Doosan D1146 Owner's manual

FOREWORD
This manual is designed to serve as an instruction for the Operation & Maintenance of the generating-
set engines of Doosan POLUS series and the power unit engines: P086TI /P086TI-1/ D1146T/ D1146/
PU086T/ PU086. The POLUS means ‘Power Plus’ that is represented more powerful Doosan
generating-set engines and it is marked on engine name as an initial P. On the other hand, initial PU
stands for ‘Power Unit’ and Initial D stands for standard engine prior to POLUS version.
The first half is for operation and the latter half is for maintenance like disassembling, inspecting and
re-assembling etc in order to help an understanding for the maintenance procedure more easily.
To keep the best performance and the durability of engine 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
Directional Indication Lubricate oil
Inspection Lubricate grease
Measurement
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.
Also some figures in this manual may be different from the actual appearance of the engine because
of explaining them with the representative figure among these models.
For the last, the contents of this instruction manual may be changed without prior notice for some
quality improvement. Thank you.
Jan. 2004
DOOSAN Infracore Co., Ltd.

CONTENTS
<Operation>
1. Safety Regulations ................................................................................................................... 1
1.1. General Notes 1.4. Regulations Designed to Prevent Pollution
1.2. Regulations Designed to Prevent Accidents 1.5. Notes on Safety in Handling Used Engine Oi l
1.3.
Regulations Designed to Prevent
Damage to Engine and Premature Wear
2. General Information .................................................................................................................. 5
2.1. Engine Assembly 2.2. Engine Specification
3. Technical Information ............................................................................................................. 12
3.1. Engine Model and Serial Number 3.7. Fuel System
3.2. Engine Type 3.8. Cooling System
3.3. Engine Timing 3.9. V-belt Tension Check and Adjust
3.4. Valves 3.10. Turbocharger
3.5. Lubrication System 3.11. Electrical Equipment
3.6. Air Cleaner
4. Commissioning and Operation ............................................................................................. 28
4.1. Preparation 4.4. Operation in Winter Time
4.2. Breaking-in 4.5. Tuning the Engine
4.3. Inspections after Starting
5. Maintenance and Care ............................................................................................................ 32
5.1. Periodical Inspection and Maintenance 5.5. Fuel System
5.2. Lubrication System 5.6. Injection Nozzle Maintenance
5.3. Cooling System 5.7. Turbocharger
5.4. Air Intake System
6. Checking and Setting ............................................................................................................. 46
6.1. Adjustment of Valve Clearance 6.3. Cylinder Compression Pressure
6.2. Adjustment of Injection Timing 6.4. V-belts
7. Operation Tip ........................................................................................................................... 52
7.1. Periodic Inspection Cycle 7.3. Causes and Remedies
7.2. Trouble Shooting

<Maintenance>
8. General Information ................................................................................................................ 63
8.1. General Repair Instructions 8.2. Engine Characteristic
9. Maintenance ............................................................................................................................ 66
9.1. Engine Disassembly 9.3. Reassembly
9.2. Inspection 9.4. Breaking-in
10. Maintenance of Major Components .................................................................................. 121
10.1. Cooling System 10.3. Fuel Injection Pump
10.2. Lubricating System 10.4. Turbocharger
11. Special Tool List .................................................................................................................. 167
•
Appendix
•
Part & After service center
•
Applications for Doosan Engine

1. Safety Regulations
1.1. General Notes
Handling diesel engines and the necessary resources is no problem when the personnel com-
missioned with operation and maintenance are trained accordingly and use their common
sense.
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 accidentoccurs, in particular through contact with caustic acids,
fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc., con-
sult a doctor immediately.
1.2. Regulations Designed to Prevent Accidents
1.2.1. During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions care-
fully and familiarize yourself with the “critical” points. If you are unsure, ask your DAEWOO rep-
resentative.
•
For reasons of safety we recommend you attach a notice to the door of the engine room pro-
hibiting 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 persons who enter the engine
room.
•
The engine must be started and operated only by authorized personnel. Ensure that the
engine cannot be started by unauthorized persons.
•
When the engine is running, do not get too close to the rotating parts. Wear close-fitting cloth-
ing.
•
Do not touch the engine with bare hands when it is warm from operation risk of burns.
•
Exhaust gases are toxic. Comply with the installation instructions for the installation of DAE-
WOO generator diesel engines which are to be operated in enclosed spaces. Ensure that
there is adequate ventilation and air extraction.
•
Keep vicinity of engine, ladders and stairways free of oil and grease.Accidents caused by
slipping can have serious consequences.
- 1 -

1.2.2. During maintenance and care
•
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.
•
Change the oil when the engine is warm from operation.
CAUTION :
There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare hands.
•
Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that
the oil will not overflow.
•
Open the coolant circuit only when the engine has cooled down. If opening while the engine
is still warm is unavoidable, comply with the instructions In the chapter entitled “Cooling”.
•
Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any addi-
tional hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.
•
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.
•
Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
•
Comply with the manufacturer’s instructions when handling batteries.
CAUTION :
Accumulator acid is toxic and caustic. Battery gases are explosive.
1.2.3. When carrying out checking, setting and repair work
•
Checking, setting and repair work must be carried out by authorized personnel only.
•
Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench
could lead to Injury.
•
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.
•
When checking injectors, do not put your hands under the jet of fuel. Do not inhale at atom-
ized fuel.
•
When working on the electrical system disconnect the battery earth cable first. Connect it up
again last in prevent short circuits.
- 2 -

1.3. Regulations Designed 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. The injection pump must not
be adjusted without prior written permission of DAEWOO.
2) If faults occur, find the cause immediately and have it eliminate in order to prevent more seri-
ous of damage.
3) Use only genuine DAEWOO spare parts. DAEWOO 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.
•
Never let the engine run when dry, i.e. without lube oil or coolant. Use only DAEWOO-
approved service products. (engine oil, anti-freeze and anticorrosion agent)
•
Pay attention to cleanliness. The Diesel fuel must be free of water. See “Maintenance and
care”.
•
Have the engine maintained at the specified intervals.
•
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.
•
Never put cold coolant into an overheated engine. See “Maintenance and care”.
•
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. Serious damage to the engine may
result if these instructions are not adhered to.
•
Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and
coolant temperature) function satisfactorily.
•
Comply with instructions for operation of the alternator. See “Commissioning and operation”.
•
Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine
switched off.
1.4. Regulations Designed to Prevent Pollution
1.4.1. Engine oil, filter element, fuel filter
•
Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not
get into the drains or into the ground.
•
The drinking water supply may be contaminated.
•
Oil and fuel filter elements are classed as dangerous waste and must be treated as such.
1.4.2. Coolant
•
Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
•
When disposing of spent coolant comply with the regulations of the relevant local authorities.
- 3 -

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
•
Avoid prolonged or repeated skin contact with used engine oil.
•
Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
•
Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
•
After washing apply a fatty skin cream to the skin.
•
Change oil-soaked clothing and shoes.
•
Do not put oily rags into your pockets.
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.
- 4 -

2. General Information
2.1. Engine Assembly
2.1.1. Engine sectional view (longitudinal)
- 5 -
12 34 5 6 7 8
9
10
11
12
13
14
15 16 17 18 19
EA9O1001
1. Cooling fan 2. Vavle seat 3. Intake valve
4. Valve spring 5. Exhaust valve 6. Oil filter cap
7. Cylinder head 8. Combustion chamber 9. Pistion
10. Cylinder liner 11. Push rod 12. Tappet
13. Camshaft 14. Connecting rod 15. Crankshaft pulley
16. Vibration damper 17. Oil Pump 18. Oil suction pipe
19. Oil pan

2.1.2. Engine sectional view (cross)
- 6 -
EA9O1002
12
9
10
34567 8
11
1. Fuel filter 7. Rocker arm
2. Intake manifold 8. Exhaust manifold
3. Injection nozzle assembly 9. Cylinder block
4. Valve cotter 10. Oil filter
5. Valve stem seal 11. Oil cooler
6. Valve guide

2.1.3. Engine assembly views
1) D1146/PU086
- 7 -
1
7891011 12
18
17
19 20 21 22 23
24
24
25
13
234 56 131415
EA9O1003
1. Cooling fan 10. Oil pan 19. Intake manifold
2. Alternator 11. Oil drain valve 20. Fuel filter
3. Thermostat 12. Flywheel 21. Injection pump
4. Oil filter 13. Flywheel housing 22. Injection pipe
5. Oil filter cap 14. Cylinder head cover 23. Water pump
6. Exhaust manifold 15. Cooling water pipe 24. Mounting bracket
7. Vibration damper 16. Fuel pipe 25. Oil level gauge
8. Oil cooler 17. Starter
9. Cooling water pipe 18. Intake stake
(from radiator)

2) D1146T/PU086T
- 8 -
12 13 14111098
12345 6 7 15161718
19 20
21 22 24 24
23
EA9O1004
1. Cooling fan 10. Cooling water pipe 18. Air pipe
2. Alternator (from radiator) (Turbocharger to
3. Thermostat 11. Oil cooler Intake manifold)
4. Oil filter cap 12. OIl drain valve 19. Intake manifold
5. Cylinder head cover 13. Flywheel housing 20. Fuel filter
6. Exhaust manifold 14. Flywheel 21. Starter
7. Breather 15. Exhaust elbow 22. Injection pump
8. Vibration damper 16. Turbocharger 23. Water pump
9. Oil filter 17. Cylinder head cover 24. Mounting bracket

3) P086TI
- 9 -
EA9O1005
12
8 9 10 12 13
16
11
34 5 67 1415
17
18 19 20 21
22 22
23
1. Cooling fan 8. Vibration damper 17. Intake manifold
2. Thermostat 9. Oil cooler 18. Injection pump
3. Oil filter cap 10. Oil fan 19. Oil filter
4. Air pipe 11. OIl drain valve 20. Oil level gauge
(Turbocharger to 12. Starter 21. Air pipe
Intake manifold) 13. Flywheel housing
(Intercooler to Intake manifold)
5. Turbocharger 14. Cylinder head 22. Mounting bracket
6. Exhaust elbow 15. Cooling water pipe 23. Water pump
7. Breather 16. Flywheel

2.2. Engine Specification
2.2.1. Specification
- 10 -
Engine Model
Items D1146/PU086
D1146T/PU086T P086TI
4 cycle in - line, 4 cycle in - line, 4 cycle in - line,
Engine type Water - cooled Water - cooled Water - cooled
type Naturally type Turbo
type Turbo charged
aspirated charged intercooled
Combustion chamber type Direct injection type
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring Compression ring 2, oil ring 1
No. of cylinder-bore x stroke (mm) 6 - 111 x 139
Total piston displacement (cc) 8,071
Compression ratio 17.6 : 1 16.8 : 1 16.7 : 1
Engine dimension
(length x width x height) (mm)
1,224 x 830 x 974 1,224 x 830 x 1,081.5 1,242 x 918 x 1,102
Engine weight (kg) 720/780 780/780 790
Fuel injection order 1 - 5 - 3 - 6 - 2 - 4
Fuel injection timing (B.T.D.C static) 18˚ 18˚/12˚ 12˚
Injection pump type Zexel in - line “ AD” type
Zexel in - line “ P” type
Governor type Mechanical governor
Electrical governor
type(RSV)
type(Ghana Control)
Injection nozzle type Multi-hole type (5 hole)
Fuel injection pressure (kg/cm2) 214 214 214
Compression pressure (kg/cm2) 28 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.3
Intake valve Open at 16
˚C (B.T.D.C)
Close at 36
˚C (A.B.D.C)
Exhaust valve Open at 46
˚C (B.B.D.C)
Close at 14 ˚C (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by camshaft
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (max./min.) (lit) 15.5 23
Oil cooler type Water cooled
Water pump Centrifugal type driven by belt
Cooling Method Fresh water forced circulation
Cooling water capacity (engine only) (lit)
14/11 14/14 19
Thermostat type Wax pallet type (71 ~ 85 ˚C)
Alternator voltage - capacity (V - A) 24 - 45
Starting motor voltage - output (V - kW) 24 - 4.5 24 - 6.0

2.2.2. Engine power
Production tolerance : ±
5%
Production tolerance :
± 5%
* Note : All data are based on operation without cooling fan at ISO 3046.
- 11 -
Generating-Set Engines
Condition
Continuous Prime Stand by
50 HZ
-
105 PS 116 PS
(1,500 rpm) (77 kW) (85 kW)
D1146 Standard
60 HZ
-
130 PS 143 PS
(1,800 rpm) (96 kW) (105 kW)
50 HZ 145PS 160 PS
(1,500 rpm)
-
(107 kW) (118 kW)
D1146T Standard
60 HZ
-
170 PS 187 PS
(1,800 rpm) (125 kW) (138 kW)
50 HZ 205 PS 240 PS 270 PS
(1,500 rpm) (151 kW) (177 kW) (199 kW)
Standard
60 HZ 253 PS 279 PS 303 PS
P086TI
(1,800 rpm) (186 kW) (205 kW) (223 kW)
50 HZ
-
203 PS 223 PS
(1,500 rpm) (149 kW) (164 kW)
P086TI-I
60 HZ
-
237 PS 260 PS
(1,800 rpm) (174 kW) (191 kW)
Power-Unit Engines
Max. Output
rpm PS kW
Naturally
PU086 6 Cyl. Aspirated 2,200 160 118
Turbo
PU086T 6 Cyl. Charged 2,200 205 151

3. Technical Information
3.1. Engine Model and Serial Number
The engine model and serial number is
located on the engine as illustrated. 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.
•
Engine serial No. (example 1 : D1146)
EACOA300001
•
Engine serial No. (example 1 : D1146T)
EADOA300001
•
Engine serial No. (example 1 : P086TI)
EBPOA300001
•
Engine serial No. (example 1 : PU086)
EACPA300001
- 12 -
EA9O2001
Engine Number
EA9O2002
DAEWOO HEAVY INDUSTRIES LTD.
MODEL
SPEED 1500/1800 rpm
STAND-BY
PRIME
BORE mm
mm
cc
STROKE
VOLUME
YEAR
SERIAL NUMBER
EA9O2003
IMPORTANT ENGINE INFORMATION
DAEWOO HEAVY INDUSTRIES LTD.
ENGINE AND MATERIAL DIV.
6, MANSECOK-DONG, DONG-GU
INCHEON, KOREA
TYPE 2-D DIESEL FUEL.
THIS DAEWOO HEAVY-DUTY DIESEL MODEL
EPA AND CARB STANDARDIZED ENGINE FAMILY DESIGNATION IS
TUNE-UP SPECIFICATIONS AND ADJUSTMENTS
IS CERTIFIED TO OPERATE ON
Serial No.
Production Year(2003)
Engine Model Suffix
Serial No.
Production Year(2003)
Engine Model Suffix
Serial No.
Production Year(2003)
Engine Model Suffix
Serial No.
Production Year(2003)
Engine Model Suffix
<Name Plate : General>
<Name Plate : EPA & CARB>

•
Engine serial No. (example 1 : PU086T)
EADPA300001
3.2. Engine Type
The Engines D1146/ D1146T/ P086TI/PU086/PU086T are in-line vertical water-cooled 6-cylin-
der four-stroke diesel engines with direct injection. D1146/PU086 are natural aspiration engine,
D1146T/PU086T are turbo-charged type, and P086TI is turbo-charged and inter-cooled engine.
3.2.1. Cylinder block
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 dry cylinder liners and indi-
vidual cylinder heads with struck-in valve seat rings and replaceable valve guides.
3.2.2. Piston con-rod / crankshaft
The forged crankshaft is a ingrate type (Counterweight is integrated with crank shaft body).
Radial oil seal on crankshaft and flywheel are provided to seal the flywheel housing inside pen-
etrations.
The con-rods (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.
- 13 -
Serial No.
Production Year(2003)
Engine Model Suffix

3.3. Engine Timing
Camshaft, oil pump and injection pump are driven by a gear train arranged at the front end.
3.4. Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker armsfrom
the camshaft.
- 14 -
EA9O2004
Injection pump gear
(Z = 54)
Camshaft gear
(Z = 54)
Crankshaft gear
(Z = 27)
Oil pump idle gear
(Z = 23)
Oil pump drive gear
(Z = 36)
Idle gear
(Z = 42)

3.5. Lubrication System
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 crank-
shaft gear at the front end of cylinder block.
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 injection pump and the turbocharger are also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
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.
•
D1146/D1146T/ P086TI/PU086/PU086T
3.5.1. Oil cooler
An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube
type with turbulence inserts and operated by the coolant.
- 15 -
CYLINDER BLOCK MAIN GALLERY
OVER FLOW VALVE
BYPASS VALVE
RELIEF VALVE
OIL FILTER
OIL COOLER
OIL PUMP
OIL STRAINER
REGULATING VALVE
OIL PAN
IDLE GEAR
(TIMING)
CAM SHAFT
BRG.
CRANK SHAFT
BRG.
INJECTION
PUMP
TURBO
CHARGER
OIL SPRAY
NOZZLE
PISTON
CYL. HEAD
VALVE SYSTEM
CON-ROD
BRG.
ED7OM001
D1146T/P086TI/PU086T

3.5.2. Oil filter
Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
C
hange the oil filter car
tridge simultaneously
at every replacement of engine oil.
3.6. Air Cleaner
In case that elements are deformed, dam-
aged or if the air cleaner has a crack,
replace it.
By the definite interval, the elements must
be cleaned and replaced.
- Cleaning of air cleaner element : Every 200 hours.
- Changing of air cleaner element : Every 400 hours.
- 16 -
EA9O2005
Oil filter head
Oil filter
(Cartridge)
EFM1002I