Doosan DV11 Operation And Maintenance Manual

PS-MMG0717-E1B

Operation and
Maintenance Manual

Diesel Engine

DV11

65.99897-8098A

DV11

Operation and Maintenance

Printed in Mar. 2005 PS-MMA0608-E1A

FOREWORD

This maintenance manual is designed to serve as a reference for DOOSAN Infracore (here
after DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN's DV11 Diesel engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for the overland transport
or industrial purpose. That meets all the requirements such as low noise, fuel economy, high
engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.

Removal Adjustment

Installation Cleaning

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental
damage;

z Take old oil to an old oil disposal point only.
z Ensure without fail that oil and diesel fuel will not get into the sea or rivers and

canals or the ground.

z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and

cartridges as special waste.

z The regulations of the relevant local authorities are to be observed for the

disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.

Apr. 2005

DV11

Operation and Maintenance

Printed in Mar. 2005 PS-MMA0608-E1A

CONTENTS

1. Safety regulations & engine specifications

1.1. Safety regulations 1

1.2. Engine specifications 6

1.3. Engine power 8

1.4. Performance curve 9

1.5. Engine assembly 14

2. Technical information

2.1. Engine model and serial number 18

2.2. Diagnostic tool (SCAN-200) 18

2.3. Engine characteristic 19

2.4. Diagnosis and remedy 42

2.5. Engine inspection 52

3. Maintenance

3.1. Engine disassembly 54

3.2. Measurement and inspection on major parts 69

3.3. Reassembly 90

3.4. Fuel injection system 115

3.5. Electrical system 129

3.6. Engine brake 142

3.7. Engine diagnostic 153

3.8. Engine control unit (ECU) 158

4. Commissioning and operation

4.1. Preparations 179

4.2. Operation of a new engine (Break-in) 179

4.3. Inspections after Starting 166

4.4. Operation in winter time 168

4.5. Tuning the engine 170

4.6. Maintenance and care 171

4.7. Cooling system 173

4.8. Adjustment of valve clearance 176

4.9. Tightening the cylinder head bolts 178

5. Maintenance of major components

5.1. Cooling system 180

5.2. Lubrication system 184

5.3. Turbo charger 187

5.4. Air cleaner 196

5.5. Belt 198

6. Special tool list 203

● Appendix

● Worldwide network

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Safety regulations & specifications

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1. Safety Regulations & Specifications

1.1. Safety Regulations

1.1.1. General notes

z Day-to-day use of power engines and the service products necessary for running

them presents no problems if the persons occupied with their operation,

maintenance and care are given suitable training and think as they work.

z This summary is a compilation of the most important regulations, These are

broken down into main sections which contain the information necessary for

preventing injury to persons, damage to property and pollution. In addition to

these regulations those dictated by the type of engine and its site are to be

observed also.

IMPORTANT:

If despite all precautions, an accident occurs, in particular through contact

with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being

splashed in the eyes etc, consult a doctor immediately.

1.1.2. To prevent accidents with injury to persons

(1) Engine starting and operation

z Before putting the engine into operation for the first time, read the operating

instructions carefully and familiarize yourself with the “critical” points. If you

are unsure, ask your DOOSAN representative or service man.

z For reason of safety we recommend you attach a notice to the door of the

engine room prohibiting the access of unauthorized persons and that you

draw the attention of the operating personal to the fact that they are

responsible for the safety of person who enter the engine room.

z The engine must be started and operated only by authorized personnel.

z Ensure that the engine cannot be started by unauthorized person.

z When the engine is running, do not get too close to the rotating parts.

z Do not touch the engine with bare hands when it is warm from operation risk

of bums.

z Exhaust gases are toxic. If it is necessary to run an engine in an enclosed

area, remove the exhaust gases from the area with an exhaust pipe

extension.

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Safety regulations & specifications

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(2) Maintenance and care

z Always carry out maintenance work when the engine is switched off. If the

engine has to be maintained while it is running, e.g. changing the elements of

change-over filters, remember that there is a risk of scalding. Do not get too

close to rotating parts.

z Change the oil when the engine is warm from operation.

CAUTION:

There is a rise of burns and scalding. Do not touch oil drain plug or oil filters

with bare hands.

z Take into account the amount of oil in the sump. Use a vessel of sufficient

size to ensure that the oil will not overflow.

z If change or refill the cooling water, disassemble the drain plug when the

engine has cooled down. Heated cooling water has the risk of scalding and

safety accidents.

z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit

and any additional hydraulic oil circuit) during the operation. The fluids which

flow out can cause injury.

z Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank

must be filled only when the engine is switched off.

z Keep service products (anti-freeze) only in containers which can not be

confused with drinks containers.

z Comply with the manufacturer's instructions when handling batteries.

CAUTION:

Accumulator acid is toxic and caustic. Battery gases are explosive.

Therefore it should be done by an expert of the handling professionally.

(3) When carrying out checking, setting and repair work

z Checking, setting and repair work must be carried out by authorized

personnel only.

z Use only tools which are in satisfactory condition. Slip caused by the worn

open-end wrench could lead to injury.

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Safety regulations & specifications

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z When the engine is hanging on a crane, no-one must be allowed to stand or

pass under it. Keep lifting gear in good condition.

z When do electric weld, stop the engine, power off, then remove the wire

harness’ connector which is connected to the ECU.

z Do not weld the electric control unit (ECU) absolutely, and do not damage on

it by electrical or mechanical shock.

z When working on the electrical system disconnect the battery earth cable

first. Connect it up again last in prevent short circuits.

1.1.3. To prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended

purpose.

Detailed information on this can be found in the sales literature. Engine control

unit must not be adjusted without prior written permission of DOOSAN.

(2) If faults occur, find the cause immediately and have it eliminated in order to

prevent more serious of damage.

(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility

for damage resulting from the installation of other parts which are supposedly

"just as good”.

(4) In addition to the above, note the following points.

z Never let the engine run when dry, i.e. without lube oil or coolant.

z Pay attention to cleanliness. The Diesel fuel must be free of water.

z Use only DOOSAN approved service products (engine oil, anti-freeze and

anticorrosion agent)

z Refer to the subjects of recommendation of the fuel.

z Have the engine maintained at the specified intervals.

z Do not switch off the engine immediately when it is warm, but let it run without

load for about 5 minutes so that temperature equalization can take place.

z Never put cold coolant into an overheated engine.

z Do not add so much engine oil that the oil level rises above the max. marking

on the dipstick. Do not exceed the maximum permissible tilt of the engine.

z Always ensure that the testing and monitoring equipment (for battery charge,

oil pressure, coolant temperature) function satisfactorily.

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Safety regulations & specifications

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z Do not let the raw water pump run dry. If there is a risk of frost, drain the

pump when the engine is switched off.

1.1.4. To prevent pollution

(1) Engine oil, filter elements, fuel filters

z Take old oil only to an oil collection point.

z Take strict precautions to ensure that oil does not get into the drains or into

the ground. The drinking water supply could be contaminated.

z Filter elements are classed as dangerous waste and must be treated as such.

(2) Coolant

z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.

z When disposing of spent coolant comply with the regulations of the relevant

local authorities.

1.1.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil

decreases the skin.

Drying, irritation or inflammation of the skin may therefore occur. Used engine oil

also contains dangerous substances which have caused skin cancer in animal

experiments. If the basic rules of hygiene and health and safety at work are

observed, health risks are not to the expected as a result of handling used engine oil

.

< Health precautions >

z Avoid prolonged or repeated skin contact with used engine oil.

z Protect your skin by means of suitable agents (creams etc.) or wear protective

gloves.

z Clean skin which has been in contact with engine oil.

- Wash thoroughly with soap and water.

- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

z After washing apply a fatty skin cream to the skin.

z Change oil-soaked clothing and shoes.

z Do not put oily rags into your pockets.

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Safety regulations & specifications

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CAUTION:

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply.

For this reason do not let engine oil get into the ground, waterways, the drains or the

sewers. Violations are punishable. Collect and dispose of used engine oil carefully.

For information on collection points please contact the seller, the supplier or the local

authorities.

1.1.6. General repair instructions

1. Before performing service operation, disconnect the grounding cable from the

battery for reducing the chance of cable damage and burning due to short-

circuiting.

2. Use covers for preventing the components from damage or pollution.

3. Engine oil and anti-freeze solution must be handled with reasonable care as they

cause paint damage.

4. The use of proper tools and special tools where specified is important to efficient

and reliable service operation.

5. Use genuine DOOSAN parts necessarily.

6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should

be discarded and new ones should be prepared for installation as normal function

of the parts can not be maintained if these parts are reused.

7. To facilitate proper and smooth reassemble operation, keep disassembled parts

neatly in groups. Keeping fixing bolts and nut separate is very important as they

vary in hardness and design depending on position of installation.

8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using

compressed air to make certain they are free from restrictions.

9. Lubricate rotating and sliding faces of parts with oil or grease before installation.

10. When necessary, use a sealer on gaskets to prevent leakage.

11. Carefully observe all specifications for bolts and nuts torques.

12. When service operation is completed, make a final check to be sure service has

been done property.

13. Work the fuel line after the common rail pressure and engine temperature is

checked with the SCAN-200. (past about 5 minutes after engine stop)

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Safety regulations & specifications

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1.2. Engine Specifications

Engine model

Items

DV11

Engine type

Water-cooled, 4 cycle V-type 90°, Turbo charged &

intercooled

Combustion chamber type Direct injection type

Cylinder liner type Wet type

Timing gear system Gear driven type

No. of piston ring 2 compression ring, 1 oil ring

No. of cylinder-bore x stroke (mm) 6 – 128 × 142

Total piston displacement (cc) 10,964

Compression ratio 17.1 : 1
Engine dimension

(length x width x height) (mm)

1,206 x 1,031 x 1,070

Engine weight (kg) 904

Rotating direction (from flywheel) Counter clockwise

Firing order 1 – 4 – 2 – 5 – 3 - 6

Fuel high pressure pump type Bosch CP3.4 fuel high pressure pump type

Engine control type Electric control type(ECU)

Injector type

Multi-hole(8 x φ0.197 Bosch DLLA146)

Fuel injection pressure (kg/cm2) 250bar (operating pressure 1,600bar)

Intake valve 0.4
Exhaust valve 0.5

Valve clearance

Jake brake 1.5
Open at

24° (B.T.D.C)

Intake valve

Close at

30° (A.B.D.C)

Open at

52.5° (B.B.D.C)

Exhaust valve

Close at

14.5° (A.T.D.C)

Fuel filter type Full-flow (cartridge)

at idle speed 1.0 ~ 3.0 Oil pressure

(kg/cm

2

)

at rated speed 3.0 ~ 5.5
Using lubrication oil ACEA-E5 (API CI-4 class)
Lubrication method Full forced pressure feed type

Oil pump type Gear type driven by crankshaft

Oil filter type Full-flow, paper element type(double)

Lubricating oil capacity (max./min.) (lit) Bus : 34/ 26 , Truck : 32/ 26
Oil cooler type Water cooled

Oil pressure indicator Oil pressure unit
Water pump Belt driven centrifugal type

Cooling method Pressurized circulation

Cooling water capacity(engine only) (lit) 14.3

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Safety regulations & specifications

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Engine model

Items

DV11

Type

Wax pallet type (79 ∼ 94 °C)
Open at (°C) 83 °C
Open wide at (°C) 95 °C

Thermostat

Valve lift (mm) 8

Water temperature indicator Water temperature sensor mounted

Type Water cooled
Capacity (cc/rev) 550 (275 × 2 each)

Air compressor

Revolution ratio 1 : 1.265 (Engine speed : Air compressor speed)
Type Gear driven, vane type
Capacity (l/min) 16 / 18 / 25
Adjusting pressure
(kg/cm

2

)

125 / 150

Power steering
pump

Revolution ratio 1 : 1.265 (engine speed : pump speed)

Turbo charger Exhaust gas driven type (waste gate)
Engine stop system Fuel feeding shut-off by ECU

Engine brake Control by ECU

Alternator (voltage – capacity) (V - A) 24 - 60 or 24 – 150

Starting motor(voltage – output) (V-kW) 24 – 6.0

Air heater capacity (V – A) 24V – 2.64 kW

Battery capacity (V - AH) 20 - 150

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Safety regulations & specifications

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1.3. Engine Power

tolerance : ±5%

Engine model Performance

Model Suffix

Power

(PS / rpm)

Torque

(kg.m / rpm)

Low idle

(rpm)

High idle

(rpm)

Remark

EUJBA W/ Jake brake

EUJBE

380 / 1,800 173 / 1,200 600 2,120↓

W/o Jake brake

EUJBB W/ Jake brake

EUJBF

340 / 1,800 145 / 1,200 600 2,120↓

W/o Jake brake

EUJBC W/ Jake brake

EUJBG

360 / 1,800 160 / 1,200 600 2,120↓

W/o Jake brake

EUJBD W/ Jake brake

EUJBH W/o Jake brake

EUJBL

400 / 1,800 173 / 1,200 600 2,120↓

W/ Retarder

EUJBI W/ Retarder

EUJBJ W/ Jake brake

EUJBK

420 / 1,800 187 / 1,200 600 2,120↓

W/o Jake brake

EUJCA
EUJCB

420 / 1,800 187 / 1,200 600 2,120↓

W/ Jake brake

EUJCC W/o Jake brake

EUJCI

380 / 1,800 160 / 1,200 600 2,120↓

W/ Jake brake

EUJCD W/o Jake brake

EUJCJ

345 / 1,800 145 / 1,200 600 2,120↓

W/ Jake brake

EUJCF W/ Jake brake

EUJCH

420 / 1,800 187 / 1,200 600 2,120↓

W/ Jake brake

EUJXA W/o Jake brake

DV11

EUJXB

380 / 1,800 160 / 1,200 600 2,120↓

W/ Jake brake

* Note : All data are based on operation without cooling fan at ISO 1585(SAE J1349)

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Safety regulations & specifications

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1.4. Engine Performance Curve

1.4.1. Performance curve (340PS)

Performance ISO 1585 (SAE J1349)

Output (max.) 250 kW (340PS) / 1,800 rpm

Torque (max) 1,423 N.m (145 kg.m) / 1,200 rpm

Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)

Revolution (rpm)

Output (PS)

Torque (kg.m)

Fuel consumption (g/ps.h)

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Safety regulations & specifications

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1.4.2. Performance curve (360PS)

Performance ISO 1585 (SAE J1349)

Output (max.) 265 kW (360PS) / 1,800 rpm

Torque (max) 1,570 N.m (160 kg.m) / 1,200 rpm

Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)

Revolution (rpm)

Output (PS)

Torque (kg.m)

Fuel consumption (g/ps.h)

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Safety regulations & specifications

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1.4.3. Performance curve (380PS)

Performance ISO 1585 (SAE J1349)

Output (max.) 280 kW (380PS) / 1,800 rpm

Torque (max) 1,570 N.m (160 kg.m) / 1,200 rpm

Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)

Revolution (rpm)

Output (PS)

Torque (kg.m)

Fuel consumption (g/ps.h)

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Safety regulations & specifications

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1.4.4. Performance curve (400PS)

Performance ISO 1585 (SAE J1349)

Output (max.) 294 kW (400PS) / 1,800 rpm

Torque (max) 1,697 N.m (173 kg.m) / 1,200 rpm

Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)

Revolution (rpm)

Output (PS)

Torque (kg.m)

Fuel consumption (g/ps.h)

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Safety regulations & specifications

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1.4.5. Performance curve (420PS)

Performance ISO 1585 (SAE J1349)

Output (max.) 309 kW (420PS) / 1,800 rpm

Torque (max) 1,834 N.m (187 kg.m) / 1,200 rpm

Fuel consumption (min.) 203 g/kW.h (149 g / PS.h)

Revolution (rpm)

Output (PS)

Torque (kg.m)

Fuel consumption (g/ps.h)

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Safety regulations & specifications

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1.5. Engine Assembly

1.5.1. Engine sectional view (longitudinal)

1 Vibration damper 7 Power steering pump
2 Thermostat 8 Oil seal
3 Exhaust valve 9 Fly wheel
4 Push rod 10 Crank shaft
5 Tappet 11 Oil pump
6 Air compressor

1

2

3 4 5

6

7

8

9

10 11

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Safety regulations & specifications

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1.5.2. Engine sectional view (cross)

1 Starting motor 8 Injector
2 Oil cooler 9 Oil spray nozzle
3 Cylinder block 10 Connecting rod
4 Cylinder head 11 Electric control unit (E.C.U)
5 Engine brake 12 Oil drain plug
6 Fuel high pressure pump 13 Oil suction pipe
7 Common rail

1

2

3

4

5

6 7

8

9

10

11

12 13

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Safety regulations & specifications

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1.5.3.

Engine assembly (Bus engine)

1 Crank shaft pulley 9 Exhaust manifold 18 Air pipe
2 Oil filter 10 Mounting bracket (rear)

( turbocharger to intercooler

3 Water pump pulley 11 Flywheel housing 19 Air heater
4 Idle pulley 12 Mounting bracket (front) 20 Air pipe
5 Water outlet 13 Oil pan 21 Cylinder head cover
6 Fuel filter 14 Electric control unit (ECU) 22 Oil filler cap
7 Air pipe 15 Power steering pump 23 Water inlet

(Air cleaner to turbocharger)

16 Air compressor 24 Starting motor

8 Breather 17 Turbocharger 25 Oil cooler

15

16

17

18 19 20

21

22

23

2524

12 13 14

11

10

9

8

6

5

4

3

2

1

7

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Safety regulations & specifications

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1.5.4.

Engine assembly (Truck engine)

1 Power steering pump 9 Fan guide 18 2nd fuel filter
2 Air compressor 10 Cooling fan 19

Air pipe

3 Exhaust outlet 11 Starter

(Air filter to intake manifold)

4 Turbo charger 12

Exhaust manifold

20 Breather

5

Oil filler cap

13 Water inlet 21

Crank shaft speed sensor

6

Intake manifold

14

Oil filter

22

Exhaust manifold

7 Air heater 15 Primary fuel filter 23 Air con compressor
8

Air pipe

16 Boost pressure sensor 24 Alternator

(Air cleaner to Turbocharger)

17 Fuel priming pump 25 Electric control unit(ECU)

1

2

3

4 5 6 7

8

9

10

11 12 13

14

15

16

17

18

19

20

21

22

23 24 25

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Technical Information

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2. Technical Information

2.1. Engine Model and Serial Number

z The engine model and serial

number is located on the engine

as illustrated.

z These numbers are required

when requesting warranty and

ordering parts. They are also

referred to as engine model and

serial number because of their

location.

z Engine serial No. (example 1 : DV11)

DV11 5 00001 BA

z Engine serial No. (example 2 : DV11)

DV11 5 00001 CA

2.2. Diagnostic tool (SCAN-200)

The SCAN-200 is a powerful tool to

support the service personal

diagnosing and repairing of electric

system for vehicle with installed DV11

engine.

<

SCAN-200 tool>

z High resolution digital type display.

z Soft touch key-board.

Engine number

(located the cylinder block)

Engine model suffix (EUJBA)
Serial no.
Production year (2005)
Engine model

Engine model suffix (EUJCA)
Serial no.
Production year (2005)
Engine model

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Technical Information

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z Diagnosis trouble code or sensor

data operation via help.

z Large memory expansion ROM

pack data storage area for flight

recorded data.

NOTE:

Inspect the electrical parts problem

with SCAN-200 and refer diagnostic

manual.

2.3. Engine Character

z DOOSAN ‘s DV11 diesel engine apply the over head valve and the turbocharger,

is the electric control engine of the air cooling type by the cooling fan.󰼿

z The fuel is stored under pressure in the high-pressure accumulator (the "Common

Rail") ready for injection. The injected fuel quantity is defined by the driver, and

the start of injection and injection pressure are calculated by the ECU on the

basis of the stored map. The ECU then triggers the solenoid valve sensor that the

injector (injection unit) at each engine cylinder injects accordingly.󰼿

z Oil gallery cooling is used for the

piston of the engine. The design of

the gallery, the design and location

of the oil spray nozzle and the

quantity of oil flowing in the gallery

are critical in order to achieve the

desired temperature reduction. The

cross section shape of the gallery

should be designed to achieve

sufficient oil movement to

maximize cooling efficiency.󰼿

Truck engine

(CB-96-0063)

Bus engine

(015-M1010)

Diagnostic tool

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Technical Information

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2.3.1. Cylinder block

z The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is

extended to a level below the crankshaft center line. The engine has replaceable

wet cylinder liners and individual cylinder heads.

2.3.2. Piston/ Connecting rod/ Crank assembly

z The forged crankshaft has screwed-on the balance weights. Radial seals with

replaceable wearing rings on crankshaft and flywheel are provided to seal the

crankcase penetrations.

z The connecting rods are die-forged, diagonally split and can be removed through

the top of the cylinders together with the pistons. Crankshaft and connecting rods

run in steel-backed lead bronze ready-to fit type bearings.

2.3.3. Electric control unit : ECU

z This electric control unit is used to

control the engine feed fuel.

z ECU is connected with various

sensors, control the engine to keep

the optimum condition on the basis

of input values from this sensors.

CAUTION:

Do not connect or disconnect the ECU to/from the wiring harness without

first removing the negative (-) battery cable from the battery. Do not perform

remove the inner parts of ECU.

󰼿
󰼿

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Technical Information

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2.3.4. Common rail system

z Pressure generation and fuel injection are completely decoupled from each

other in the "Common Rail" fuel injection system. The injection pressure is

generated independent of engine speed and injected fuel quantity stored in the

ECU.

No. 3 injector

No. 2 injector

No. 1 injector

Pressure limiter

valve

No. 6 injector

No. 4 injector

No. 5 injector

Common rail
pressure sensor

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Technical Information

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2.3.5. Engine timing

z Camshaft, oil pump, air compressor, steering pump, and fuel high pressure pump

are driven by a gear train arranged at the inside of flywheel housing.

2.3.6. Valves

z The overhead valves are actuated via tungsten carbide tappets, push rods and

rocker arms from the camshaft.

High pressure pump

gear (Z=24)

Power take off(PTO) gear

(Z=40)

Air compressor gear

Power steering pump

(Z=34)

Crank shaft gear

(Z=43)

Oil pump drive gear

(Z=44)

Cam shaft gear

(Z=86)

High pressure pump drive gear

(Z=80)

Viewed from crankshaft pulley

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Technical Information

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2.3.7. Lubrication system

z The engine is equipped with force-feed lubrication. The pressure is produced by a

gear pump whose drive gear is in direct mesh with the crankshaft gear at the

flywheel end.

z The oil pump draws the oil from the oil sump and delivers it through the oil cooler

and oil filter to the main distributor gallery and from there to the main bearings,

big-end bearings and camshaft bearings as well as to the small-end bearings and

the rocker arms. The turbocharger is also connected to the engine lubricating

system. The cylinder walls and timing gears are splash-lubricated.

z Each cylinder has an oil jet provided for cooling the underside of the pistons. The

lube oil is cleaned in a full-flow oil filter.

To Engine brake

To Engine brake

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2.3.8. Engine oil

z Check oil level with the oil level gauge and replenish if necessary.
z Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ∼

10 minutes for oil drain into the crankcase before checking oil level. The oil level

must be between Max. and Min. lines on the gauge.

z Engine oil should be changed at the specified intervals. Oil filter cartridge should

be changed simultaneously.

- First oil change : After 5,000km operating

First oil change After 5,000km operating

1 day operating distance 500km less

(Bus, truck)

After once replenishment,

every 40,000km

1 day operating distance 500km more

(Bus, truck)

After once replenishment,

every 60,000km

z The following oils are also recommended.

Engine oil SAE No. API No.

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SAE 10W40

ACEA-E5

(API CI-4)

󰼿

z Engine oil capacity

Engine oil capacity

Oil pan inside

Engine model

Max.

(lit)

Min.

(lit)

Total

(lit)

Bus 34 26 37

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Truck 32 26 35

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Operation and Maintenance

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Technical Information

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2.3.9. Oil filter

z Check for oil pressure and oil leaks,

and repair or replace the oil filter if

necessary.

z Change the oil filter cartridge

simultaneously at every

replacement of engine oil.

2.3.10. Fan belt

z Use a fan belt of genuine part, and

replace if damaged, frayed, or

deteriorated.

z Check the fan belt for belt tension,

inspect suitability for specified

dimensions.

Engine oil viscosity – ambient temperature

Ambient

temperature

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- Adjust the tension of poly belt

when pressed down with

specified force (F kg):

T = 0.015 x S

(Deflection : 1.5 mm per 100 mm)

2.3.11. Air cleaner

z In case that elements are

deformed, damaged or if the air

cleaner has a crack, replace it.

(genuine parts use)

z By the definite interval, the

elements must be cleaned and

replaced.

2.3.12. Pre fuel filter

z Drain water in cartridge with

loosening the drain plug under

cartridge manually from time to

time.

z The filter cartridge should be

replaced at every 40,000 km.

2.3.13. Fuel filter

z The filter cartridge should be

replaced at every 40,000 km.

Priming pump

Pre fuel filter &

cartridge

Drain plug

Fuel filter &
cartridge

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2.3.14. Fuel requirements

z DOOSAN diesel engines was designed to use Number 2-D diesel fuel or

equivalent that meets specification

ASTM D (Grade Low Sulfur). For maximum fuel

economy, Number 2-D fuel whenever possible. When temperatures are below -7

°C, use Number 1-D fuel. If Number 1-D fuel is not available, the mixture of one

kerosene to two gallons of Number 2-D fuel can be used. Once kerosene has

been added, the engine should be run for several minutes to mix the fuel.

2.3.15. How to select fuel oil

z Fuel quality is an important factor in obtaining satisfactory engine performance,

long engine life, and acceptable exhaust emission levels. DOOSAN engines are

designed to operate on most diesel fuels marketed today. In low sulfur, fuels

meeting the properties of ASTM Designation D975 (grades 1-D and 2-D : Grade

Low Sulfur) have provided satisfactory performance.

z The ASTM 975 specification, however, does not in itself adequately define the

fuel characteristics needed for assurance of fuel quality.

z The properties listed in the fuel oil selection chart below have provided optimum

engine performance. Grade 2-D fuel is normally available for generator service.

Grade 1-D fuel should not be used in pleasure craft engines, except in an

emergency.