Doosan d34 p scr diesel engine service repair operation maintenance manual

Forward
This Operation and Maintenance Manual provides information on engine management and maintenance techniques to
customers and technicians of Doosan Infracore's DL03-LEF00/LEF01/LEF02/ LEL00/LEL01/LEL02/LEL03 electronically
controlled industrial diesel engine .
To provide the best engine to our customers, the DL03-LEF00/LEF01/LEF02/LEL00/LEL01/LEL02/LEL03 electronically
controlled industrial diesel engine is designed to satisfy all requirements for low noise, economic fuel consumption, high
speed and durability with the latest technology and quality.
Exact operation and proper maintenance are essential for operating engines for an extended time with optimum condi-
tions and best performance. This Operation and Maintenance Manual provides detailed descriptions of specifications,
specified values, defect diagnosis, component diagrams, and drawings for easier and more precise understanding of
the product and for proper maintenance and troubleshooting.
With the help of the recommended operation methods and procedures, high-level maintenance techniques and safety
of workers can be ensured. Please read and understand this manual before working with our engines.
To ensure best performance and quality as well as to enhance maintenance techniques, Doosan Infracore is doing it's
best to continuously develop and invest. The design of our product may be changed without prior notice and Doosan
shall not be held liable for the failure of this manual to contain all the design changes made to improve the product.
We, Doosan Infracore, do our best to provide more convenient and safe maintenance techniques and to meet the
requirements of our customers.
If you have any questions or find any errors in this Operation and Maintenance Manual, please do not hesitate to
contact us.
Thank you for purchasing our engine and we hope this Operation and Maintenance Manual be helpful for you.
2014.10..
950106-01498(C)
Doosan Infracore
* The contents included in the Operation and Maintenance Manual are property of Doosan Infracore. It is forbidden to
copy, print or distribute this manual without prior permission.

Table of contents
1. General introduction ...............................................................................................................1
General information .................................................................................................................................. 3
Danger, warning, caution, and note ....................................................................................................... 4
Engine maintenance ................................................................................................................................. 7
2. Operation and maintenance ...................................................................................................9
Starting and stopping of the engine .................................................................................................... 11
Break-in period of the engine ............................................................................................................... 12
Operation in winter ................................................................................................................................ 14
Inspection and repair of the engine ..................................................................................................... 15
3. Performance and specifications ..........................................................................................17
Engine specifications and performance ................................................................................................ 19
Outside drawing of the engine (DL03-LEF00/LEF01) ......................................................................... 37
Outside drawing of the engine (DL03-LEF02/LEF03) ......................................................................... 41
Outside drawing of the engine (DL03-LEL00/LEL01/LEL02/LEL03/LEL04) ....................................... 45
Engine identification number ................................................................................................................. 49
4. Regular inspection ................................................................................................................53
General information ................................................................................................................................ 55
Regular inspection table ........................................................................................................................ 56
Cooling system ....................................................................................................................................... 57
Lubrication system ................................................................................................................................. 63
Fuel system ............................................................................................................................................ 70
Intake/exhaust system ............................................................................................................................ 74
Cylinder block/head ................................................................................................................................ 76
Others/driving system ............................................................................................................................. 77
5. About the engine ...................................................................................................................79
Marking system of units ........................................................................................................................ 81
Tightening torque ................................................................................................................................... 82
Special tool ............................................................................................................................................. 86
Engine disassembly ............................................................................................................................... 88
Engine assembly .................................................................................................................................. 108

6. Cooling system ....................................................................................................................133
General information .............................................................................................................................. 135
Water pump .......................................................................................................................................... 137
Thermostat ............................................................................................................................................ 140
Cooling fan ........................................................................................................................................... 142
7. Lubrication system ..............................................................................................................145
Oil pump ............................................................................................................................................... 149
Oil filter assembly ................................................................................................................................ 156
Oil pan .................................................................................................................................................. 161
8. Fuel system ..........................................................................................................................165
Fuel return hose .................................................................................................................................. 168
Injector .................................................................................................................................................. 173
Common rail ......................................................................................................................................... 183
Fuel injection pump ............................................................................................................................. 193
9. Intake/exhaust system ........................................................................................................203
Turbocharger ......................................................................................................................................... 206
Exhaust gas reduction ......................................................................................................................... 215
EGR (Exhaust Gas Recirculation) system ......................................................................................... 225
Intake manifold ..................................................................................................................................... 230
Exhaust manifold .................................................................................................................................. 237
Intake pipe ............................................................................................................................................ 242
10. Cylinder block/head .............................................................................................................249
Cylinder block ....................................................................................................................................... 252
Cylinder head ....................................................................................................................................... 254
Valve ..................................................................................................................................................... 255
Rocker arm ........................................................................................................................................... 258
Tappet and push rod ........................................................................................................................... 268
Camshaft ............................................................................................................................................... 278
Flywheel housing .................................................................................................................................. 280
Breather ................................................................................................................................................ 283
Cylinder head cover ............................................................................................................................. 284

Idle gear ............................................................................................................................................... 292
Lifting hook ........................................................................................................................................... 297
Oil seal ................................................................................................................................................. 299
11. Electric system ....................................................................................................................303
Circuit diagram ..................................................................................................................................... 305
Switches and sensors .......................................................................................................................... 313
Wire harness ........................................................................................................................................ 318
ECU (Electronic Control Unit) ............................................................................................................. 319
Starter ................................................................................................................................................... 322
12. Others/driving system .........................................................................................................327
Crankshaft ............................................................................................................................................. 330
Piston .................................................................................................................................................... 336
Connecting rod ..................................................................................................................................... 339
Flywheel ................................................................................................................................................ 341
Crankshaft pulley .................................................................................................................................. 343
Others ................................................................................................................................................... 345

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

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

4
Danger, warning, caution, and note
General Information
This Operation & Maintenance manual divides mainte-
nance operations such as performing engine checks, trou-
bleshooting, or diagnosing faults into three categories,
"Danger," "Warning," and "Caution." In addition, Note) is
used to provide additional descriptions and information
required for maintenance technicians to successfully
operate our engines. The recommended repair methods
and 'Danger,' 'Warning,' and 'Caution' can enhance the
degree of completion of engine maintenance and prevent
bodily injury which may occur to workers. However, this
manual cannot predict all possible risks.
Note) Indicates additional description, information, and
references for workers' easy understanding.
General Instructions
1. In order to maintain the best long term performance
and safety, please read and understand this manual
and execute routine inspections and regular inspec-
tions.
2. We have divided the content of this manual into
causes of bodily injury and damage to assets and
causes of pollution.
Cautions for Starting the Engine
1. Before starting the engine, please read this manual
carefully and fully understand 'Danger,' 'Warning,' and
'Caution'. If you cannot fully understand it or have any
question, please contact us.
2. For safety reasons, attach "Warning" signs around
engines in operation to keep people other than
workers from accessing the engines. Let engine oper-
ators know that they are responsible for the safety of
the engine room.
3. Only authorized people may start and operate
engines. Unauthorized people should not be allowed
to handle engines.
4. Do not access running or rotating parts while the
engine is in operation.
5. Be careful not to touch or contact the engine during
operation since it becomes hot during operation.
6. Exhaust gas is poisonous. Fully ventilate before
starting engine. If the space is airtight, ensure that it
is well ventilated.
Cautions for Inspection and Repair
1. Inspection and repair of engine should be performed
only when the engine is stopped. Otherwise, burns or
safety accidents may occur, so do not perform inspec-
tion or repair while the engine is running.
2. If it is absolutely necessary to perform inspection or
repair on the operating engine, do not get close to
the rotating parts.
DANGER
Workers must observe instructions, otherwise fatal
or serious injuries to workers and other persons
may occur.
WARNING
Workers must follow this instruction as failing to do
so may result in the death or serious bodily harm
of workers or others.
CAUTION
Workers must observe this instruction since failing
to do so may cause critical faults which can have
impact on the engine performance and operation.
WARNING
When a safety accident, such as skin contact with
corrosive acids or fuel, burns with hot oil, exposure
of eyes to fuel or antifreeze, occurs while starting,
inspecting, or repairing an engine, see a doctor
immediately.
DANGER
When accessories such as necklaces, rings,
watches, or gloves become stuck in rotating parts
while the engine is running, serious bodily injury
may occur.

5
3. Use an engine oil drain container that is large enough
to prevent the overflow of engine oil while draining
engine oil.
4. Open the engine coolant cap after fully cooling the
engine to exchange or replenish coolant.
5. Fuel is highly flammable. Smoking or use of fire
around an engine may cause fire.
6. Mark and separately manage the containers for storing
coolant from beverage containers for avoiding confu-
sion. See a doctor immediately in case of drinking
coolant.
7. Follow the instructions provided by the battery manu-
facturer when checking or handling batteries.
8. Only certified professional technicians should repair
and maintain engines.
9. Only appropriate tools should be used. If the jaws of
a wrench are worn out, the wrench might slip during
use, causing safety accidents.
10. Do not allow other persons to stay or pass under an
engine when lifting the engine with a crane. Before
lifting the engine, ensure that there is no one around
the engine and reserve enough safety space.
11. Before inspecting or replacing the electrical apparatus,
disconnect the battery ground wire first. Connect the
battery ground wire after completing all required work
for checking or replacing the electrical apparatus in
order to prevent a short circuit.
12. Before performing electric welding works, turn off
engine, block the power supply to the engine, and
remove the wire harness connector connected to the
engine control unit (ECU).
13. Do not give any electric or mechanical shocks or
perform welding works on the electrical apparatus or
the ECU.
General Repair
1. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
Before performing fuel line work, check the common
rail pressure and engine temperature by using the
failure diagnosis device.
2. Disconnect the battery ground wire from to prevent
damage of wires and sensors caused by a short
circuit.
3. Engine oil and coolant may damage paint and should
be stored in a separate container and marked for safe
management.
4. Store the disassembled parts in a specified space to
avoid damage or pollution.
5. Use specified and special tools for efficient and safe
repair.
6. If parts need to be replaced, use only genuine parts
for replacement. Using unauthorized or remanufac-
tured parts may cause critical damage and faults in
engine performance.
7. Replace parts such as cotter pins, gaskets, O-rings,
seal rings, oil seals, and washers with new ones
during repairs. Reuse of parts may be the cause of
engine faults and engine may not operate properly.
8. Group and store disassembled parts in disassembling
order. The strength, shape, and screw torque of bolts
and nuts are different according to their assembly
position. Please divide and store them accordingly to
these characteristics.
9. Clean disassembled parts to remove foreign
substances before inspecting or reassembling parts.
Use compressed air to clean the oil holes or holes.
10. Thinly spread oil or grease on rotating parts or parts
requiring lubrication, before assembling them.
11. If required, use a specified adhesive to assemble
gaskets to prevent water or oil from leaking.
WARNING
Do not exchange or disassemble a pipe or horse
(from the engine fuel circuit, engine oil circuit,
coolant circuit, or compressed air circuit) while the
engine is running. The leaked liquid may cause
bodily injuries.
WARNING
If the coolant cap is opened while the engine is still
hot, hot water will spurt out and may cause burns.
Open the engine coolant cap after fully cooling the
engine.
WARNING
Only refuel when the engine is stopped.
WARNING
Battery fluid is corrosive and dangerous because of
its explosiveness and toxicity. Therefore, it should
only be handled by a skilled technician who special-
izes in battery fluid.

6
12. Assemble bolts and nuts with the specified tightening
torque.
13. After completing repairs, conduct a final inspection
and perform a test operation to check if all works
have been successfully completed.
Other Safety Instructions and Environmental
Pollution
Observe the following instructions to protect workers from
danger and to prevent the environmental pollution while
performing engine repairs.
1. Good ventilation and low humidity should be main-
tained in the work space.
2. The workspace should be clean, in good order, and
no flammables are allowed in the workshop.
3. Smoking is strictly forbidden in the workshop.
4. Workers should wear working clothes, protective
goggles, and safety shoes.
5. Workers are not allowed to wear accessories such as
necklaces, rings, watches, and earrings.
6. Start the engine in a well-ventilated space and fully
ventilate the space before starting engine to prevent
carbon monoxide poisoning.
7. Wait until the engine is properly cooled down before
starting work, since you may get burned by the heated
engine.
8. Do NOT work on rotating or running parts once the
engine has been started.
9. Discard oil according to the regulations set forth by
the relevant authorities.
10. If engine oil or fuel leaks on the floor or is improperly
discharged, serious environmental pollution of sea,
river or underground water may occur.
11. Discard the undiluted anticorrosive agent, antifreeze,
filter elements, and cartridges as special wastes.
12. Discard coolant and special waste according to the
regulations of the appropriate authorities.
Use of Genuine Parts
An engine consists of many parts which are mechanically
harmonized. To prevent engine faults in advance and use
engines with best performance for a long period, mainte-
nance and replacement of expendable parts should be
conducted regularly.
Use of genuine parts is recommended. Using unautho-
rized or remanufactured parts may cause critical damage
and faults to engine for which Doosan shall not be held
liable.
WARNING
Failure to observe the regulations of the relevant
authorities violates environmental pollution regula-
tions and may be subject to legal penalties.

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

8
6. Do not put oil-stained gloves or cloth in ones pocket.
WARNING
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil
into the ground, sewers, drains, rivers, or the sea
will cause serious environmental pollution. Violation
of regulations regarding discard of engine oil without
observing the handling regulations, will be punished.

9
2. Operation and maintenance
Starting and stopping of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparing for Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
After Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Break-in period of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Break-in Period of a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation after Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection after Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Revolutions per Minute (rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation in winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventing Coolant from Freezing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventing Overcooling of the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection and repair of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking Engine Parts after Prolonged Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection and Repair of Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intake Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

11
Starting and stopping of the engine
Preparing for Start
Check the following before starting the engine for the first
time after purchase.
1. Before starting an engine, check the levels of fuel,
coolant, and oil and replenish those fluids if required.
2. Check if engine oil level is between the upper and
lower limit of the oil level gauge. The upper and lower
limit of the oil level gauge indicate the maximum and
minimum of the engine oil level.
3. Be careful not to mix foreign substances in fuel,
engine oil, or coolant while adding the fluid, and keep
the fluid clean while it is not in use. Use fuel, oil, and
coolant recommended by Doosan. Otherwise, critical
damage to the engine may occur.
Starting the Engine
Observe the following when starting the engine.
1. For a cold start, start the engine after preheating it
sufficiently through the glow plug.
2. Starting the engine too quickly leads to engine rotation
without lubricating the supercharger and other engine
parts, causing abnormal wear to or burning of bear-
ings. Therefore, start the engine with the starter motor
to check raising of oil pressure (until the gradation of
the oil pressure gauge mounted on the apparatus
moves or the pressure indicator lamp is turned on).
3. If the engine was not used or kept cold for a long
period of time, oil circulation will be poor. If you
replace oil, oil filter cartridge, or lubrication system
parts or use an engine in cold areas, or the engine
has been stopped for a long period, loosen the oil
pipe joint at inlet of the supercharger and run the
starter motor until oil flows out. After completing the
work, tighten the oil pipe joint again and start the
engine.
After Starting the Engine
1. Do not rapidly raise the rpm while the engine and
turbocharger do not rotate smoothly after starting the
engine. Otherwise, it may increase the load upon the
engine and burning may occur at the positions that
have not been sufficiently lubricated yet. To prevent
this, rotate the engine at idle after starting it to lubri-
cate the turbocharger with oil.
2. Oil, air, or gas leaks may lower the oil pressure. Addi-
tionally, oil leaks may cause burning of bearings. As
such, if oil, air, or gas leaks occur, check the leaking
parts and solve the problem.
During Operation
1. Insufficient oil pressure may cause abnormal wear and
burning of bearings and excessive oil pressure may
cause leaks.
2. Continuing to operate the engine after noises or vibra-
tions coming from the engine may lead to serious
engine damage. As such, if noises or vibrations come
from the engine, slowly decrease the rpm to a stop
the engine and examine the cause.
Stopping the Engine
Do not suddenly stop the engine after it was operated
under high loads for a long period. If oil burns because
of heat sent from the high-temperature turbine blade to
the bearing part, the bearing metal and rotating shaft may
burn. As such, if the engine was operated under high
loads for a long period, sufficiently rotate the engine at
idle before stopping it.
CAUTION
When replenishing engine oil, do not exceed the
maximum on the oil level gauge. Too much oil may
cause damage to the engine.

12
Break-in period of the engine
General Information
Doosan engines are subjected to a final approval test to
ensure the provision of high quality engines before being
shipped to ensure the best quality possible. However,
engines are not operated for a long period of time in this
test. Therefore, new engines require a break-in period of
during the initial 50 hours after delivery. By properly
breaking-in an engine, the highest levels of engine perfor-
mance can be maintained long-term.
Break-in Period of a New Engine
If the engine's bearings are not properly broken in, they
may be easily damaged and the lifetime of the engine
may be shortened by overloading or high-speeds. In order
to prevent this, please follow the guidelines below for the
initial 50 hours after delivery of new engine.
1. Fully warm up the engine until the engine temperature
reaches normal operation condition, before starting
operation of the engine.
2. Do not overload the engine or operate it at excessive
RPM.
3. Do not operate the engine with high speed at idle.
4. Do not rapidly start up or stop the engine.
5. Operate the engine with less than 70 % of the engine
load.
6. Inspection, check, and repair of engines should be
managed by officially-certified technicians at certified
service centers in compliance with corresponding
rules.
Check Points
check the following during the break-in period of a new
engine.
1. Periodically check if the engine oil level is between
the minimum and maximum limit of the oil level
gauge.
2. If the oil indicator lamp on the apparatus is turned on
or blinks, the oil pressure may be insufficient. In this
case, check the oil level and replenish the oil if
required. When replenishing engine oil, do not exceed
the maximum on the oil level gauge. If the oil level
is normal, check other related parts such as the oil
pressure sensor, oil pump, or oil line.
3. Check the coolant gauge on the apparatus and if the
coolant circulates properly. If the coolant level in the
supplementary tank is too low, the coolant gauge may
be inaccurate. (may be disturbed).
4. Exchange engine oil and oil filter after the break-in
period.
Operation after Break-in
Slowly preheat the engine when starting up during cold
weather or in areas with cold climate. Do not rapidly raise
the rpm while the engine has not been properly
preheated yet. The engine consumes additional oil until
its piston ring is positioned properly and operates
successfully. Please check the engine oil level frequently
during the initial 50 hour break-in period.
Inspection after Starting the Engine
Check the pressure of the engine lubrication system by
using the engine oil pressure gauge mounted on the
apparatus while the engine is in operation. If the oil pres-
sure is low on oil pressure gauge, immediately stop the
engine. In addition, make sure that the recharge alarm
indicator lamp of the alternator is turned off while the
engine is operating.
CAUTION
If you cannot accurately check the oil level through
the oil level gauge, rotate the oil level gauge to 180
degree, put it in the guide tube, and then pull it out
again to check.
CAUTION
The oil pressure may increase with high rpm and
decrease with low rpm. In addition, the pressure of
cold oil may be higher at a specific rpm than of
warm oil. This phenomenon may occur when the
engine is operating successfully.
CAUTION
If engine oil and oil filter need to be replaced, use
only the genuine engine oil and parts recommended
by Doosan.

13
1. Tightly connect the +/- terminals to prevent gaps
between them. The sheath of battery connection
cables should not be damaged or broken.
2. If the recharge alarm indicator lamp suddenly turns on
or blinks during engine operation and the engine
stops, fix the fault of the electric apparatus.
3. If color or odor of exhaust gas is unusual during oper-
ation, stop the engine, diagnose the cause and fix the
fault.
4. Check the engine status through the alarm indicator
lamp and gauges mounted on the apparatus during
operation.
Engine Oil Pressure
If the engine oil pressure is not consistent at idle or does
not reach the reference value while the engine is oper-
ating in high speed mode, immediately stop the engine
and check the oil level and leakage.
Coolant Temperature
Operating an engine with insufficient coolant temperature
increases fuel consumption, abrasion of the cylinder liner,
shortening the engine's life span.
Revolutions per Minute (rpm)
In the electronic control engine, the engine control unit
(ECU) prevents the engine from being operated at too
high rpm over the specifications to protect the engine.
The memory of ECU has various functions which cannot
be changed by operators, such as fuel flow control, igni-
tion time delay, and blocking of fuel and ignition.

14
Operation in winter
Cold Start
Periodically check for frozen coolant and viscosity of lubri-
cation oil.
Perform the cold start in the following order.
1. Turn the key switch to 'Preheat' and then the preheat
lamp will operate for about 20 seconds.
Note) Operate the preheater if coolant is below 10 °C
during cold weather. If preheating is not necessary,
the preheat lamp will not switch on.
2. When the preheat lamp switches off, turn the key
switch to 'Start' to start the engine.
Note) If the key is turned to 'Start', the air heater is
continuously heated to provide an easy start and
reduce white exhaust gas. If the coolant tempera-
ture is above 10 °C, it is not necessary to heat the
air heater.
3. After starting the engine, the key switch changes to
ON.
Preventing Coolant from Freezing.
When only water used as coolant without mixing with
antifreeze, corrosion in the engine, degradation of cooling
efficiency, and freezing of the engine in winter may occur.
If the engine is not operated for a long period during cold
weather or in areas with cold climate, fully discharge the
coolant from the engine. Freezing of coolant leads to crit-
ical damage to the engine. Please use a mixture of
coolant with antifreeze at revised ratio when replacing or
replenishing the coolant. The antifreeze prevents coolant
from freezing.
Preventing Overcooling of the Engine
When the engine is cooled below the normal operating
temperature, thermal efficiency is lowered and fuel
consumption as well as abrasion of the cylinder liner may
increase. Therefore, the engine should be operated within
the normal operating temperature. If the engine has been
sufficiently operated, but the temperature of coolant
remains below the normal operating temperature, check
the water temperature controller or other parts related to
the cooler.
Engine Oil
When the viscosity of engine oil increases due to its low
temperature during cold weather or in areas with cold
climate, the rpm may not be stable after starting the
engine. To prevent this, replace the oil with engine oil for
cold weather or areas with cold climate. When replacing
engine oil, Use only engine oil recommended by Doosan.
CAUTION
• A preheater should be mounted on the engine to
improve the cold start performance.
• Start the engine after turning off the preheating
lamp.
• Do not operate the starter motor for over 10
seconds. If the engine does not start even though
it is fully preheated, wait for about 30 seconds,
preheat the engine again, and then start the
engine.
CAUTION
As the ECU heats the intake air for about 180
seconds after starting the engine, the white exhaust
gas is reduced quickly.

15
Inspection and repair of the engine
Checking Engine Parts after Prolonged
Operation
Wear, corrosion, or degradation of engine elements and
assemblies may occur, causing lowered performance of
engine parts. To maintain high engine performance, check
the engine after prolonged operation to enhance the dura-
bility of the engine.
Unexpected faults may occur in some weak engine parts
after normal operation of the engine, when operation time
is prolonged. In this case, it is difficult to maintain high
engine performance by simply repairing some parts. We
recommend the entire part be replaced or repaired in
order to find out the causes more accurately and maintain
high engine performance.
To prevent engine failure in advance and use the engine
safely for a long period, perform periodic replacements
and inspections.
It is recommended to perform engine adjustments and
preventive inspections during spring after the engine was
exposed to winter or cold weather. This allows economic,
long-term use of the engine without faults.
As the following parts affect the engine output and perfor-
mance, these parts should be regularly checked and
inspected.
1. Parts affecting intake and exhaust
• Air filter
• Intercooler
• Supercharger, silencer
• EGR cooler and Calve
• Other parts
2. Parts affecting lubrication and cooling
• Air filter
• Oil filter
• Antifreeze
• Other parts
Inspection and Repair of Supercharger
As performance of supercharger significantly affects the
engine performance, regular inspections and repairs
should be performed and inspection and maintenance
regulations should be observed.
Intake Unit
Be careful when handling the air filter in the intake unit.
If oil level of the wet air filter is below the specified level,
filtering performance is degraded. On the other hand, if
the oil level is higher, oil may flow into the case, and it
may become polluted. In regards to the dry air filter,
intake resistance should be small to ensure the smooth
intake of air.
Exhaust Unit
If exhaust emission is leaked from the part connecting
the exhaust tube and the turbocharger, the supercharger
efficiency is lowered, causing degraded engine output
and, if serious, burning of related parts. As parts related
to exhaust and turbocharger are used at high tempera-
ture, be careful not to mix the bolts and nuts with other
parts when performing repair.
Lubrication system
Inspection and replacement of the lubrication system
should be performed according to the replacement
schedule of oil and oil filter. Overheated engine oil can
affect not only the engine itself, but also the engine
performance.

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3. Performance and specifications
Engine specifications and performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine Performance Curve (DL03-LEF04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Performance Curve (DL03-LEL01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Outside drawing of the engine (DL03-LEF00/LEF01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Isometric assembly drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly drawings (Front/Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Assembly drawings (Left/Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly drawings (Top/Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Outside drawing of the engine (DL03-LEF02/LEF03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Outside drawing of the engine (DL03-LEL00/LEL01/LEL02/LEL03/LEL04) . . . . . . . . . . . . 45
Engine identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine number engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cylinder block number engraving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engraving of piston bore level of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engraving of main bearing bore level of cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crankshaft main journal engraving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Connecting rod engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Piston engraving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cylinder head gasket engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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