Table of Contents
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Table of Contents
Related Manuals for Doosan PU086
Summarization of Contents
Safety Regulations
General Notes
General information on safe handling of diesel engines and necessary resources.
Regulations Designed to Prevent Accidents
Instructions to prevent injury to persons and damage to property during operation.
Regulations Designed to Prevent Damage to Engine and Premature Wear
Guidelines to prevent engine damage and premature wear from improper use.
Regulations Designed to Prevent Pollution
Procedures for preventing pollution from engine oil, filters, and coolant.
Notes on Safety in Handling Used Engine Oil
Health precautions and proper disposal guidelines for used engine oil.
General Information
Engine Assembly
Detailed views and component identification of the engine assembly.
Engine Specification
Detailed technical specifications for various engine models.
Engine Power
Performance data including continuous, prime, and stand-by power outputs.
Technical Information
Engine Model and Serial Number
Information on locating and identifying engine model and serial numbers.
Engine Type
Description of engine configurations, aspiration, and cooling systems.
Engine Timing
Details on the gear train driving the camshaft, oil pump, and injection pump.
Valves
Explains valve actuation via tappets, push rods, and rocker arms from the camshaft.
Lubrication System
Explains the engine's force-feed lubrication system and its components.
Air Cleaner
Maintenance procedures for the air cleaner element, including cleaning and replacement intervals.
Fuel System
Details on fuel delivery, filtration, and requirements for optimal engine performance.
Cooling System
Explains the liquid-cooling system, water pump, and thermostat functions.
V-belt Tension Check and Adjust
Procedure for checking and adjusting V-belt tension for proper component drive.
Turbocharger
Details on turbocharger operation, lubrication, and air cooling.
Electrical Equipment
Information on wiring circuits, alternators, and starter motors.
Commissioning and Operation
Preparation
Checks and preparations required before initial engine commissioning or overhaul.
Breaking-in
Procedures for breaking in a new engine to ensure proper seating of parts.
Inspections after Starting
Checks to be performed after engine startup, including monitoring gauges and lamps.
Operation in Winter Time
Precautions for operating the engine in cold weather, focusing on coolant and oil.
Tuning the Engine
Steps and components involved in an engine tune-up to restore power and performance.
Maintenance and Care
Periodical Inspection and Maintenance
Importance of regular inspection, adjustment, and maintenance for engine performance.
Lubrication System
Procedures for exchanging lubrication oil, checking oil level, and filter replacement.
Cooling System
Procedures for changing coolant, draining, and cleaning the cooling system.
Intercooler (for P086TI)
Details on intercooler cleaning and heat transfer efficiency.
Air Intake System
Maintenance of the air intake system, including dust bowl emptying and filter element changes.
Fuel System
Procedures for fuel filter maintenance, fuel system checks, and contamination prevention.
Priming Pump Strainer Cleaning
Cleaning procedure for the priming pump strainer filter.
Injection Nozzle Maintenance
Procedures for checking and adjusting injection nozzle opening pressure and spray patterns.
Turbocharger
Maintenance procedures, special hints, and clearance checks for the turbocharger.
Checking and Setting
Adjustment of Valve Clearance
Detailed procedure for adjusting valve clearances on engine components.
Adjustment of Injection Timing
Method for adjusting engine injection timing using flywheel marks.
Cylinder Compression Pressure
Procedure for measuring cylinder compression pressure to assess engine health.
V-belts
Guidelines for changing, checking, and measuring V-belt tension.
Operation Tip
Periodic Inspection Cycle
A table outlining daily, 50hr, 200hr, etc. inspection and maintenance tasks.
Trouble Shooting
Diagnostic flowcharts for common engine starting and operational problems.
Repair Information
General Repair Instructions
Essential precautions and guidelines for performing engine service operations.
Engine Characteristic
Explanation of toroidal and OMEGA combustion bowl characteristics.
Maintenance
Engine Disassembly
Step-by-step instructions for disassembling various engine components.
Inspection
Procedures for inspecting cylinder blocks and cylinder heads for damage and wear.
Camshaft
Inspection of camshaft end play, cam lobe height, and clearances.
Crankshaft
Inspection of crankshaft for defects, wear, run-out, and bearing clearances.
Piston Assembly
Disassembly and inspection of pistons, piston rings, and piston pins.
Reassembly
General precautions and detailed steps for reassembling engine components.
Crankshaft
Installation of main bearings and crankshaft into the cylinder block.
Flywheel housing
Procedure for installing the flywheel housing with gasket and bolts.
Rear Oil Seal
Installation of the rear oil seal using a fitting jig.
Tacho Sensor (Pick-up Sensor)
Installation and adjustment of the tacho sensor on the flywheel housing.
Cylinder Liner
Procedures for cleaning and installing cylinder liners into the cylinder block.
Piston and Connecting Rod
Heating pistons and assembling pistons with connecting rods using piston pins.
Timing Gear Case
Mounting and tightening the timing gear case with a new gasket.
Injection Pump Flange
Assembling the injection pump gear and flange with gasket and bolts.
Injection Pump
Installing the injection pump bracket and adjusting shims for run-out.
Oil Pump and Oil Pipe
Assembling the oil pump, oil delivery pipe, and return pipe.
Water Pump
Mounting the water pump on the cylinder block and connecting water pipes.
Vibration Damper
Inserting and tightening the vibration damper onto the crankshaft.
Oil Filter
Installing the oil filter onto the cylinder block and tightening fixing bolts.
Cylinder Head
Cleaning the head gasket surface and assembling the new head gasket.
Cylinder Head Bolts
Procedures for tightening cylinder head bolts using specified torque and angle.
Rocker Arm Assembly
Applying oil and assembling rocker arm assemblies with adjusting bolts.
Intake Manifold
Installing the intake manifold with a new gasket and tightening assembling bolts.
Exhaust Manifold
Installing the exhaust manifold gasket and assembling the manifold with heat resisting plate.
Fuel Filter
Assembling the fuel filter with the intake manifold and fuel feed hose.
Cylinder Head Cover
Assembling the cylinder head cover with a new gasket and tightening fixing bolts.
Maintenance of Major Components
Cooling System
General information and specifications for the engine's water-cooling system.
Cooling System Specifications
Specifications for water pump, thermostat, and cooling fan belt.
Thermostat
Inspecting and replacing the thermostat, with precautions for handling.
Cooling System Diagnostics and Troubleshooting
Troubleshooting common cooling system complaints like overheating and noise.
Lubricating System
General descriptions and specifications for the engine's lubricating system.
Oil Pump
Disassembly, inspection, and correction procedures for the engine oil pump.
Lubricating System Diagnostics and Troubleshooting
Troubleshooting common issues related to oil consumption, pressure, and deterioration.
Fuel Injection Pump
General information on the fuel system and injection pump servicing recommendations.
Governor System (P086TI Only)
Description of the governor system for fuel injection pumps, including integral actuator.
Speed Control Unit for Governor System
Details on the DWC-2000 Series speed control unit for engine governing.
Governor System Specifications
Performance, environmental, power input, and reliability specifications for the governor.
Governor System Adjustments
Procedures for setting gain, stability, idle speed, and starting fuel.
Governor System Troubleshooting
Troubleshooting steps for inoperative or poorly performing governing systems.
Fuel Feed Pump
General descriptions and construction of the fuel feed pump, including priming pump.
Injection Nozzle
General descriptions, construction, disassembly, inspection, and reassembly of injection nozzles.
Injection Nozzle Adjustment and Testing
Procedures for adjusting injection pressure and testing for fuel leakage.
Fuel Injection System Diagnostics and Troubleshooting
Troubleshooting common fuel injection system issues like starting problems and power loss.
Turbocharger
Main data, specifications, and construction details of the turbocharger.
Turbocharger General Descriptions
Explanation of how turbochargers increase engine output by compressing air.
Turbocharger Operation Precautions
Safety precautions for starting, operating, and stopping the engine with a turbocharger.
Turbocharger Walk-around Check and Servicing
Servicing guidelines for intake, exhaust, fuel, and lubricating systems affecting turbocharger.
Turbocharger Periodical Checking and Servicing
Procedures for checking rotor rotating condition and end play for the turbocharger.
Turbocharger Diagnostics and Troubleshooting
Troubleshooting common turbocharger issues like black smoke and low engine output.
Appendix
Tightening Torque for Major Parts
Standard torque values for tightening major engine components and bolts.
Standard Bolt Tightening Torque Table
Comprehensive table of standard tightening torques for various bolt sizes and strengths.
Maintenance Specification Table
Table detailing stand values and limits for various engine component inspections.
Crankshaft and Connecting Rod Maintenance Specifications
Specifications for crankshaft, connecting rod, and camshaft inspections and measurements.
Valve System Maintenance Specifications
Specifications for valve stem, clearance, spring, and rocker arm inspections.
Tappet and Oil Pressure Specifications
Specifications for tappet clearance, oil pressure, and oil pump clearances.
Cooling System and Fuel System Specifications
Specifications for radiator, water pump, thermostat, and fuel system components.
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