2) Soak the element in the warm cleaning solvent for 10

minutes and then shake it back and forth for about 5

minutes.

3) Rinse the element with clean water, drain the water,

and then dry it at room temperature. Fully dry the

element before reassembling it to the engine.

3. In an emergency, temporarily clean the element by

using the following method.

1) Tab the end plate of the element with the thumb to

clean it temporarily.

EDL022157A

Note) Before reassembling the element, make sure that

the filter paper is not wrinkled, the state of rubber

sealing is good, and there is no deformed part in

the element.

Note) Under any circumstances, do not reuse damaged

elements. When in doubt, replace the element with

a new one.

DANGER

Always wear protective goggles before starting work.

Otherwise, dust or foreign substances from the

element may get in your eyes and cause injuries.

CAUTION

Never use steam spray, gasoline, alkali or hot

cleansing solution to cleansing the element.

CAUTION

•

This method should only be used in an emer-

gency when cleaning of element is necessary and

no compressed air or cleansing solution is avail-

able.

•

Under no circumstances should the surface of

the element be hit or beaten with a hard object

to shake the dust off.

4. Regular inspection

Changing the air filter element

1. Remove the hex nut, remove the dirty element.

DV2213030A

2. Replace with a new one or wash it.

3. Using a wet rag, wipe the inside of the filter housing.

4. The sealing contact of element.

Turbocharger

The Turbocharger does not need a specific maintenance.

Whenever replacing the engine oil, check oil pipe for

leakage or clogging.

•

You should handle the air filter with special care to

prevent foreign substance from getting in.

•

The turbocharged compressed air and exhaust gas

pipe should be checked periodically. Air leakage

causes engine overheat, so repair is required.

•

If the impeller is severely contaminated, soak only the

wheel in a solvent and clean it with a rigid brush thor-

oughly. Here, be sure to soak only impeller, and the

turbocharger should be supported by a bearing

housing, not by an impeller.

Routine check and serving the turbocharger

The turbocharger performance is determined by mainte-

nance state of the engine. So you should regularly

perform inspection and check as specified.

1. Intake system

For the intake system, the air filter should be carefully

managed. For a wet type air filter, the intake resis-

tance should be small as possible.

2. Exhaust system

For the exhaust system, when exhaust gas leaks from

the exhaust pipe or turbocharger joint, supercharging

efficiency is lowered. So you need to pay attention to

prevent gas leakage and burn. Heat resistant nuts are

used for parts which are highly heated during opera-

tion, such as the turbine seal, and the nuts should

not be mixed with other nuts. The screw burn preven-

tion paint should be applied to the assembly nuts of

the specified positions.

3. Fuel system

If the spray status of the fuel injection nozzle is not

good, or the injection timing is not correct, the exhaust

gas temperature increases to give a negative impact

on the turbocharger. So, the nozzle should be tested.

4. Lubrication system

For the lubrication system, pay attention with the oil

quality and the replacement time of the cartridge of

the oil filter. Degradation of engine oil has bad effect

on the turbocharger, as well as the engine body.

Disassembly and cleaning a turbocharger

You can disassemble the turbocharger from the engine

to clean or inspect it. Here, be sure to seal the oil inlet

and oulet with a tape, etc.

DANGER

Do not let dust come into the end of air filter.

CAUTION

Be careful not to bend it.

GENERATOR DIESEL ENGINE DP158LCF/LCS/LDF/LDS, DP180LBS/LAS/LBF/LAF, DP222LAS/LBF/LBS/LCF/LCS. Maintenance Manual - page 1