DOOSAN Marine Diesel Engine L136 T TI L086TI Service Repair Manual

FOREWORD This manual is designed to serve as an instruction for the Operation & Maintenance of marine propulsion engines (L136/T/TI/086TI) and marine auxiliary engines (AD136/T/TI/086TI), combined in one book. The first half is explained for operation and the latter half is described 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. Some figures of this manual may be different from the actual appearance of the engine because of explaining them with the representative figure among these models. 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 manual instruction may be changed without prior notice for some quality improvement. Thank you. Sep. 2003 DOOSAN Infracore Co., Ltd. Removal Adjustment Installation Cleaning Disassembly Pay close attention-Important Reassembly Tighten to specified torque Align the marks Use special tools of manufatur’s Directional Indication Lubricate with oil Inspection Lubricate with grease Measurement

CONTENTS Operation Parts 1. Specification ......................................................................................................................... 1 1.1. Engine Specification 1.3. Engine Performance Curve 1.2. Engine Aspects 1.4. Engine Model & Serial Number 2. Safety Regulations .............................................................................................................. 8 2.1. General Notes 2.4. Regulations Designed to Prevent Pollution 2.2. Regulations Designed to Prevent 2.5. Notes on Safety in Handling Used Engine Oil Accidents with Injury to Persons 2.3. Regulations Designed to Prevent Damage to Engine and Premature Wear 3. Commissioning and Operation ..................................................................................... 12 3.1. Inspections Before Operation 3.5. Check After Initial 50 Hours Operation 3.2. Starting 3.6. Operation in Winter Time 3.3. Engine Break-in 3.7. Tuning the Engine 3.4. Inspection After Starting 4. Maintenance and Care ..................................................................................................... 21 4.1. General Instructions 4.6. Fuel System 4.2. Periodical Inspection & Maintenance 4.7. Electric System 4.3. Cooling System 4.8. Cylinder 4.4. Lubrication System 4.9. Engine Preservation Points for a Long Time 4.5. Intake & Exhaust System 4.10. Management for Sunken Engine 5. Main Accessory Parts ...................................................................................................... 43 5.1. Reduction Gear 5.3. Propeller Selection 5.2. Front Power Take-Off (F.P.T.O) 5.4. Electric System Maintenance Parts 6. Disassembly and Assembly of Major Components ................................................. 50 6.1. Disassembly 6.3. Engine Re-assembly 6.2. Inspection 6.4. Break-in After Maintenance 7. Main Parts Maintenance ................................................................................................ 105 7.1. Lubricating System 7.3. Fuel System 7.2. Cooling System 7.4. Turbocharger 8. Trouble Shooting ............................................................................................................. 166 9. Special Tool List ................................................................................................................ 172 10. Tightening Torque ........................................................................................................... 174 11. Maintenance Specification Table for Major Parts .................................................. 176 • Part & After service center • Applications for Doosan Engine

1. Specification 1.1. Engine Specification 1.1.1. L136/T/TI - 1 - Engine type Rating output (B.H.P) PS(kW)/rpm 160(118)/2,200 200(147)/2,200 240(177)/2,500 230(169)/2,200 Displacement cc 8,071 Cyl. No. – bore( ) x stroke mm 6 - 111 x 139 Valve clearance at cold mm In. : 0.3 , Ex. : 0.3 Low idling rpm rpm 725 ± 25 No load max. rpm rpm below 2,400 below 2,750 below 2,400 Mean effective press. (Initial ) kg/cm 2 8.07 10.14 10.71 11.66 Mean piston speed m/sec. 10.19 11.58 10.19 Compression ratio 17.6 16.7 Max. firing pressure of cylinder kg/cm 2 80 117 128 106 Comp. pressure (at 200 rpm) kg/cm 2 28 ( Initial condition) Governor type of injection pump Mechanical all speed (R.S.V) Fuel consumption g/PS.h 165 155 172 162 liter/h 32 37 50 45 Injection timing (B.T.D.C) deg. 18° ±1° 14° ±1° Inj. nozzle opening pressure kg/cm 2 214 + 8 Starting system Electric Starting by starter motor Starter motor capacity V- kW 24 V – 4.5 Alternator capacity V- A 24 V – 50 Battery V- Ah 24V – 150 Cooling system Indirect cooling by sea water with heat exchanger Cooling water capacity lit Max. : 27 , Min. : 25 Fresh water pump type Centrifugal type, driven by V- belt Sea water pump type Rubber impeller type driven by gear Lub. Oil Pan capacity lit Max : 23, Min : 17 ( Engine total : 25) (Engine) Pressure kg/cm 2 Full : 3.5, Idle: 1.2 Direction of Crankshaft Counter clockwise viewed from stern side revolution Propeller Clockwise viewed from stern side Engine size Without M.G mm 1,182 x 770 x 925 1182 x 766 x 925 1,182 x 825 x 925 (L x W x H) With M.G mm 1,546 x 770 x 937 1,541 x 766 x 963 1,552 x 825 x 1,027 Engine Without M.G kg 735 745 773 dry weight With M.G kg 920 935 994 Units L136 L136T L136TL L136TI Model Spec. 4 cycle, in line, direct- injection, water cooled naturally aspirated 4 cycle, in line, direct- injection, water cooled with turbo charger 4 cycle, in line, direct- injection, water cooled with turbo charger & inter-cooler

1.1.2. L086TI Note : L086TIL model is not available right now but shows only the development target in future. Engine type Rating output (B.H.P) PS(kW)/rpm 285(210)/2,100 300(221)/2,300 360(265)/2,500 Displacement cc 8,071 Cylinder No. - bore( ) x stroke mm 6 - 111 x 139 Valve clearance at cold mm In. : 0.3, Ex. : 0.3 Low idling rpm rpm 750 ± 25 No load max. rpm rpm below 2,310 below 2,530 below 2,750 Mean effective press. (Initial ) kg/cm 2 15.14 14.55 16.06 Mean piston speed m/sec. 9.73 10.66 11.58 Compression ratio 16.7 15.3 Max. firing pressure of cylinder kg/cm 2 130 130 135 Comp. pressure (at 200 rpm) kg/cm 2 above 28 (Initial condition) Fuel consumption g/PS.h 152 163 170 liter/h 52 62 74 Injection timing (B.T.D.C) deg. 15° ±1° Inj. nozzle opening pressure kg/cm 2 214 + 8 Starting system Electric Starting by starter motor Starter motor capacity V- kW 24 V - 4.5 Alternator capacity V- A 24 V - 50 Battery V- Ah 24V - 150 Cooling system Indirect sea water cooling with heat exchanger Cooling water capacity lit Max. : 25 , Min. : 23 Fresh water pump type Centrifugal type, driven by V- belt Sea water pump type Rubber impeller type driven by gear Pan capacity lit Max : 23, Min : 17 (Engine total : 25) Pressure kg/cm 2 Full : 3.5, Idle: 1.2 Crankshaft Counter clockwise viewed from stern side Propeller Clockwise viewed from stern side Without M.G mm 1,182 x 825 x 962 With M.G mm 1,557 x 825 x 1,062 Without M.G kg 790 With M.G kg 1,015 L086TI L086TIH L086TIM L086TIL - 2 - Units Model Spec. 4 cycle, in line, direct- injection, water cooled with wet-turbo charger & inter-cooler Lub. Oil (Engine) Governor type of injection pump Mechanical all speed (R.S.V) Engine size (L x W x H) Engine dry weight Direction of revolution

1.1.3. AD136/T/TI/086TI - 3 - Engine type 105(77) / 1,500 145(107) / 1,500 157(115) / 1,500 205(151) / 1,500 Rating output PS(kW) (AD136F) (AD136TF) (AD136TIF) (AD086TIF) (B.H.P) / rpm 126(93) / 1,800 170(125) / 1,800 188(138) / 1,800 253(186) / 1,800 (AD136S) (AD136TS) (AD136TIS) (AD086TIS) Displacement cc 8,071 Cylinder No. - bore( ) x stroke mm 6 - 111 x 139 Valve clearance at cold mm 0.3 / 0.3 Low idling rpm rpm 725 ± 25 No load max. rpm rpm (50Hz / 60Hz) Mean effective press. (Initial ) kg/cm 2 7.81 / 7.81 10.78 / 10.53 11.65 / 11.65 15.24 / 15.67 Mean piston speed m/sec. 6.95 / 8.34 Compression ratio 17.6 16.7 Max. firing press. of cylinder kg/cm 2 74.4 / 79.5 105 / 117.3 109.1 / 127.5 109.1 / 127.5 Comp. Press. (at 200 rpm) kg/cm 2 About 28 (Initial condition) Governor type of inj. pump Electric Governor Fuel consumption g/PS.h 160 / 160 153 / 155 153 / 153 150 / 151 liter/h 20 / 24 27 / 32 29 / 34 37 / 46 Injection timing (B.T.D.C) deg. 14° ±1° 15° ±1° Inj. nozzle opening press. kg/cm 2 224 Starting system Starter motor capacity V- kW 24 V - 4.5 Alternator capacity V- A 24 V - 50 Battery V- Ah 24V - 150 Cooling system Cooling water capacity lit Fresh water pump type Sea water pump type Lub. Oil Pan capacity lit (Engine) Pressure kg/cm 2 Revolution of Crankshaft Engine only size (L x W x H) mm 1,182x770x925 1,182x766x925 1,182x825x925 1,182x825x962 Engine only (Dry weight) kg 735 745 773 790 Units AD136 AD136T AD136TI AD086TI Model Spec. 4 cycle, in line, direct- injection, water cooled naturally aspirated 4 cycle, in line, direct- injection, water cooled with turbo charger 4 cycle, in line, direct- injection, water cooled with turbo charger & inter-cooler 4 cycle, in line, direct- injection, water cooled with wet-turbo charger & inter-cooler Mechanical governor : 1575 (52.5 Hz) / 1890(63Hz), Electric governor : 1575 (52.5 Hz) / 1890(63Hz), 18° ±1° Electric Starting by starter motor 50 Hz 60 Hz Indirect cooling by sea water with heat exchanger Max. : 25, Min. : 23 Centrifugal type, driven by V- belt Rubber impeller type driven by gear Max : 23, Min : 17 (Engine total : 25) Full : 3.5, Idle: 1.2 Counter clockwise viewed from stern side

1.2. Engine Aspects 1.2.1. Engine Sectional Drawing - 4 - 13 12 25 20 26 8 18 3 2 4 14 16 5 6 15 1 17 27 28 19 7 22 9 21 23 11 10 24 EC5OM100 1. Cylinder block 11. Camshaft 21. Oil pump 2. Cylinder head 12. Vibration damper 22. Oil cooler 3. Cylinder head cover 13. Camshaft pulley 23. Oil pan 4. Cylinder liner 14. Piston 24. Oil suction pipe 5. Flywheel housing 15. Connecting rod 25. Water pump 6. Flywheel 16. Piston pin 26. Sea water pump 7. Rocker arm 17. Piston cooling spray nozzle 27. Exhaust manifold 8. Push rod 18. Turbocharger 28. Intake manifold 9. Tappet 19. Multi-hole injection nozzle 10. Crankshaft 20. Valve

1.2.2. Engine Assembly 1. Crank pulley 10. Oil pan 19. Thermostat housing 2. Expansion tank 11. Injection pump ass’y 20. Breather ass’y 3. Fuel filter 12. Oil guide tube & level gauge 21. Exhaust manifold 4. Oil cooler cover 13. Water pump 22. Oil filler cap 5. Intake manifold 14. Fresh water filler cap 23. Exhaust outlet pipe 6. Intercooler 15. Sea water pump 24. Turbocharger(wet) 7. Oil drain pump 16. Heat exchange ass’y 25. Clutch oil press. gauge 8. Flywheel housing 17. Starter 26. Marine gear oil cooler 9. Oil filter 18. Marine gear ass’y 27. Sea water outlet pipe 27 26 13 21 8 7 12 11 10 6 5 3 14 15 1 4 16 17 18 9 22 19 20 23 24 25 2 EC5OM099 - 5 -

1.3. Engine Performance Curve 1.3.1. L136 / L136T / L136TI /L136TL 1.3.2. L086TI - 6 - EC5OM136 1000 1500 100 200 300 400 (g/ps.h) 2000 2500 1000 1500 100 200 300 400 2000 2500 1000 1500 100 200 300 400 2000 2500 1000 1500 100 200 300 400 2000 2500 150 160 170 (g/ps.h) 150 160 170 (g/ps.h) 150 160 170 (g/ps.h) 150 160 170 L136 Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m) Output (PS) Output (PS) Output (PS) Output (PS) L136T L136TI L136TL Full Load Propulsion Curve Propulsion Curve Fuel Consumption Operation Range Operation Range Full Load Fuel Consumption Propulsion Curve Operation Range Full Load Fuel Consumption Operation Range Full Load Propulsion Curve Fuel Consumption EC5OM137 1000 1500 100 (g/ps.h) 2500 2000 160 150 170 200 300 400 500 1000 1500 100 (g/ps.h) 2500 2000 160 150 170 200 300 400 500 1000 1500 100 (g/ps.h) 2500 2000 160 150 170 200 300 400 500 Heavy Duty Medium Duty Light Duty Engine Speed (r.p.m) Engine Speed (r.p.m) Engine Speed (r.p.m) Output (PS) Output (PS) Output (PS) Full Load Propulsion Curve Fuel Consumption Operation Range Full Load Propulsion Curve Fuel Consumption Fuel Consumption Operation Range Full Load Propulsion Curve Operation Range

1.4. Engine Model & Serial Number The engine serial number is inscribed on the engine as illustrated. This number is required when requesting warranty and ordering parts. It is also referred to as engine model and serial number because of their location. Note : The engine model name (L136/T/TI/086TI) is described in the name plate on the cylinder block. • Engine serial No. (Example : L086TI) EBPKM300001 - 7 - EC5OM138 Name Plate Engine Plate Serial No. Production Year(2003) Engine Model Suffix

DOOSAN Marine Diesel Engine L136 T TI L086TI Service Repair Manual

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