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

5. About the engine

12. Attach the piston to the connecting rod.

DV2213177A

1) Install the 1st ring(D), 2nd ring(E), and the oil ring(F)

with the piston ring plier(T7621010E).

2) Apply engine oil on the piston pin(C).

3) Align the pin hole of the connecing rod(G) small-end

with that of the piston(A).

4) Attach the piston pin(C).

5) Attach 2 snap rings(B) with the snap ring plier

(T7610001E).

6) Align the upper bearing groove with connencting rod.

Attacht the upper connecting rod bearing(I) to the

connecting rod(G).

7) Align the lower bearing groove with connecting rod.

Attach the lower connecting rod bearing(J) to the

connecting rod bearing cap(H).

13. Attach the connecting rod and piston assembly.

DV2213088A

1) Attach the connecting rod and piston assembly to the

cylinder block.

2) Attach the connecting rod cap(B).

3) Tighten 2 M16X1 flange hex bolts(A) at a tightening

torque 10 kgf

m + 90

by using the angle method.

CAUTION

•

Ensure that the ‘Y’ mark of the piston ring faces

the top surface of the piston.

•

Make the piston ring position dislocated to 120

CAUTION

•

The intake valve pocket is larger than the exhaust

valve pocket.

•

Attach the engine as the same piston weight.

Place the Class of the piston weight on the top

surface of the piston.

CLASS

Piston Weight(g)

2,371 ~ 2,380

2,381 ~ 2,390

2,391 ~ 2,400

2,401 ~ 2,410

2,411 ~ 2,420

D
E

CAUTION

Check the attached piston and piston ring. If the

piston should be replaced, replace the piston pin

along with the piston.

CAUTION

•

Do not reuse the snap rings.

•

Assemble snap rings with the opening of the

snap rings facing 12 o’clock.

CAUTION

•

Be careful the direction when assembling the

connecting rods and the connecting rod caps.

•

Ensure that the marks of the connecting rod and

the bearing cap are facing the same direction.

5. About the engine

4) Attach 12 connecting rod and piston assembly as the

same procedure.

14. Attach the oil suction pipe and the oil pump.

DV2213087A

1) Attach the oil suction pipe and the oil pump(D).

2) Tighten M8 fixing bolt(C) at a tightening torque 2.2

kgf

3) Tighten 2 M8 fixing bolts(B) at a tightening torque 2.2

kgf

4) Tighten 2 M8 fixing bolt(A) at a tightening torque 2.2

kgf

15. Attach the oil pan.

DV2213086A

1) Attach the oil pan(B).

2) Tighten 20 M8 fixing bolts(A) at a tightening torque

2.2 kgf•m ± 0.33kgf•m.

16. Change the engine position.

DV2213185A

1) Change the engine positon. The piston direction is

upward.

17. Adjust the fuel injection timing.

DV2213027A

CAUTION

•

Be careful to note the direction when attaching

the connecting rods and the connecting rod caps.

Ensure that the number engraved on the

connecting rods is same with that engraved on

the connecting rod caps and the assembly direc-

tion is same.

•

Attacht the connecting rod and piston assembly

without contacting the crankshaft weight. Rotate

the crankshaft.

5. About the engine

100

1) Rotate the crankshaft so that the #1 cylinder piston

may be positioned at the top dead center(OT) and the

#6 cylinder piston may be posiitioned at the valve

overlap.

Note) In case of 8/12 cylinder engine, #6. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positioned at the compression TDC(Top Dead

Center).

Note) In case of 10 cylinder engine, #7. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positoned at the compression TDC(Top Dead

center).

2) Rotate the crankshaft until the yellow mark of the

camshaft gear is not shown.

3) Adjust the fuel injection timing with rotating the

flywheel to the engine rotating direction.

18. Attach the fuel injection driven gear temporarily.

DV2213186A

DV2213171A

1) Attach the driven gear(A) to the fuel injection pump

temporarily.

2) Attach the O-ring(B) and (C) to the fuel injection

pump.

3) Align the injection timing pointer of the fuel injection

pump driven gear with the marking on the cylindrical

surface.

Engine Model

Fuel Injection Timing (

)

DP158L

DP158LCS

DP158LCF

DP158LDS

DP158LDF

DP180L

DP180LBS

DP180LBF

DP180LAS

DP180LAF

DP222L

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

5. About the engine

101

19. Attach the fuel injection pump.

DV2213072A

1) Attach the fuel injection pump(B) with the injection

pump alignment jig(EF.120-189).

2) Tighten 6 fixing bolts(A) at a tightening torque 5.0

kgf

0.5kgf

20. Attatch the fuel injection pump driven gear.

DV2213187A

1) Tighten 3 M8 fixing bolts(A) of the fuel injection pump

driven gear at a tightening torque 3.1 kgf

0.46kgf

2) Rotate the fuel injection pump driven gear 360

with

rotating flywheel.

3) Tighten 3 the other M8 fixing bolts(A) of the fuel injec-

tion pump driven gear at a tightening torque 3.1 kgf

0.46kgf

21. Attach the flywheel housing cover.

DV2213188A

1) Attach the flywheel housing cover(A).

2) Tighten 4 M8 fixing bolts(B) at a tightening torque 2.2

kgf

0.3kgf

22. Attach the cylinder head.

DV2213189A

1) Attach the inner washer(C) and the outer washer(D).

2) Attach the valve stem seal(A) with the valve stem seal

punch(EF.120-183).

CAUTION

Do not give an excessive shock on the valve stem

seals; otherwise, they may be damaged.

5. About the engine

102

3) Attach the vavle(B).

4) Attach the valve spring(E).

5) Compress the valve with the valve spring press

(EF.120-262).

6) Attach the valve cotters(F).

23. Attach the cylinder head assembly.

DV2213077A

1) Attach the gasket assembly.

2) Attach the cylinder head assembly(B).

3) Tighten 6 cylinder head fixing bolts(A) at a tightening

torque 8kgf

m + 15kgf

m + 90

+ 90

by using the

angle method.

4) Attach 12 cylinder head assembly as the same proce-

dure.

24. Attach the push rods.

DV2213076A

1) Attach 24 push rods(A).

25. Attach the rocker arm assembly.

DV2213075A

1) Attach the rocker arm assembly(B).

2) Tighten the fixing bolts(A).

3) Attach 12 rocker arms as the same procedure.

26. Attach the injectors.

DV2213073A

CAUTION

Be careful to use the right valve without confusing

the intake valve with the exhaust valve. The intake

valve is the mark “ I ” engraved on the head and

the exhaust valve is the mark “ E ” engraved on the

head.

CAUTION

Be carful the valve direction. The yellow mark on the

valve is upward.

CAUTION

Check if the valve cotters have been positioned

correctly with the plastic hammer after completing

attaching them.

5. About the engine

103

1) Attach the seal ring and then attach the injector(A).

2) Tighten the injector holder fixing nut with the jig for

injection nozzle detach(60.99901-0036).

3) Attach 12 injectors as the same procedure.

27. Attach the fuel return pipe.

DV2213069A

1) Attach the fuel return pipe(B).

2) Attach the double seal ring.

3) Tighten the hollow screw(A) at a tightening torque

0.8kgf

m ± 0.12kgf

4) Attach the other fuel return pipe as the same proce-

dure.

28. Adjust the valve clearance. (Method 1)

DV2213041A

DV2213042A

DV2213213A

DV2213043A

1) Rotate the crankshaft so that #1. cylinder may be

positioned at the compression TDC(Top Dead Center).

Note) #1. Cylinder is located at the side where cooling

water pump was installed.

Note) In case of 8/12 cylinder engine, #6. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positioned at the compression TDC(Top Dead

Center).

CAUTION

Be careful not to damage the fuel pipes.

lin

engine

9
8
7
6
5
4
3
2
1

lin

er engine

12
11
10

9
8
7
6

5
4
3
2
1

lin

er engine

5. About the engine

104

Note) In case of 10 cylinder engine, #7. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positoned at the compression TDC(Top Dead

center).

2) Loosen the lock nut of the #1. cylinder rocker arm.

3) Push the feeler gauge between a rocker arm and a

valve stem.

4) Adjust the clearance screw respectively and then

tighten with the lock nut.

5) As for the valve clearance, adjust it when in cold, as

follws.

6) Rotate the crankshaft. When a cylinder reaches the

compression TDC(Top Dead Center), adjust the valve

clearance of the cylinder.

7) When a cylinder vavle overlap, adjust the valve clear-

ance cylinder of the compression TDC(Top Dead

Center), as follow.

•

8 cylinder engine(DP158L)

•

10 cyliner engine(DP180L)

•

12cyliner engine(DP222L)

29. Adjust the valve clearance. (Method 2)

DV2213041A

DV2213208A

Engine Model

In. valve

Ex. valve

DP158L

DP158LCS

0.25mm

0.35mm

DP158LCF

0.25mm

0.35mm

DP158LDS

0.25mm

0.35mm

DP158LDF

0.25mm

0.35mm

DP180L

DP180LBS

0.25mm

0.35mm

DP180LBF

0.25mm

0.35mm

DP180LAS

0.25mm

0.35mm

DP180LAF

0.25mm

0.35mm

DP222L

DP222LAS

0.25mm

0.35mm

DP222LBS

0.25mm

0.35mm

DP222LBF

0.25mm

0.35mm

DP222LCS

0.25mm

0.35mm

DP222LCF

0.25mm

0.35mm

Valve overlap cylinder No.

Adjusting valve cylinder No. (In./Ex. Valve)

Valve overlap cylinder No.

Adjusting valve cylinder No. (In./Ex. Valve)

Valve overlap cylinder No.

Adjusting valve cylinder No. (In./Ex. Valve)

8
7
6
5
4
3
2
1

lin

er engine

5. About the engine

105

DV2213214A

1) By cranking the engine, let the cylinder No. 7 on the

overlap TDC in 10 cylinder engine (but 8 & 10

cylinder engine is No. 6) that is, cylinder No. 1

becomes the ignition TDC position. Then adjust the

valves corresponding to mark “

○

” in the below figure.

Note) #1. Cylinder is located at the side wherecooling

water pump was installed.

2) After that, turn the crankshaft one rotation (360

)

clockwise, put the cylinder No. 1 on overlap TDC posi-

tion that is, cylinder No. 7 (but 8 & 10 cylinder engine

is No. 6) becomes the ignition TDC position. Then

adjust the valves corresponding to “

●

” in the below

figure.

Note) In case of 8/12 cylinder engine, #6. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positioned at the compression TDC(Top Dead

Center).

Note) In case of 10 cylinder engine, #7. cylinder is posi-

tioned at the valve overlap when #1. cylinder is

positoned at the compression TDC(Top Dead

center).

•

8 cylinder engine(DP158L)

•

10 cyliner engine(DP180L)

•

12 cyliner engine(DP222L)

9
8
7
6
5
4
3
2
1

lin

er engine

9
8
7
6
5
4
3
2
1

lin

er engine

Engine Model

In. valve

Ex. valve

DP158L

DP158LCS

0.25mm

0.35mm

DP158LCF

0.25mm

0.35mm

DP158LDS

0.25mm

0.35mm

DP158LDF

0.25mm

0.35mm

DP180L

DP180LBS

0.25mm

0.35mm

DP180LBF

0.25mm

0.35mm

DP180LAS

0.25mm

0.35mm

DP180LAF

0.25mm

0.35mm

DP222L

DP222LAS

0.25mm

0.35mm

DP222LBS

0.25mm

0.35mm

DP222LBF

0.25mm

0.35mm

DP222LCS

0.25mm

0.35mm

DP222LCF

0.25mm

0.35mm

Cylinder No.

Valve

#1TDC
#6TDC

●

○

●

○

●

○

Cylinder No.

Valve

#1TDC
#6TDC

○

●

○

●

○

Cylinder

No.

Valve

Ex In

#1TDC
#7TDC

●

○

●

○

●

○

○ ●

Cylinder

No.

Valve

Ex In

#1TDC
#7TDC

●

○

●

● ○

5. About the engine

106

30. Attach the cylinder head cover.

DV2213074A

1) Attach the dylinder head cover(B).

2) Tighten 3 fixing bolts(A) at a tightening torque

2.2kgf

0.33kgf

31. Attach the breather.

DV2213096A

1) Attach the breather(B).

2) Tighen the clamp.

3) Attach the other breather as the same procedure.

32. Attach the intake manifold.

DV2213066A

1) Attach the intake mainfold(B).

2) Tighten the fixing bolts(A) by hand temporarily.

3) Tighten thd fixing bolts(A) at a tightening torque

2.2kgf

0.33kgf

4) Attach the other intake manifold as the sameproce-

dure.

Cylinder No.

Valve

#1TDC
#6TDC

●

○

●

○

Cylinder No.

Valve

#1TDC
#6TDC

○

●

○

●

○

Cylinder No.

Valve

#1TDC
#6TDC

●

○

●

CAUTION

#3 and #4 cylinder head covers have the breather.

#10 cylinder head cover has the oil filler cap. the

others are the same cylinder head cover.

CAUTION

•

Be careful not to let dust inside the engine.

•

Be careful not to mix the fixing bolts.

5. About the engine

107

33. Attach the fuel pre filter.

DV2213065A

1) Attach the fuel return pipe and fuel pre filter(C).

2) Tighten the fixing bolts(B) at a tightening torque

2.2kgf

0.33kgf

3) Tighten the hollow screw(A) at a tightening torque

1.2kgf

0.14kgf

34. Attach the fuel and oil hose.

DV2213070A

1) Attach the fuel and oil hose(C).

2) Tighten the hollow screw(B) at a tightening torque

1.8kgf

0.27kgf

3) Tighten the fixing bolts(A) at a tightening

torque1.8kgf

0.27kgf

35. Attach the fuel pipe.

DV2213068A

1) Attach the fuel pipe(D).

2) Tighten the fixing nut(B) and (C) at a tightening torque

5.5kgf

0.825kgf

3) Tighten the fixing nut(A) at a tightening torque

5.5kgf

0.825kgf

36. Attach the fuel pipe.

DV2213067A

1) Attch the fuel pipe(C).

2) Tighten the hollow screw(B) at a tightening torque

1.2kgf

0.14kgf

3) Tighten the fixing bolt(A) at a tightening torque

2.2kgf

0.33kgf

CAUTION

Be careful not to damage the fuel pipes.

CAUTION

Be careful not to damage the fuel pipes.

CAUTION

•

Be careful not to lose the O-ring.

•

Be careful not to damage the fuel pipes.

5. About the engine

108

37. Attach the fuel injection pipe.

DV2213064A

1) Attach 3 fuel injection pipe assemblies(D).

2) Attach the fuel pipe nut temporarily.

3) Tighten 12 fuel pipe nuts(A) of the injectiion pump at

a tightening torque 5.5kgf

0.825kgf

4) Tighten 12 fuel pipe nuts(A) of the injector at a tight-

ening torque 5.5kgf

0.825kgf

5) Tighten the fixing bolt(A).

38. Attach the inlet pipe.

DV2213063A

1) Attach the inlet pipe(B).

2) Tighten the fixing bolt(A) at a tightening torque

4.4kgf

0.66kgf

Note) Tighten the fixing bolts to attach the inlet elbow and

the inlet pipe at a tightening torque 2.2kgf

0.33kgf

39. Attach the fuel filter.

DV2213062A

1) Attach the fuel filter assembly(B).

2) Tighten the fixing bolt(A) at a tightening torque

7.5kgf

1.12kgf

40. Attach the intake stake.

DV2213061A

1) Attach the intake stake(D).

2) Tighten the V-clamp(C).

3) Tighten the hose clamp(B).

4) Tighten the fixing bolt(A) at a tightening torque

2.2kgf

0.33kgf

CAUTION

•

Be careful not to damage the fuel pipes.

•

Be careful not to let dust inside the engine.

CAUTION

Be careful not to let dust inside the engine.

5. About the engine

109

5) Attach the other intake stake as the same procedure.

41. Attach the exhaust manifold and exhaust elbow.

DV2213060A

1) Attach the exhaust manifold and exhaust elbowas-

sembly(D).

2) Tighten 8 fixing bolts(B) and 4 fixing bolts(C) at a

tightening torque 7.0kgf

1.05kgf

3) Tighten the exhaust elbow bracket fixing bolts(A) at a

tightening torque 20.0kgf

1.5kgf

4) Attach the other exhaust manifold and exhaust elbow

assembly as the same procedure.

Note) Tighten the fixing bolts to attach the exhaust mani-

fole and the elbow bracket at a tightening torque

8.0kgf

0.5kgf

42. Attach the turbocharger.

DV2213070A

1) Attach the turbocharger(B).

2) Tighten 4 fixing bolts(A).

3) Attach the other turbocharger as the same procedure.

43. Attach the oil return pipe.

DV2213169A

1) Attach the oil return pipe(C).

2) Tighten 2 fixing bolts(B).

3) Tighten the clamp.

4) Attach the other turbocharger as the same procedure.

CAUTION

Be careful not to let dust inside the engine.

CAUTION

Be careful not to mix the fixing bolts.

5. About the engine

110

44. Attach the oil delivery pipe.

DV2213058A

1) Attach the oil delivery pipe(D).

2) Attach the hollow screw(C).

3) Tighten the oil delivery pipe fixing bolts(B) at a tight-

ening torque 2.2kgf

0.33kgf

4) Tighten the oil delivery pipe fixing bracketbolts(A) at

a tightening torque 2.2kgf

0.33kgf

45. Attach the inlet elbow.

DV2213057A

1) Attach the inlet elbow(C).

2) Tighten the V-clamp(B).

3) Tighten the hose clamp(A).

4) Attach the other inlet elbow as the same procedure.

46. Attach the oil cooler housing.

DV2213085A

1) Attach the oil cooler housing(C).

2) Tighten 5 M10 outer fixing bolts(B) at a tightening

torque 6.2kgf

3) Apply LOCTITE 262 on the M10 inner socket bolts(A).

4) Tighten 5 M10 inner socket bolts(A) at a tightening

torque 6.2kgf

47. Attach the cooling water pipe.

DV2213084A

1) Attach the cooling water pipe(B).

2) Tighten 4 fixing bolts(A) at a tightening torque

8.0kgf

1.2kgf

CAUTION

Make sure that the O-rings and the gaskets have

been attached.

CAUTION

Make sure that the O-ring and the insert parts have

been attached.

5. About the engine

111

48. Attach the oil cooler cover.

DV2213083A

1) Attach the oil cooler and the oil cooler cover(B).

2) Tighten 20 M8 fixing bolts(A) at a tightening torque

2.2kgf

49. Attach the oil filter assembly.

DV2213082A

1) Attach the oil filter housing(D).

2) Tighten the fixign bolts(B) and (C).

3) Attach the oil filter(A) with the chain plier(EF.200-038).

50. Attach the crankshaft pulley.

DV2213190A

1) Attach the crankshaft pulley(B).

2) Tighten 8 M16 stud head bolts(A) at a tightening

torque 21.0kgf

1.0kgf

Note) Tighten the stud head bolts in the order from (1)

~ (8).

51. Attach the cooling fan pulley and the idle pulley.

DV2213174A

1) Attach the cooling fan pulley assembly(I).

2) Tighten 3 fixing bolts(G) and 1 socket bolt(H) at a

tightening torque 4.4kgf

0.33kgf

3) Fix the cooling fan pulley using the jig.

4) Tighten 1 cooling fan fixing bolt at a tightening torque

20kgf

5) Attach the idle pulley bracket(F).

6) Tighten 3 fixing bolts(G) and 1 socket bolt(H) at a

tightening torque 4.4kgf

0.33kgf

7) Tighten 1 fixing bolt(D).

8) Attach the idle pulley(C).

CAUTION

Make sure that the gaskets have been attached.

CAUTION

•

Make sure that the gaskets have been attached.

•

Be careful not to run down oil.

5. About the engine

112

9) Tighten 1 fixing bolt(A) and 2 fixing nuts(B).

52. Attach the water pump.

DV2213097A

1) Attach the water pump assembly(B).

2) Tighten 16 fixing bolts(A).

53. Attach the thermostat.

DV2213172A

1) Attach the gasket(C).

2) Attach the thermostat(A).

3) Attach the o-ring(B).

4) Attach 3 thermostats as the same procedure.

54. Attach the cooling water pipe.

DV2213078A

1) Attach the cooling water pipe(C).

2) Tighten the fixing bolts(A) and nuts(B) at a tightening

torque 2.2kgf

0.33kgf

55. Attach the starter.

DV2213053A

1) Attach the starter(B).

2) Tighten 3 fixing bolts(A) at a tightening torque

4.4kgf

1.2kgf

CAUTION

Make sure that the cooling fan pulley can be rotated

after attaching.

CAUTION

Be careful not to mix the fixing bolts each other.

5. About the engine

113

56. Attach the alternator bracket.

DV2213056A

1) Attach the alternator(D).

2) Tighten the fixing bolts(C) at a tightening torque

7.0kgf

0.5kgf

3) Attach the eyebolt(B).

4) Tighten the fixing bolt(A) at a tightening torque

2.2kgf

0.33kgf

57. Attach the alternator.

DV2213055A

1) Attach the alternator(C).

2) Tighten the fixing bolt(B).

3) Tighten the fixing nut(A) at a tightening torque

2.2kgf

0.33kgf

58. Adjust the tension after attaching the V-belt.

DV2213054A

1) Attach the V-belt and then adjust the tension with

turning the adjusting nut(B).

2) Attach the V-belt and then adjust the tension with

turning the adjusting nut(A).

59. Attach the cooling fan.

DV2213052A

1) Attach the cooling fan(B).

2) Tighten 6 fixing bolts(A).

60. Inject the coolant.

1) The mixing ratio for the engine coolant is 40% anri-

freeze and 3~5% additives (DCA4) to prevent corro-

sion.

2) Add the coolant of the correct mixing ratio.

CAUTION

Use coolant recommended by Doosan.

6. Cooling system

117

General information

General Information

This engine is water-cooled. It uses coolant to cool the

engine by absorbing heat from the combustion chamber

and the engine oil and then releases the heat, allowing

for normal engine operation.

In this cooling system, coolant provided by the coolant

pump flows into the oil cooler through the coolant pipe

to absorb oil heat and passes through the coolant jacket

of the cylinder block and the cooling path of the cylinder

head to absorb the combustion heat.

Coolant which absorbed the oil and combustion heat

flows into the water temperature controller through the

coolant pipe. If the coolant temperature is lower than the

valve-opening temperature of the water temperature

controller, the coolant flows into the coolant pump. If

higher, it flows into the radiator. The radiator releases the

heat absorbed from the coolant and sends the coolant to

the coolant pump again.

DV2213098A

Specifications

Detail

Jacket

Heater

Port

M30

Jacket

Heater

Detail

Jacket

Heater

Port

M30

From

Jacket

Heater

OIL

OOLER

HEATER

LINDER

BLO

AIR

VENT

WATER

PUMP

PASS

THERMOSTAT
OPENING

Temperture

AIR

FLOW

WATER

RADIATOR

FILER

Positive

Pressure

kPa

Negative

Pressure

kPa

Item

DP158L

Remarks

DP158LCS

DP158LCF

DP158LDS

DP158LDF10

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)

6. Cooling system

118

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.

(

Cooling fan

Type

Blow Type

Diameter -
blades

915mm - 7 blades

Item

DP180L

Remarks

DP180LBS

DP180LBF

DP180LAS

DP180LAF

Cooling System

Cooling method

Fresh water forced circulation

Coolant capac-
ity (L)

Engine only

Approx. 21

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.

(

Cooling fan

Type

Blow Type

Diameter -
blades

915mm - 7 blades

Item

DP158L

Remarks

DP158LCS

DP158LCF

DP158LDS

DP158LDF10

6. Cooling system

119

Item

DP222L

Remarks

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

Cooling System

Cooling method

Fresh water forced circulation

Coolant
capacity (L)

Engine only

Approx. 23

With radiator

Approx. 114 (Air on 43°C) / Approx 125 (Air on 52°C)

Coolant flow rate (L/min)

660

550

660

550

Pressure cap (kPa)

Max. 49

Water tem-

perature (

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. (

Cooling fan

Type

Blow Type

Diameter -
blades

915mm - 9 blades

6. Cooling system

120

Failure Diagnosis

Phenomenon

Causes

Troubleshooting

Overheated engine

Not enough coolant

Replenish the coolant

Defective radiator cap

Replace it

Contaminated radiator

Clean the exterior of the radiator

Defective V-belt offset

Adjust or replace it

Contaminated or damaged V-belt

Replace it

Damaged impeller

Replace the coolant pump

Defective impeller fix

Replace the coolant pump

Bad coolant pump operation

Replace it

Bad water temperature controller operation

Replace it

Bad coolant flow

Clean the coolant path

Improper injection time

Check it with the failure diagnosis
unit

Damaged cylinder head gasket

Replace it

Overcooled engine

Bad water temperature controller operation

Replace it

Too low ambient temperature

Heat the block

Leaking coolant

Damaged radiator

Repair or replace it

Loosened or damaged radiator connection

Repair or replace the connection

Defective radiator cap

Replace it

Badly mounted coolant pump

Repair or replace it

Bad or damaged coolant pump gasket

Replace the gasket

Badly mounted water temperature controller

Repair or replace it

Bad or damaged water temperature controller
gasket

Replace the gasket

Damaged cylinder head gasket

Replace the gasket

Damaged cylinder head or block

Replace it

Noise

Bad coolant pump bearing

Replace the bearing

Bad or damaged cooling fan

Repair or replace it

Bad rotation of the cooling fan

Replace it

Defective V-belt offset

Adjust or replace it

6. Cooling system

121

Thermostat

General Information

The thermosatat maintains water temperature in the

engine consistently and prevents heat loss to improve

heat efficiency of the engine.

When the coolant temperature is below the normal

temperature, the thermostat is closed and the coolant is

bypassed and directly flows into the water pump. When

the coolant temperature reaches the normal temperature

or is higher than the temperature, the thermostat is fully

open and the bypass circuit is closed. So the coolant

flows into the radiator.

DV2213099A

Check of the thermostat

1. Check whether the wax pellet and the spring are

damaged or not.

2. Put the water temperature controller into water and

heat the water slowly to check water temperature

controller operation.

3. The water temperature controller is normal in the

following case: it starts to be open at the water

temperature of 82°C and it is fully open at the water

temperature of 97

DV2213100A_E

4. Check if there is any foreign substance in the water

temperature controller.

Note) Clean the inside of the water temperature controller

with an air gun.

5. Check if there are any foreign substance or damage

part inside and outside of the hose.

CAUTION

•

The wax pellet type thermostat shows slower

response to the change of cooling water than the

bellows type thermostat. This happens because

the heat capacity of the wax pellet type water

temperature controller is larger than that of the

bellows type water temperature controller. There-

fore, to prevent rapid increase of engine coolant

temperature, you must first operate the engine at

idle until the engine is fully warmed up. When the

weather is very cold, do not operate the engine

in an overloaded condition or at high speed after

starting the engine.

•

When draining water from the engine cooler or

injecting water to the engine cooler, work slowly

to let the air in the cooler is fully exhausted.

•

When a defect is found in the water temperature

controller, replace it with a new one.

1. Heat exchanger

3. Coolant pump

2. Bypass valve

4. Coolant pipe

Themometer

Bar

Woo

Plate

7. Lubrication system

125

General information

General Information

This engine is the forced lubrication type of engine. Oil

pressure is generated and delivered by rotating the gear

of the oil pump which is directly engaged with the crank-

shaft gear on the front of the cylinder block.

The oil pump delivers oil sucked from the oil pan with

the suction pipe to the main path of the cylinder block

through the oil cooler and oil filter.

From the cylinder block, oil is delivered to the crankshaft

bearings, camshaft bearings, and rocker arm for lubrica-

tion.

In addition, the turbocharger is connected to the engine

lubrication circuit. Around the cylinder block and the

timing gear, lubricating oil is dispersed. Each cylinder has

an oil injection nozzle for cooling the bottom of the piston.

Engine oil is filtered through the oil filter and purified.

DV2213101A

Specifications

Item

DP158L

Remarks

DP158LCS

DP158LCF

DP158LDS

DP158LDF10

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

7. Lubrication system

126

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

Item

DP180L

Remarks

DP180LBS

DP180LBF

DP180LAS

DP180LAF

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

Item

DP222L

Remarks

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

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.

Item

DP158L

Remarks

DP158LCS

DP158LCF

DP158LDS

DP158LDF10

7. Lubrication system

127

Failure Diagnosis

Lubrication
oil pressure
(kPa)

Idle speed

Min. 100

Governed
speed

Min. 250

Max. oil temperature (

120

Oil specifica-
tion

Oil class

above API CD

SAE

15W/40

Item

DP222L

Remarks

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

Phenomenon

Causes

Troubleshooting

Too much oil consumption

Bad oil

Replace oil with specified oil.

Oil leakage from the oil seal ring and packing part Replace it

Worn or damaged piston and piston ring

Replace it

Worn cylinder liner

Replace it

Burnt piston ring

Replace it

Worn valve guide oil seal, valve guide, or valve
stem

Replace it

Low oil pressure

Bad oil

Replace oil with specified oil.

Burnt oil pump relief valve

Replace it

Clogged oil pump strainer

Cleanse the strainer

Worn oil pump gear

Replace it

Cracked oil delivery pipe of the oil pump

Replace it

Defect oil pump

Repair or replace it

Oil pressure gauge fault

Repair or replace it

Worn bearings

Replace it

Contaminated oil

Clogged oil filter

Replace the oil filter with a new
one

Gas leakage

Replace piston ring with a new one

Bad oil

Replace oil with specified oil.

8. Fuel system

131

General information

General Information

The fuel is supplied by the fuel delivery pump through

fuel filter to the fuel injection pump which delivers the fuel

to the fuel injection nozzle.

The fuel is injected to the cylinder through the nozzle

assembled to the fuel injection nozzle holder of the

cylinder head.

Over-supplied fuel returns to the fuel tank through the

return pipe.

DV2213102B

The fuel lines should have a sufficient inner diameter.

The fuel lines should be routed so that the fuel is not

excessively heated by the heat radiation from the engine.

The pipes should be laid as straight as possible without

sharp bends. Make sure the pipes are protected against

mechanical wear and well fastened to avoid vibrations.

It is important that there are no fuel leakages or air infil-

tration neither on the suction or return line installation.

Therefore securely fasten all the connections of fuel line.

The return line back to the fuel tank must not be adjoin

the suction line.

In case of diesel fuel containing high water content due

to insufficient fuel quality, maintenance difficulty or envi-

ronmental adversity, an extra water separator with

adequate capacity must be installed as user supply

scope.

High Sulfur content in diesel fuel

Doosan diesel engines can be operated with fuels Whose

sulfur content is max. 0.05wt%.

Fuels with a sulfur content of > 0.05wt% are not

Permitted as they result in increased corrosion and Hence

greatly reduce the service life of the engines.

The oil and oil filter change intervals must be halved If

the sulfur content is > 0.02wt%.

ser

upply

oosan

upply

8. Fuel system

132

Water (Moisture) in diesel fuel

Water in the fuel causes;

•

Incomplete combustion

•

lammed or clogged nozzle

•

Damaged to the injection pump

•

Piston damage

•

Destruction of engine

In case of diesel fuel containing high water content due

to insufficient fuel quality, maintenance difficulty or envi-

ronmental adversity, an extra water separator with

adequate capacity must be installed as user supply

scope.

Specifications

Item

DP158L

Remarks

DP158LCS

DP158LCF

DP158LDS

DP158LDF10

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

Item

DP180L

Remarks

DP180LBS

DP180LBF

DP180LAS

DP180LAF

Fuel System

Injection pump

Bosch in-line "P" type

Governor

Electric type

Fuel feed
pump

Type

Mechanical type injection pump

Capacity (L/hr)

630

Injection nozzle

Type

Multi-hole (4 hole)

Opening pres-
sure (MPa)

Fuel filter

Full flow, Cartridge type with water drain valve

Fuel Used

Diesel fuel oil

Item

DP222L

Remarks

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

Fuel System

Injection pump

Bosch in-line "P" type

8. Fuel system

133

Failure Diagnosis

Governor

Electric type

Fuel feed
pump

Type

Mechanical type injection pump

Capacity
(L/hr)

630

Injection noz-
zle

Type

Multi hole type

Opening pres-
sure (MPa)

Fuel filter

Full flow, Cartridge type with water drain valve

Fuel Used

Diesel fuel oil

Item

DP222L

Remarks

DP222LAS

DP222LBS

DP222LBF

DP222LCS

DP222LCF

Symptom

Causes

Troubleshooting

1. Engine does not start
A. Fuel is not supplied from
the fuel delivery pump

B. Fuel is not injected from
the fuel injection pump

C. Improper fuel injection tim-
ing

D. Fuel injection nozzle not
working

•

Clogged fuel pipe, or air entered the fuel pipe line

•

Defective delivery pump valve

•

Seized delivery pump piston or push rod

•

Correct

•

Replace

•

Disassemble / correct

•

Clogged fuel filter cartridge

•

Air entered to the fuel filter or injection pump

•

Seizure or defect in the plunger or delivery valve

•

Clean / replace

•

Bleed

•

Disassemble / correct

•

Defective installation of fuel injection pump bracket

•

Defective adjustment of the fuel injection pump

tappet

•

Excessively worn cam of camshaft

•

Inspect / correct

•

Inspect / correct

•

Replace

•

Seizure of needle valve of nozzle

•

Fuel leakage between nozzle and needle valve

•

Improper fuel injection pressure

•

Service or replace

•

Service or replace

•

Adjust

2. Engine starts but stops
immediately

•

Clogged fuel filter or clogged pipe between fuel

delivery pump and injection pump

•

Air entered into fuel

•

Insufficient supply of oil by fuel delivery pump

•

Clogged air breather in fuel tank, causing insuffi-

cient fuel supply.

•

Clean or replace

•

Air bleeding

•

Disassemble / correct

•

Replace breather

3. Insufficient engine power

•

Excessively work plunger

•

Improper injection timing

•

Defective delivery valve

•

Excessive fuel leakage in injection nozzle

•

Nozzle not working properly

•

Replace

•

Adjust

•

Replace

•

Service or replace

•

Disassemble / correct

4. Engine knocking occurs

•

Early injection timing

•

High nozzle injection pressure

•

Nozzle not working properly

•

Adjust

•

Adjust

•

Disassemble / correct

8. Fuel system

134

5. Excessive engine smoke
and knocking

•

Defective injection timing

•

Too low nozzle injection pressure

•

Broken nozzle spring

•

Nozzle not working properly

•

Excessively work plunger

•

Defective delivery valve seat

•

Excessive fuel supply

•

Adjust

•

Adjust

•

Replace it

•

Replace it

•

Adjust

•

Replace it

•

Check feed pump

6. Unstable engine power

•

Insufficient fuel supply

•

Air entered into fuel

•

Water entered into fuel

•

Defective plunger operation

•

Defective actuator operation

•

Defective nozzle

•

Injection start pressure different between cylinders

•

Defective controller

•

Check feed pump

•

Air bleeding

•

Replace fuel

•

Disassemble / correct

•

Disassemble / correct

•

Disassemble / correct

•

Adjust

•

Adjust

7. Engine cannot reach the
max. speed

•

Nozzle not working properly

•

Defective operation of actuator or controller

•

Disassemble / correct

•

Adjust

8. Unstable engine idling

•

Defective controller operation

•

Defective plunger operation

•

Defective magnetic pickup sensor

•

Adjust

•

Disassemble / correct

•

Inspect or replace

Symptom

Causes

Troubleshooting

GENERATOR DIESEL ENGINE DP158LCF/LCS/LDF/LDS, DP180LBS/LAS/LBF/LAF, DP222LAS/LBF/LBS/LCF/LCS. Maintenance Manual - page 3