Doosan D1146 User Manual

General guidelines for safe engine operation and maintenance.

Rules for preventing accidents during commissioning, starting, and operation.

Safety precautions during maintenance and care operations.

Safety guidelines for checking, setting, and repair tasks.

Regulations to prevent engine damage and premature wear.

Guidelines for preventing pollution from engine oil, filters, and coolant.

Precautions for safe handling and disposal of used engine oil.

Sectional views illustrating the longitudinal assembly of the engine.

Cross-sectional view of the engine assembly.

Assembly views for D1146/PU086 engine models.

Assembly views for D1146T/PU086T engine models.

Assembly views for P086TI engine model.

Detailed specifications for different engine models.

Power output specifications for generating-set and power-unit engines.

Location and importance of engine model and serial numbers.

Description of engine types (in-line, water-cooled, 6-cylinder).

Details about the cylinder block construction.

Information on piston, con-rod, and crankshaft construction.

Gear train arrangement for engine timing components.

Description of valve actuation mechanism.

Overview of the engine's force-feed lubrication system.

Description of the flat tube type oil cooler.

Instructions for checking and replacing the oil filter cartridge.

Maintenance requirements for the air cleaner elements.

Description of the fuel delivery and injection system.

Functions and replacement interval of the fuel filter.

Specifications and recommendations for diesel fuel.

Guidance on selecting appropriate fuel oil for optimal performance.

Overview of the engine's liquid-cooling system.

Checking and replacing the coolant pressure cap.

Recommendations for using soft water and antifreeze solutions.

Procedure for checking and adjusting V-belt tension.

Description of the turbocharger's operating principle and components.

Overview of the engine's electrical components.

Diagram of the engine's wiring circuit.

Information on the alternator's features and operation.

Explanation of the starter motor's function and maintenance precautions.

Steps for preparing the engine for initial commissioning.

Procedures and recommendations for engine break-in.

Guidelines for operating a new engine during the break-in period.

Key points to monitor during the engine break-in period.

Recommendations for operating the engine after the initial break-in period.

Checks to perform after the engine has started.

Normal and abnormal lubricating oil pressure ranges.

Optimal cooling water temperature and effects of deviation.

Special considerations for operating the engine in winter.

Measures to prevent cooling water from freezing.

Methods to avoid excessive cooling of the engine.

Selection of lubricating oil suitable for winter conditions.

Purpose and components to check during engine tune-up.

Importance of regular inspection, adjustment, and maintenance.

Procedures for maintenance of the lubrication system.

Procedure for changing engine oil and oil filter.

Method for checking engine oil level using a dipstick.

Step-by-step guide for exchanging engine oil.

Recommendations for engine oil specifications (API, SAE).

Procedure for replacing the oil filter cartridge.

Coolant change intervals and consequences of fouling.

Procedure for draining cooling water.

Steps for cleaning the internal cooling system circuit.

Information on intercooler cleaning and maintenance.

Maintenance of the air intake system.

Routine maintenance of the air intake system while the engine is off.

Procedure for changing the air filter element.

Methods for cleaning filter elements (compressed air, washing).

Overview of the fuel system.

Draining water/sediment and replacing the fuel filter.

Detailed steps for replacing the fuel filter.

Checks for fuel tanks, priming, and water separators.

Information on fuel contaminants and prevention.

Cleaning the priming pump strainer.

Procedure for bleeding air from the fuel system.

Checks and recommendations for the injection pump.

Maintenance procedures for injection nozzles.

Maintenance for turbochargers.

General maintenance points for turbochargers.

Recommendations for checking rotor clearances.

Procedure for adjusting valve clearance.

Situations requiring valve clearance adjustment.

Sequence for adjusting valve clearance.

Detailed steps for adjusting valve clearance.

Procedure for adjusting injection timing.

Steps to adjust the injection timing.

Procedure for measuring cylinder compression pressure.

Procedure for checking and maintaining V-belts.

When to replace V-belts.

How to check V-belt condition.

Method for testing V-belt tension by hand.

Using a tension tester to measure V-belt tension.

Steps for tensioning and changing V-belts.

Table outlining the periodic inspection and maintenance schedule.

Troubleshooting guide for engine starting issues.

Troubleshooting steps for engine overheating.

Troubleshooting steps for insufficient engine output.

Troubleshooting steps for low oil pressure.

Troubleshooting steps for excessive fuel consumption.

Troubleshooting steps for excessive oil consumption.

Troubleshooting steps for engine knocking.

Troubleshooting steps for battery discharge issues.

Table of common engine problems, causes, and remedies.

General guidelines for performing engine repair operations.

Description of engine operating characteristics.

Explanation of the toroidal combustion mode.

Explanation of the OMEGA combustion bowl system.

Details of the oil gallery cooling piston for P086TI.

General precautions and steps for engine disassembly.

Precautions and preparation for engine disassembly.

Procedure for draining cooling water.

Procedure for draining engine oil.

Procedure for removing the cooling fan.

Procedure for removing the V-belt.

Procedure for removing the starter motor.

Procedure for removing the fuel filter.

Procedure for removing the intercooler.

Procedure for removing the alternator.

Procedure for removing the oil cooler.

Procedure for removing the oil filter assembly.

Procedure for removing the water pump.

Procedure for removing the cylinder head cover.

Procedure for removing fuel injection nozzles.

Procedure for disassembling the turbocharger.

Procedure for removing the exhaust manifold.

Procedure for removing the intake manifold.

Procedure for removing cooling water pipes.

Procedure for removing rocker arm assembly and push rod.

Procedure for removing the cylinder head.

Procedure for removing the oil pan.

Procedure for removing the vibration damper.

Procedure for removing the timing gear case cover.

Procedure for removing the oil pump.

Procedure for disassembling the piston assembly.

Procedure for disassembling the cylinder liner.

Procedure for removing camshaft and idle gears.

Procedure for disassembling the fuel injection pump.

Procedure for removing the water chamber cover.

Procedure for removing the flywheel.

Procedure for removing the flywheel housing.

Procedure for removing the injection pump drive gear.

Procedure for removing the timing gear case.

Procedure for removing bearing caps.

Procedure for disassembling the crankshaft.

Procedure for disassembling camshaft and tappets.

Procedure for removing oil spray nozzles.

General inspection procedures for engine components.

Inspection of the cylinder block for cracks, damage, and blockages.

Disassembly and inspection of the cylinder head.

Measuring cylinder head distortion and flatness.

Checking flatness of cylinder head surfaces.

Performing hydraulic tests on the cylinder head.

Inspection of valves and valve guides.

Inspection of valves, including stem diameter and thickness.

Checking valve seat contact surfaces for wear and damage.

Measuring valve head thickness and replacement criteria.

Measuring valve guide clearance and replacement.

Checking valve stem end play.

Checking valve seat contacting face amount and depression.

Visual check and testing of valve springs.

Steps for assembling the cylinder head.

Disassembly and inspection of the rocker arm assembly.

Steps for disassembling the rocker arm assembly.

Inspection of rocker arm assembly components.

Checking rocker arm shaft run-out.

Measuring rocker arm shaft diameter.

Visual check and inspection of rocker arms.

Measuring rocker arm bushing diameter.

Checking clearance of tappets and push rods.

Visual inspection of tappet faces.

Measuring tappet outside diameter.

Measuring push rod run-out.

Reassembly steps for the rocker arm assembly.

Inspection of camshaft end play, cam lobe height, and surface.

Procedure for measuring camshaft end play.

Measuring cam lobe height and inspecting cam surface.

Checking clearance and run-out of camshaft.

Inspection of crankshaft for defects and wear.

Procedures for inspecting the crankshaft.

Visual and magnetic particle inspection for defects.

Measuring crankshaft journal and pin wear.

Standard and limit values for crankshaft journal diameter.

Standard and limit values for crankshaft pin diameter.

Measuring crankshaft run-out.

Visual check of bearings and measuring oil clearance.

Visual inspection of crankshaft and connecting rod bearings.

Measuring oil clearance using a dial gauge.

Measuring connecting rod bearing clearance.

Measuring oil clearance using plastic gauge.

Checking bearing spread and crush.

Measuring crankshaft bearing crush.

Measuring connecting rod bearing crush.

Measuring crankshaft end play.

Piston assembly inspection.

Disassembly process for piston assembly.

Inspection of pistons.

Visual check of pistons for cracks, scuff, wear.

Measuring piston to cylinder liner clearance.

Measuring cylinder liner inside diameter.

Calculating piston-to-liner clearance and replacement criteria.

Inspection and measurement of piston rings.

Visual inspection of piston rings.

Measuring piston ring gap.

Measuring piston ring side clearance.

Measuring piston ring tension.

Inspection of piston pins.

Measuring piston pin wear.

Measuring clearance between piston pin and connecting rod bushing.

Checking the engagement of piston and piston pin.

Inspection of connecting rods.

Checking connecting rod for distortion.

Measuring alignment of connecting rod holes.

Measuring connecting rod wear.

General precautions and steps for engine reassembly.

Essential precautions for engine reassembly.

Preparation for cylinder block reassembly.

Procedure for assembling oil spray nozzles.

Procedure for assembling tappets and camshaft.

Procedure for assembling the crankshaft.

Procedure for assembling the flywheel housing.

Procedure for assembling the rear oil seal.

Procedure for installing the flywheel ring gear and bearings.

Procedure for installing the tacho sensor.

Procedure for assembling the water chamber cover.

Procedure for installing cylinder liners.

Procedure for assembling pistons and connecting rods.

Aligning piston and connecting rod big end.

Installing snap rings and checking assembly.

Installing piston rings using pliers.

Adjusting piston ring gaps.

Installing connecting rod bearings.

Inserting piston into cylinder.

Installing connecting rod bearings and caps with torque.

Procedure for assembling the timing gear case.

Procedure for assembling timing gears and idle gear pins.

Aligning and installing idle gear with thrust washer.

Checking and adjusting gear backlash.

Procedure for assembling injection pump flange.

Procedure for installing and adjusting the injection pump.

Steps for adjusting injection timing.

Table showing fuel injection timing angles for different models.

Adjusting injection pump drive gear fixing bolt.

Aligning injection pump indicator plate notch.

Procedure for assembling oil pump and oil pipes.

Procedure for assembling the water pump.

Procedure for assembling the front oil seal.

Procedure for assembling the timing gear case cover.

Procedure for assembling the vibration damper.

Procedure for assembling the oil pan.

Procedure for installing the oil filter.

Identifying and assembling intake and exhaust valves.

Assembling valve stem seals and cotter pins.

Procedure for assembling the cylinder head.

Mounting cylinder head assembly and checking alignment.

Replacing cylinder head gasket and tightening bolts.

Torque specifications and tightening order for cylinder head bolts.

Step-by-step procedure for tightening cylinder head bolts.

Guide for adjusting valve clearance.

Steps for adjusting valve clearance using feeler gauge.

Final steps for valve clearance adjustment with torque.

Procedure for assembling the rocker arm assembly.

Procedure for assembling the intake manifold.

Procedure for assembling the exhaust manifold.

Procedure for assembling the turbocharger.

Procedure for assembling the cooling water pipe.

Procedure for installing the alternator.

Procedure for assembling the fuel filter.

Procedure for installing the injection nozzle.

Procedure for assembling injection pipes.

Procedure for assembling the cylinder head cover.

Procedure for installing the cooling fan.

Procedure for installing and tensioning the V-belt.

Procedure for assembling the oil level gauge.

Reference to the breaking-in section in Chapter 4.

General information about the engine's cooling system.

Explanation of how the liquid-cooling system operates.

Specifications for water pump, thermostat, and cooling fan.

General description, data, and inspection of the thermostat.

Common complaints and solutions for cooling system issues.

General descriptions and specifications of the lubricating system.

How the lubricating oil is circulated and filtered.

Diagram illustrating the lubricating system flow.

Disassembly, inspection, and reassembly of the oil pump.

Measuring shaft and bushing clearances for the oil pump.

Reassembly steps for the oil pump.

Troubleshooting common lubricating system issues.

General information and servicing of the fuel injection pump.

Components of the fuel system.

Servicing and adjustment of the injection pump.

Specifications for the D1146 injection pump and related parts.

Governor adjustment graph for D1146.

Specifications for the D1146T injection pump and related parts.

Governor adjustment graph for D1146T.

Specifications for the P086TI injection pump and related parts.

Main specifications and calibration data for PU086.

Rack diagram for PU086 governor adjustment.

Main specifications and calibration data for PU086T.

Rack diagram for PU086T governor adjustment.

Governor system components for P086TI.

Details of the integral actuator.

Overview and function of the speed control unit.

Introduction to the speed control unit's electronic governing function.

Detailed description of the speed control unit's features.

Procedure for starting the engine with speed control.

How to set and adjust governed engine speed.

Adjustments for governor performance (gain, stability).

Adjusting starting fuel to minimize exhaust smoke.

Setting and adjusting idle speed.

Explanation and adjustment of speed droop operation.

Connecting external accessories to the speed control unit.

Using the +10V regulated supply for accessories.

Using a potentiometer for remote speed adjustment.

Setting and testing the overspeed shutdown function.

Setting the run ramp turn-on speed.

Setting the crank ramp turn-on speed.

Troubleshooting steps for inoperative governing system.

Tests for unsatisfactory performance of the governing system.

Understanding and mitigating EMI effects on the governor system.

Identifying and correcting instability in the speed control system.

General descriptions and construction of the fuel feed pump.

Construction and operating principle of the fuel feed pump.

Steps for disassembling the fuel feed pump.

Inspection of fuel feed pump components.

Reassembly of the fuel feed pump.

Testing procedures for the fuel feed pump.

Testing the suction capacity of the fuel feed pump.

Testing the delivery rate of the fuel feed pump.

Testing the sealing of the fuel feed pump.

General descriptions, construction, and maintenance of injection nozzles.

How fuel is sprayed into the combustion chamber.

Components of the injection nozzle.

Steps for disassembling the injection nozzle.

Inspecting disassembled nozzle components.

Reassembly procedure for the injection nozzle.

Adjusting injection pressure and checking spray pattern.

Testing the nozzle for fuel leakage.

Troubleshooting engine starting and running issues.

Main data and specifications for turbochargers.

Technical data and specifications for turbochargers.

Diagram showing turbocharger construction.

How the turbocharger operates.

Explanation of supercharging and turbocharging.

Functions of turbocharger components.

Function of the turbine component.

Function of the compressor component.

Description of thrust and journal bearings.

Sealing mechanism for the compressor shaft.

Precautions for engine operation related to turbochargers.

Precautions for starting, operating, and stopping the engine.

Routine checks and servicing for the turbocharger.

Attention to air cleaner when servicing intake system.

Preventing gas leaks and seizure in the exhaust system.

Risks from improper fuel injection pump adjustment.

Importance of oil quality and filter changes for turbochargers.

Periodical checks for turbocharger condition and contamination.

How to check rotor rotating condition by sound.

Checking rotor axial and radial play.

Measuring rotor axial play.

Measuring rotor radial play.

Action if plays exceed limits.

Steps for turbocharger disassembly, cleaning, and checking.

Precautions for reassembling the turbocharger.

Lubricating system precautions during reassembly.

Intake system precautions during reassembly.

Exhaust system precautions during reassembly.

Troubleshooting common turbocharger issues.

Tools for injection pump setting.

Tools for inserting oil seals.

Tools for inserting oil seals.

Tools for pulling oil seals.

Tools for pulling oil seals.

Adapter for cylinder pressure tester.

Tool for pulling cylinder liners.

Tool for installing valve stem seals.

Tool for adjusting valve clearance.

Tool for pressing valve springs.

Tool for punching crankshaft gears.

Sleeve for piston installation.

Tool for measuring clearances.

Pliers for snap rings.

Pliers for piston rings.

Torque values for major engine parts.

Torque values for fuel injection pump system components.

Table of standard bolt tightening torques based on size and grade.

Tightening torque for hollow screws.

Table of maintenance specifications for engine components.