Doosan MD Series, L Series, V Series, L034, L034TI Installation Instructions Manual

PREFACE

•

General information

This installation instruction is designed as a guide for the proper installation of DOOSAN

(Doosan Infracore Ltd. hereafter DOOSAN) marine diesel engines and to create conditions for

faultless operation of the entire system and to prevent installation related malfunctions and

possible consequential damage to the engine.

•

Scope

This installation instruction applies to all DOOSAN engines for marine propulsion and marine

generator.

•

Warranty

Warranty claims against DOOSAN Marine Engines will be accepted only if this installation

instruction has been complied with.

If any modification to the engine installation intended by DOOSAN is planned, DOOSAN must be

informed in writing, and a new inspection may necessary.

We reserve the right to make technical modifications in the course of further development.

•

Validity

DOOSAN reserves the right to make changes at any time, without notice, in specifications and

models and also to discontinue models. The right is also reserved to change any specifications or

parts at any time without noticing any obligation to equip same on models manufactured prior to

date of such change.

The continuing accuracy of this manual cannot be guaranteed.

All illustrations used in this manual may not depict actual models or equipment and are intended

as representative views for reference only.

- a -

•

Marine engine Recommendation on applications

The engine must be able to achieve rated engine speed when operated under fully

loaded conditions;

Secondary drive loads must be considered engine horse power which could be available to

drive the primary load. Therefore any such parasitic load requirements must be deducted when

sizing an engine for the primary load.

The engine must be used in accordance with the application guidelines for that

particular rating;

It is important to choose the proper engine rating to provide the optimum performance in a

given application. Ratings below show DOOSAN marine engine guidelines on applications.

(1) Heavy duty

•

Operation hours : Unlimited per year

•

Average load application : Up to 90%

•

Percentages of time at full load : Up to 80%

•

Typical gear box ratio : 2.5 ~ 6

(Application: Fishing trawler, Tug boat, Pushing vessel, Cago boat, Freighter, Ferry)

(2) Medium duty

•

Operation hours : Up to 3,000hr per year

•

Average load application : Up to 70%

•

Percentages of time at full load : Up to 30%, 4hrs per 12 hour operation period

•

Typical gear box ratio : 2 ~ 3.5

(Application:

Fishing boat, Pilot boat, Escort boat, Passenger boat, Ferry, Cruising Vessel

)

(3) Light duty

•

Operation hours : Up to 1,000hr per year

•

Average load application : Up to 50%

•

Percentages of time at full load : Up to 20%, 2hrs per 12 hour operation period

•

Typical gear box ratio : 1 ~ 2.5

(Application:

Fishing boat, Pilot boat, Escort boat, Passenger boat, Ferry, Cruising Vessel

)

- b -

•

Other country regulation

Other country may apply additional internal regulation. Please follow their appropriate advice.

Korea : KR = Korean Resister of Shipping

Sweden : Navigation Office

Finland : Navigation Office

Norway : DNV = Det Norske Veritas

USA : ABS = American Bureau of shipping

Indonesia : BKI = Biro Klasifikasi Indonesia

USA : NMMA = National Marine Manufacturers Association

England : LR = Lloyds Register of Shipping

France : BV = Bureau Veritas

Germany : GL = Germanisher Lloyd

Italy : RINA = Regislro Italiano Navale

Bulgaria : BKP = Bulgarian Register of Shipping

China : CCS = China Classification Society

China Rep.(Taiwan) : CR = China Corporation Register of Shipping

Spain : FN = Fidenavis

Croatia : CRS = Croatian Register of shipping

India : IRS = Indian Register of Shipping

Japan : NK = Nippon Kaiji Kyokai

Poland : PRS = Polski Register Statkow

Portugal : RP = Rinave Portuguesa

Rumania : RNR = Registrul Naval Roman

Russia : MRS = Russian Maritime Register of Sipping

Turkey : TL = Turk Loydu Vakfi

- c -

CONTENTS

CHAPTER 1 Engine Room .............................................................................................................1

1.1. Engine Room Ventilation 1.4. Power Rating

1.2. Engine Foundation 1.5. Inclinations

1.3. Max. Permissible Engine Inclination

CHAPTER 2 Engine Mounting .......................................................................................................6

2.1. Flexible Mounting 2.3. Arrangement of Engine and Reduction Gear

2.2. Solid Mounting

CHAPTER 3 Front Power Take off...............................................................................................13

3.1. Marine Installation Requirements 3.3. Belt Drives

3.2. Front Power Take-off Clutches

CHAPTER 4 Exhaust System.......................................................................................................18

4.1. Marine Installation Requirements 4.4. Direction of Exhaust Outlet

4.2. Dry Exhaust Systems(without sea 4.5. Permissible Back Pressure

water injection) 4.6. Designing the Exhaust System

4.3. Wet Exhaust System(with sea water 4.7. Measuring the Pressure Drop

injection)

CHAPTER 5 Intake System ..........................................................................................................30

5.1. Air Intake 5.4. General Note on Air Guidance

5.2. Engine Room Ventilation 5.5. Clear Cross Section

5.3. Radiant Heat to be Removed

CHAPTER 6 Cooling System .......................................................................................................35

6.1. Marine Installation Requirements 6.5. Engine Coolant

6.2. Selection of Piping Materials 6.6. Sea Water Lines

6.3. Cooling Circuit 6.7. Keel Cooler

6.4. Engine Cooling System

CHAPTER 7 Lubricating System .................................................................................................55

7.1. Marine Installation Requirements 7.3. Lube Oil Drain Pump

7.2. Engine Blow- by Gas Vent 7.4. Oil Dipstick Level Gauge

CHAPTER 8 Fuel System ...........................................................................................................57

8.1. Fuel Circuit 8.2. Fuel Tank

- a.4 -

CHAPTER 9 Propulsion System..................................................................................................64

9.1. Marine Gear Ratio Selection 9.5. Designing of the Propeller

9.2. How to Select the Right Propeller System 9.6. Propeller Tip Clearance

9.3. Propeller selection 9.7. Propeller Rotation in Twin Engine Applications

9.4. Power Drive with Fixed Pitch Propeller

CHAPTER 10 Electrical System...................................................................................................75

10.1. Electric Circuit 10.2. Electric Components

•

Appendix ....................................................................................................................................81

•

Part & After service center

•

Applications for DOOSAN Engine

- a.5 -

CHAPTER 1 ENGINE ROOM

When installing the engine, ensure that there is sufficient space for regular maintenance work

and possible engine overhaul after prolonged periods of operation. It must be possible to carry

out the following jobs on engine and gearbox without obstruction;

•

Removing heat exchanger and inter-cooler for cleaning

•

Exchanging starter, alternator and water pump

•

Filling up with fuel, oil and coolant

•

Checking oil and coolant level

•

Changing fuel, oil and air filter

•

Setting valves, re-tightening cylinder head bolts

•

Draining oil and coolant

•

Re-tightening and exchanging V - belts

•

Maintenance and exchange of battery

•

Exchanging injection nozzles

•

Changing the sea water pump impeller

•

Changing the reduction gear

1.1. Engine Room Ventilation

Calculation of the air requirements for the dissipation of convection and radiation heat can be

simplified the following formula:

where

•

m Air mass flow rate in kg/h

•

Q Convection and radiation in MJ/h

C

p

Specific heat capacity of air = 1 kJ/(kg x degree)

Δt Difference in temperature between heated waste air and cold intake air in degrees Celsius

In order to obtain the air volume flow (m

3

/h) the air mass flow (kg/h) must be divided by the air

density, which depends on the temperature.

Air density as a function of the temperature at the air pressure of 0.98kg/cm

2

(1000 mbar).

- 1 -

•

•

m =

Q x 1000

C

p

x Δt

Temperature in ˚C Density in kg/m

3

0 1.28

10 1.23

20 1.19

30 1.15

40 1.11

50 1.08

The before-mentioned formula is based on the assumption that the engine room is a heat-tight

system, i.e. for the sake of simplicity it is assumed that no thermal energy whatever is

dissipated through the hull to the ambient air or water.

In practice, however, such heat losses are likely to occur and depend on the following factors:

•

Size and surface area of the engine room

•

Difference in temperature between the engine room and the ambient air

•

Hull material (thermal conductivity) and hull thickness

•

Heat dissipation via pipes (e.g. exhaust pipes)

This heat transfer is therefore hard to estimate qualitatively.

Note : The difference of engine room and ambient air temperature (

Δ

t) would be better

below than 15

˚

C, but should not exceed maximum 20

˚

C.

Δt = (Air temperature of engine room) - (Ambient temperature)

<Conversion table of physical units >

•

Temperature

t(degree Celsius) = T(Kelvin) - 273

T(Kelvin) = t (degree Celsius ) +273

t (degree Fahrenheit) = 1.8 x t (degree Celsius) + 32

•

Pressure

1 kilo-Pascal (kPa) = 10 millibar (mbar)

1 hecto-Pascal (hPa) = 1 millibar (mbar)

•

Energy flow

Mega - Joule/hour (MJ/h) x

1000

= Kilocalories/hour (kcal/h)

4.187

Mega - Joule/hour (MJ/h) x

1

= Kilowatt (kW)

3.6

- 2 -

1.2. Engine Foundation

Requirements for the engine foundation are as following;

•

The foundation in the vessel should be able to take up propeller thrust in both directions

(ahead & astern) and transmit it on to the hull.

•

The weight of the drive system as well as all dynamic forces that occur in rough seas must

be safely taken up.

•

The torsion of the hull owing to rough seas and the load status must not be transferred to

the engine. The engine foundation is to be connected to the hull on an area as large as

possible

EB0O1001

Engine bed

Stringer

Engine mounting bracket

EB0O9007

•

Transverse cross bracing on the engine

bed and stringers should be used to

prevent lateral engine movement on solid

mounted systems.

•

In order to properly support the weight of

the engine and marine gear, a six-point

mounting system is recommended on all

DOOSAN marine engines.

When using a six-point mounting system,

the engine should be aligned using the

mounts at the front and at the marine gear

at first. Once the alignment is complete,

the next flywheel housing mounts should

be added.

- 3 -

1.3. Max. Permissible Engine Inclination

The installation angle of the engine is an important factor in the construction of the sub-frame.

When the engine is to be installed in longitudinal direction, The maximum permissible inclination

must not be exceeded. The maximum permissible inclination is defined as the largest angle that

occurs in driving operation, ie, installation inclination plus the ship’s maximum trim angle.

The maximum installation angle of the engine is the maximum permissible inclination angle ( )

of the boat less the angle of the maximum trim( ) while the vessel is in motion. ie, the maximum

installation angle of the engine is( - ).

= max. permissible vessel inclination angle ; angle towards the flywheel end

= angle towards the non flywheel end

= trim of the vessel

<The maximum angles of inclination for the various engine are shown in below table>

Note : angle

The angle of 5˚toward the non-flywheel and must occur only while the vessel

is in motion.

- 4 -

Water line

EB0O1003

Max. oil pan permissible Max. angle of

Engine model angle of inclination engine installation

to the rear : ( ) inclination : ( - )

L034 / L034TI 20

˚

5

˚

L066TI 30

˚

5

˚

L136 / L136T 17

˚

5

˚

L136TI / L086TI 17

˚

5

˚

L196T / L196TI / L126TI 17

˚

5

˚

V158TI 17

˚

5

˚

V180TI 25

˚

5

˚

V222TI 25

˚

5

˚

If the installation angle of the engine is greater than that listed upper, the engine may occur

any engine damage. That is, connecting rods begin to dip into the oil in oil pan. So, this may

also cause high oil consumption, low power and the breather gas increasing and more

smokes. We recommend the engine installation angle to install below 6 degree for DOOSAN

marine engines.

1.4 Power Rating

Diesel engines are to be so designed that when running at rated speed their rated power can

be delivered as a continuous power. Continuous power means the net brake power which an

engine is capable of delivering continusously between the maintenance intervals stated by the

engine manufacturer.

To determine the power of all engines used on board ships with an unlimited range of service,

the following ambient conditions are to be used:

Engine driving generators are to be capable of developing 10% for a short period.(15minutes)

1.5 Inclinations

All components and systems shall be capable to operate in the following trim and pitch

positions.

1) Athwartships and for - and - aft inclinations may occur simultaneously.

2) Where the length of the ship exceeds 100m, the fore - and - aft static angle of inclination

may be taken as : (500)˚/L where L = length of ship(m).

3) In ships for the carrige of liquefied gases and of chemicals the emergency power supply

must also remain operable with the ship flooded to a final athwartships inclination up to

maximum 30˚.

- 5 -

Classification Barometric

Temperatures

Relative

societies pressure

Intake air

Seawater/

humidity

charge air coolant

DNV According to ISO3046/1

BV 1,000 mbar 45

˚C

32

˚C

60%

GL 1,000 mbar 45

˚C

32

˚C

60%

LR 1,000 mbar 45

˚C

32

˚C

60%

RINA Propuision 1,000 mbar 15

˚C

15

˚C

-

RINA Aux. service 1,000 mbar 45

˚C

30

˚C -

KR 1,000mbar 45

˚C

32

˚C

60%

Angle of inclination

1)

Installation ABS BV DNV GL LR RINA KR

Stat. Dyn. Stat. Dyn. Stat. Dyn. Stat. Dyn. Stat. Dyn. Sta. Dyn. Sta. Dyn.

Main and AUX athwartships

15 22.5 15 22.5 15 22.5 15 22.5 15 22.5 15 22.5 15 22.5

For - and - aft 5 7.5 5 7.5 5 7.5 5 7.5 52)7.5 5 7.5 5 7.5

Emergency athwartships

3)

22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5 22.5

For - and - aft 10 10 10 10 10 10 10 10 10 10 10 10 10 10

CHAPTER 2 ENGINE MOUNTING

2.1. Flexible Mounting

Flexible mounting will generally be chosen for yachts and small boats because it reduces

vibration and noise levels.

Flexible engine mounts use the rubber isolators to absorb engine vibration before it is

transmitted to the hull. This will reduce noise and vibration in the boat. There are wide variety

of flexible mounts available on the market. Any mounts selected must hold the engine in

alignment and provide for acceptable mounting life. The isolator manufacturer should be

consulted for further recommendations.

The engine should be installed with sufficient clearance on all sides so that the allowable

engine movement will not cause structural or component damage.

Note : If the reduction gear must be mounted prior to installation in the hull, the

engine and reduction gear should be mounted on base rails and the whole

system installed together.

- 6 -

1

2
3

4

5

6

max. 10mm

EHO9001S

1. Mounting nut

2. Washer

3. Threaded pin

4. Clamp sleeve

5. Height adjustment

6. Shim
( manufactured as required)

Shims

2.2. Solid Mounting

The solid mounting engine is usually done by using brass or steel shims, pourable choking

compound and pads. The use of pourable choking compounds is the simplest and preferred

ways to solid mount the engine.

When using a choking compound, the alignment of the reduction gear and propeller shaft is

accomplished using jacking screws between the support brackets and the engine bed. The

mounting bolts can be loosely put into place at this point or a hole can be drilled through the

choking compound later. The jacking screws, mounting bolts and bottom of the engine bracket

should be coated with a grease or anti-bonding substance to allow them to be removed later.

Temporary dams are put on the engine bed and should extend approximately 13mm (0.5”)

above the bottom of the engine beds. The choking compound is poured in to fill the space

between the bracket and engine bed. Once the compound has solidified, the jacking screws

can be removed or left in place and the final mounting bolts are torqued down.

When using jacking screws on wood or fiberglass engine beds, steel plates should be used

under the jacking screws to prevent damage to the engine bed.

The choking compound manufacturer should be consulted for further recommendations.

- 7 -

EB0O2001

Engine
bracket

Chocking
compound

Temperary
dam

13mm(0.5")

Engine
bed

Jacking
screw

If a front power take-off clutch is used, it is a good practice to support the clutch. The clutch

available from DOOSAN marine Vee Series Models must be supported to avoid over stressing

the nose of the crankshaft due to the overhung weight.

- 8 -

EB0O2002

Fabreeka

washer

Steel tubing

approx. 0.8mm(1/32")

shorter than total

thickness of

fabreeka pads and

support bracker

13mm(1/2") fabreeka pad

Engine bad

4.8mm(3/16") steel plate
same length and

width as

fabreeka pads

Fabreeka type washers and pads consist of

layers of rubber impregnated canvas and

will provide a small amount of flexibility for

minor misalignment and a degree of

protection from shock loading. A steel plate

is required between the nut and Fabreeka

pad to protect the pad from wear and should

be the same size as the pad. It is still

necessary to use brass or steel shims to

align the engine and gear with the shafting.

Clutch support

EB0O2003

2.3. Arrangement of Engine and Reduction Gear

2.3.1. Engine and flanged-on reversing reduction gear

Engine and reduction gear can be constitute a unit. Propeller thrust is taken up by a

reduction gear thrust bearing.

In order to isolate engine vibration and prevent it from being transferred to the hull through the

propeller shaft, DOOSAN recommends that the distance from the reduction gear output flange

to a fixed stuffing box or first fixed bearing should be a minimum of 20 times the shaft

diameter. If the distance is less than this, a flexible coupling may be necessary to isolate the

engine vibration.

2.3.2. Engine and detached reduction gear

- 9 -

Stuffing box

Min. Shaft length

20 x o

Output flange

EB0O2004

o

Sliding shaft

Flexible coupling

EB0O9008

The reduction gear is installed separately

from the engine, taking up propeller thrust

via a thrust bearing. A constant velocity

joint, or a pair of universal joints, and

sliding shaft must be used to allow for the

relative motion between the flexible

mounted engine and the fixed reduction

gear.

2.3.3. V - type drive

2.3.4. Jet type drive

More and more civilian and military boats, such as rescue boats, pilot boats, transport boats,

taxi boats, police boats and patrol boats, are using waterjets for propulsion. The waterjet

offers many benefits, which include giving the boat greater availability and maneuverability.

The waterjet also minimizes the draught of the boat and enables it to operate in shallow

water, as well as reducing the risk of personal injury during rescue and diving operations.

To obtain good economy from a waterjet installation, the jet unit and the engine should be

correctly matched to the full load service speed of the boat. The differences between a good

and a poor match are enormous with regard to fuel efficiency and overall performance of the

boat. A correctly sized and installed waterjet gives very small torque variations and creates

no engine overload, regardless of the boats loading conditions and speed. The jet is always

rotating in one direction, but the reversing of the boat is done by changing the jet stream

direction with a reverse deflector, which further reduces the load variations on the engine.

Waterjet has excellent characteristics when it comes to general maneuverability and comfort.

Superior control of the boat is achieved across the complete speed range, with small turning

radius and quick stops. The boat can rotate within its own length and with two jets the bot

can also move sideways. The lack of need of underwater rudder can make the vessel less

course stable, it is therefore important that the hull and the maneuvering control system is

correctly designed for the use of waterjets.

A waterjet installation has no underwater appendages which reduces the drag of the hull and

increases the overall efficiency in speeds above 20 - 30 knots depending on type of waterjets.

In comparison with conventional propeller system the inboard noise, vibration and the hydro-

acoustic noise is reduced as well.

Jet-type drives work according to the principle of jet propulsion. A jet of water is generated

whose thrust sets the vessel in motion.

- 10 -

EB0O2006

2

2

Engine and reduction gear is installed

separately and connected via an elastic

coupling and a universal joint. If universal

joints are to be used, it is important to

remember that it is necessary to have the

exact same angle at each joint under all

operating conditions in order for the

system to work properly.

The drive-line component manufacturer should always be consulted for more details on the

installation of their product.

2.3.5. The alignment of propeller

The alignment of the engine and marine transmission with the propeller shafting is essential

to minimize vibration, noise, power loss and stress in the driveline components.

While aligning the engine and gear, check both the propeller shaft flange bore and face. The

shaft and gear flanges should fit together without deflecting either the engine or the shaft

from its operating position. This will allow the propeller shaft flange and reduction gear output

flange to mate properly without over stressing the driveline components.

The shaft should then be rotated 180

˚

and checked again. The propeller shaft flange bore

and face alignment should not be done before the vessel is in the water and, on a solid

mounted engine, should be rechecked after the vessel has been in the water and loaded to

its normal operating condition.

Engine, gearbox and propeller shaft must be aligned in such a way that radial and angular

offset of all components remain within the pre-set tolerances.

(1) Radial offset check

The feeler of the dial indicator runs on the peripheral surface of the fixed flange. The

shaft end with the dial indicator placed on it must be turned. The reading must not vary

by more than 2 x 0.5 mm = 1.0 mm.

- 11 -

EB0O2009

(2) Angular offset check

The feeler of the dial indicator runs on the front side of the fixed flange. The shaft end

with the dial indicator placed on it is to be turned.

The feeler must contact the mating surface. A 360

˚

turn is required for each check. The

max. Permissible angular offset must not be exceeded at any measuring point.

- 12 -

x

1

2

EB0O9009

1. Flange (e.g. gearbox output shaft)

2. Flange (e.g. propeller shaft)

1

2

X

3

X + max. 0.1mm

EB0O9010

1. Flange (e.g. gearbox output shaft)

2. Flange (e.g. propeller shaf)
Radial offset : x = max. 0.1 mm relative to a 200 mm flange diameter
or : x = max. 0.05 mm relative to a 100 mm flange diameter

CHAPTER 3 FRONT POWER-TAKE-OFF

3.1. Marine Installation Requirements

•

Belt-driven accessories must be mounted on the engine when a flexible mounting system is

used.

•

Brackets used to mount accessories must provide adequate strength to hold the static and

dynamic load of the accessory and avoid resonant vibration within the normal operating

range of the engine.

•

Variance in accessory loads must be considered when selecting accessory drive location

and capacity. Design service factors given in the installation recommendations should be

used when determining accessory loads.

•

Belt-driven equipment must be held in alignment to a tolerance of 1 mm in 200 mm (1/16

inch in 12 inches).

•

The total power taken off at the front of the crankshaft cannot exceed the maximum capacity

of the FPTO clutch and the total power absorbed from the engine may not exceed the

specified value of each model.

•

All exposed rotating components must have a protective guard.

3.2. Front Power Take-off Clutches

More power may be taken from a direct drive at the front of the crankshaft than any other

accessory drive location. Many DOOSAN marine engines can be fitted with FPTO clutch for

driving accessories such as a winch, fire pump, hydraulic pumps or generator.

All direct driven equipment will have some effect on torsional vibration. Excessive torsional

vibration in a system can result in excessive noise, gear failure, main bearing wear or, in the

most severe cases, crankshaft failures.

The total power taken off at the front of the crankshaft cannot exceed the capacity of the

FPTO clutch and the total required power from the engine may not exceed the values in the

list below.

This is the maximum amount of power that can be transmitted through the particular clutch.

3.2.1. For maximum FPTO power

- 13 -

Engine

Crank pulley

Pillow blocks

Fiexible coupling

Driveshaft

V-pulley

EA4O7001

For front power take-off in engine, install a

flexible coupling to the engine front crank

shaft pulley and connect drive shaft and V-

pulley by supporting them with two pillow

blocks as shown in Fig. It is a standard

procedure to support driveshaft and V-

pulley with two pillow blocks by using

flexible coupling for connection to engine.

DOOSAN recommends you this type to

use front power take-off. (FPTO).

When the front PTO is installed, be sure to take deflection reading. Radial run-out should be

no more than 0.02 mm.

Be sure to limit the front PTO output within the maximum allowable horsepower as specified

for each model in figure below.

(Load represents when there is no propeller load)

Note : Upper listed loads represent allowable maximum torque.

3.2.2. For small cross drive power

- 14 -

Model Load(kW) rpm

L034 15 2,200

L034TI 31 2,600

L066TI 65 1,500

L136 60 1,800

L136T 72 1,400

L136TI 88 1,200

L086TI 120 1,600

Model Load(kW) rpm

MD196T 115 1,600

MD196TI 122 1,400

L126TI 132 1,600

V158TI 176 1,400

V180TI 220 1,600

V222TI 265 1,600

Engine

Crank
pulley

V-pulley, PTO

L

MAX. 170mm
(6.7 in) dia.

EA4O7002

(No supporting bearing on front side of

PTO pulley)

DOOSAN does not recommend this type

arrangement, which is not standard

procedure. However, If the FPTO as in

figure have to apply the drive arrangement,

the distance between the coupling end

face of engine pulley and the centerline

through pulley groove is not greater than

60 mm. The distance is indicated as “L” in

the figure.

<Driven loads by V-belt>

(L = Max. 60mm)

(Load represents when the propeller is running with engine)

Note : Upper listed loads represent allowable maximum torque.

3.3. Belt Drives

DOOSAN marine engines usually have belt drives for an alternator, sea water pump and at

least one or two free(grooves of) drive pulleys for other accessories. Many engines also have

crankshaft pulleys available for driving accessories. All of DOOSAN marine engine drives are

available with either A or B type V-belts that are designed to ISO 3046 standards.

If two power take-offs are at the same time, make sure that the resultant radial forces are as

small as possible.

The combination of companion flange and V-belt pulley can be used for such a multi power

take-off, as shown in below figure. It is advisable to shield V-belts and flanges properly, to

avoid accidents.

- 15 -

Model Load(kW) rpm

L034 12 2,200

L034TI 20 2,600

L066TI 38 1,800

L136 35 1,800

L136T 40 1,400

L136TI 50 1,200

L086TI 70 2,000

Model Load(kW) rpm

MD196T 68 1,600

MD196TI 74 1,400

L126TI 80 1,600

V158TI 95 1,400

V180TI 115 1,600

V222TI 125 1,600

Marine continuous rating

Engine speed (r.p.m)

Output (PS)

(g/PS

.

h)

500

170
160
150

400

300

200

100

1000 1500 2000 2500

1. Max. Power available
intermittant USE only

2. Propulsion curve

Fuel consumption

Max. FPTO
power

1

2

EB0O3001

Additionally, the total power(Load) required

by the propeller and FPTO cannot exceed

curve #1 on the power curve at any given

rpm. If the propeller is engaged, this

means that the max. power available at the

front is equal to the distance between

curves #1 and #2.

Note : New belts require a run-in period of 10 ~ 15 minutes under tension and should then

be retensioned. This allows for the initial stretch of the belt and will help prevent it

from jumping the pulley.

Brackets used to mount accessories must provide adequate strength to hold the

static and dynamic load of the accessory and avoid resonant vibration within the

normal operating range of the engine.

If a bracket has a natural frequency within the operating range of the engine, operation at that

speed will result in resonant vibration and failure of the bracket. So DOOSAN has no control

over the design or material of the component, they are not responsible for any damage

resulting from the failure of a non-DOOSAN supplied part.

When accessories are mounted on the engine, the mounting bracket should be attached to a

basic part of the engine such as the cylinder block or cylinder head whenever possible.

Accessories should not be mounted where they must be removed for normal engine

maintenance or where they are supported through a gasketed joint.

Note : Variance in accessory loads must be considered when selecting accessory drive

location and capacity. Design service factors given in the installation

recommendations should be used when determining accessory loads.

Since engine-driven accessories will have experience fluctuations in the load during normal

operation, the rated load of the accessories should be multiplied by a design service factor

when determining the load imposed on the engine by the accessory.

The direction as well as the load is important when considering belt driven accessories. The

load capacity of crankshaft pulleys and other drive locations will vary at different angles due to

the loading capability of the bearings.

- 16 -

Pillow blocks

V-pulley

Drive shaft

Crank pulley

Engine

EB0O3002

Flexible coupling

Note : Belt driven equipment must be

held in alignment to a tolerance of

1 mm in 200 mm (1/16 inch in 12

inches).

EB0O3003

A

B

C

EB0O3004

Crankshaft pulley

Accessory

1 mm in 200 mm
(1/16" in 12")

If two or more accessories are being

driven from a single multigroove pulley,

the accessories should be arranged to

have opposing belt pulls so that the

resulting force on the drive shaft is kept to

a minimum.

Additional pulley grooves or increasing

the belt size may exceed the safe loading

of the crankshaft or drive location.

Therefore the overloading should not be

allowed to prevent any malfunction.

Any device rigidly attached to the front of

the crank, other than an approved option,

must be analyzed for the effects on crank

bending, side-pull loading, mean and

vibratory torques, and the capability of

the crank bolted joint capacity.

Misalignment between the belt-driven

equipment and the engine will result in

bending forces on the shafts involved,

wearing of the belt, belt jumping and can

result in bearing or belt failure. This can

usually be checked with a straight edge.

- 17 -

CHAPTER 4 EXHAUST SYSTEM

The purpose of the exhaust system is to carry the exhaust gas from the engine to the

atmosphere with minimal flow restriction. Marine applications have two types of exhaust

systems, wet and dry.

4.1. Marine Installation Requirements

•

Thermal insulation or guards must be installed on dry exhaust systems.

•

Dry exhaust piping must not be installed near combustible material.

•

The exhaust system components must not impose excessive stresses on the exhaust

manifold or turbocharger due to weight, inertia, relative motion of the components or

dimensional change due to thermal growth.

•

The exhaust system must automatically prevent the entrance of water into the engine or

turbocharger whether it is from spray, rain, washing or any other source.

•

The exhaust gas must be dispersed so that it does not detrimentally affect the air cleaner

function, the engine ambient environment or the crew or passengers.

4.2. Dry Exhaust Systems (without sea water injection)

Depending on the temperature, the standard value for longitudinal expansion of steel pipes is

1 mm per meter and 100

˚

C.

It is not permissible to channel exhaust gases of several engines into one system. Multi-

engine systems are required to have a separate exhaust system for each and every engine to

prevent exhaust gases from penetrating from one running engine into another one.

For V-type engines it is recommended that the exhaust gases of both cylinder rows be

combined via an Y-pipe type.

Owing to high exhaust temperatures of several hundred degrees Celsius, exhaust pipes heat

up. For reasons of safety the pipes must be fitted with suitable anti-heat protection.

In order to prevent the engine room from heating up too much, a fireproof fuel and lubricating-

oil-repellent insulation is recommended.

To minimize exhaust gas back pressure, avoid sharp turns and manifolds.

- 18 -

R

d

EHO1202I

Design pipe bends with large radius only

(R/d

≥

1.5). If silencers are installed, ensure

that the max. permissible exhaust gas back

pressure is not exceeded.

Any bends in the exhaust system should be

made as smooth as possible. Sharp bends

can drastically increase the exhaust back

pressure.

Dry exhaust systems use steel or iron pipe for the exhaust piping, stainless steel flexible

sections, and steel for the mufflers. Due to the high exhaust temperatures and the thermal

conductivity of the metal components they can be very dangerous unless certain precautions

are taken.

One more flexible exhaust connection must under initial tension be installed between the

engine and the exhaust system.

A flexible exhaust connection must be installed in the exhaust piping within 1.2 m (4 feet) of

the engine exhaust outlet.

If the exhaust system has both long vertical and horizontal sections, separate flexible exhaust

sections must be used to absorb the thermal growth in each direction. The horizontal flexible

sections should be installed as far away from the vertical piping as possible to avoid collecting

soot and condensation in the bellows.

If water enters the turbocharger or engine it will damage the turbocharger and, if it enters the

exhaust manifold, may cause a hydraulic lock and engine failure upon start-up.

Condensation water collects in the exhaust system and under any circumstances water (rain,

spray) must not penetrate into the exhaust system of the engine.

- 19 -

EB0O4001

Flexible
support

Flexible
support

Muffler

Solid

support

Flexible

connection

Arrow show the directions of thermal expansion.

Solid support

to engine

The actual exhaust piping size may vary depending upon the complexity of the routing and the

silencer used in the system.

The below table is showed the MINIMUM dry exhaust outlet pipe diameters for various engine

models and ratings when total exhaust piping length is below 5m. Add the diameter additional

5mm every 5m increasing. The actual exhaust piping size may vary depending upon the

complexity of the routing and the silencer used in the system.

4.3. Wet Exhaust System (with sea water injection)

In a wet exhaust, sea water is sprayed into the exhaust pipe. Heat is transferred from the

exhaust gases to the sea water and the exhaust gas temperature drops low enough.

A pipe bend (swan neck) is required in the exhaust pipe system followed by a downward

sloping exhaust pipe to prevent water from penetrating into the engine. The pipe bend must be

mounted immediately downstream of the engine. Following picture shows an example of a

swan neck for sea water injection into the exhaust pipe.

The diameter of the exhaust pipe

behind the sea water inlet must be 25% larger than that of the pipe bend.

Any bends in

the exhaust system should be made as smooth as possible. Sharp bends can greatly increase

the back pressure and should be avoided.

- 20 -

EB0O4002

Bow

45

o

Stern

Drain

Condensation trap

For this reason the water collector with a

drainage device must be installed near the

engine if long exhaust pipes are laid at an

ascending angle.

This can usually be accomplished in a dry

exhaust system by using a 45 degrees or

greater bend at the top of the piping. The

pipe should also have a slight overhang to

make the entrance of water more difficult.

The exhaust outlet should face the stern of

the boat so that any water that comes over

the bow will not enter the exhaust system.

Engine model

Minimum dry exhaust

Engine model

Minimum dry exhaust

inner diameter(mm) inner diameter(mm)

L034 76 MD196T / TI 115

L034TI 76 L126TI 115

L066TI 76 V158TI 145

L136 / T / TI 76 V180TI 145

L086TI 115 V222TI 145

<Schematic diagram for sea water injection>

Wet exhaust system

(Engine should be mounted above water line)

1. The water cooling exhaust elbow : sea water cools elbow, then discharges through

peripheral slot at discharge end of elbow into exhaust pipe.

2. The rubber exhaust hose flexible connection : must be oil and heat resistant.

3. Backwater surge chamber : prevents sea water surging into engine exhaust when vessel at

rest with stern exposed to oncoming waves.

4. Exhaust pipe : should have slight downward gradient toward discharge end.

5. End cover plate : available for inspection and cleanup purposes

4.3.1. Design of water injection

In a wet exhaust system, sea water is

sprayed into the exhaust pipe at some

point downstream of the turbocharger.

If a water injection elbow is used, the

elbow should be directed downward at a

minimum of 15 degrees to prevent the

water being injected from getting back

into the turbocharger and should have a

pipe tap (1/8”) for exhaust restriction

measurements. Heat is transferred from

the exhaust gases to the sea water and

the exhaust gas temperature drops low

enough to allow the use of hard rubber

hose, fiberglass tube or other corrosion

resistant materials downstream of the

water injection.

- 21 -

EB0O4003

1

2

2

2

2

2

3

4

5

Slope(2 )

o

Exhaust discharge piping must have
adequate slope to avoid water entering
engine.

15O MIN

EB0O4006

Note : The surface temperature of the

exhaust piping should not exceed

93

˚

C (200˚F) under any operating

conditions.

DOOSAN recommends using evenly

distributed holes with an 8 mm (0.31 in)

diameter with the number of holes being

dependent upon the sea water flow. The

following equation can be used to

determine the number of holes:

No. of holes =

Lit./min(sea water flow)

10

4.3.2. Location of water injection

- 22 -

EB0O4004

BAD

Wherever water is injected in the exhaust

system, it is important that an even spray

pattern is achieved. If the spray pattern is

uneven, parts of the exhaust piping may

not be sufficiently cooled. This can result in

failure of the exhaust piping system due to

overheating and a possible safety hazard

from high surface temperatures.

EB0O4005

GOOD

If the engine is installed at a deep position

and the exhaust gas outlet at the system is

located just above or even below the water

line, a pipe bend (swan neck) must be

integrated into the pipe. This prevents

water from flowing into the engine when

the ship reverses or the water is rough.

Therefore, all exhaust outlets should be

located above the loaded water line.

A flapper valve may also be installed at the

exhaust outlet to help prevent water from

entering the exhaust system while the boat

is at rest.

EB0O4007

Supports

1. Water jacket exhaust elbow

2. Surge pipe

3. Exhaust piping

4. Water muffler

5. Flapper valve

6. Supporters

Waterline

12"(300mm)Minimum

1

2

3

4

5

6

2 Downward slope

o

The diameter of the exhaust piping will

have a large effect on the exhaust back

pressure in the system. Below table is

showed the minimum wet exhaust

diameter for DOOSAN marine engines when total exhaust piping length is below 5m. Add the

diameter additional 5mm every 5m increasing. The actual exhaust piping size may vary

depending upon the complexity of the routing and the silencer used in the system.

4.4. Direction of Exhaust Outlet

EB0O4008

Exhaust

Air inlet

45

O

EB0O4009

All exhaust outlets should be located aft and

above all air Intake locations so as to

prevent exhaust gases from re-entering the

engine room.

The exhaust outlet should be high enough

above the deck or far enough aft so that the

exhaust gases are dispersed into the

atmosphere without adversely affecting the

passengers or crew.

The exhaust outlet should also be angled

out to the side of the vessel to allow the

exhaust gas to disperse and not be drawn

back onto the deck.

- 23 -

Engine model

Minimum wet exhaust

Engine model

Minimum wet exhaust

inner diameter(mm) inner diameter(mm)

L034 76 MD196T 115

L034TI 80 MD196TI 125

L066TI / L136 90 L126TI 145

L136T 95 V158TI 165

L136TI 100 V180TI 172

L086TI 110 V222TI 182

The location of the water injection should

be at least 300mm(12 inches) from any

sharp bends to prevent a water buil-up that

would result in high back pressure and the

pipe bends should be made as smooth as

possible in the exhaust system.

EB0O4014

305mm (12 ) Minimum

o

Note : The exhaust gas must be dispersed so that it does not detrimentally affect the air

cleaner function, the engine ambient environment or the crew or passengers.

4.5. Permissible Back Pressure

The permissible exhaust back pressure measured immediately downstream of the collecting

pipe is :

•

Natural aspirated engines : max. 0.11 kg/cm2(110 mbar, 1100 mm Ws)

•

Turbocharger engines : 0.01 ~ 0.08 kg/cm

2

(10 ~ 80 mbar, 100 ~ 800 mm Ws)

To exceed these values results in impermissible exhaust temperatures and thermal stress as

BAD

EB0O4010

Exhaust output

Air inlet

Exhaust gas

BAD

EB0O4011

EB0O4012

Exhaust gas

Exhaust gas

Exhaust outlet

All exhaust outlets should be a sufficient

distance from all intake and exhaust

ventilation areas so as to prevent exhaust

gases from re-entering the engine room.

The exhaust outlets should not be angled

directly into the water as this will result in

higher noise levels and the sudden

quenching of the exhaust gases may

result in a visible film of carbon deposits

on the water

Whenever possible, it is recommended

that the exhaust outlets be situated on

the side of the vessel. As the air flows

around the vessel, a slight vacuum will be

created at the stern side. If the exhaust

outlets are located on the transom, the

exhaust gas may be drawn back onto the

deck of the boat. Locating the outlets on

the side will help prevent this from

occurring.

- 24 -

well as unsatisfactory engine power and excessive smoke development.

For this reason it is indispensable that the exhaust back pressure be measured when the

engine is commissioned and, if necessary, the exhaust system is re-dimensioned.

A vacuum at the exhaust gas outlet (e.g. caused by the flow behavior in an underwater

exhaust) leads to an increase in ignition pressures in turbocharged engines and is therefore to

be avoided.

4.6. Designing the Exhaust System

We recommend that, if possible, the maximum permissible back pressure value (= pressure

drop) be not fully exploited when the exhaust system is designed. The exhaust pipe diameter,

the number of manifolds, the silencers and the pipe routing are to be selected so that 75% of

the maximum value is not exceeded when the engine is new.

The total back pressure (total pressure drop)

Δ

p in the exhaust system is calculated as follows:

Δp = Δp

R

x L + ΔpKx nK+ Δp

S

Explanation of the formula:

Δp

R

= Back pressure (pressure drop) per 1 m of pipe

L = Length of pipe in m

Δp

K

= Back pressure (pressure drop) per 90” manifold

n

K

= Number of manifolds

Δp

S

= Back pressure (pressure drop) in silencer

4.6.1. Example of a dry exhaust system calculation

A dry exhaust system with a pipe length of 5 m, two 90

˚

manifolds and a silencer is planned

for a vessel. The clear diameter is to be 120 mm.

Is this system adequately designed for a turbocharger diesel engine with an exhaust gas

mass flow of 1,300 kg/h?

The following values can be found in the tables:

Back pressure per 1 m of pipe = 0.3 kPa

Back pressure per 90

˚

manifold = 0.51 kPa

For back pressure data in manifold, contact manufacturer.

A value of 5 hPa is assumed.

The total back pressure Δp is calculated as follows : (1 kg/cm

2

= 98 kPa = 980hPa)

Δp = Δp

R

x L + ΔpKx nK+ Δp

S

Δp = 3.0hPa x 5 + 5.1hPa x 2 + 5hPa = 30.2hPa

The calculated value is within the permissible area(10~80 hPa).

4.6.2. Example of a wet exhaust system calculation

- 25 -

A wet exhaust system with a pipe length of 7 m and four 90

˚

manifolds is planned. The

clearance diameter is 100 mm.

Is this system adequately designed for a diesel engine with an exhaust gas mass flow of

1,300 kg/h?

The following values can be found in the tables:

Back pressure per 1 m of pipe = 8 hPa

Back pressure per 90

˚

manifold = 10.6 hPa

As the exhaust gas noises are well silenced by the water injection, no silencer is installed.

The total back pressure

Δ

p is calculated as follows:

Δp = 8.0hPa x 7 + 10.6hPa x 4 = 98.4hPa

The calculated value is above the maximum permissible back pressure of 80 hPa (mbar).

For this reason an exhaust system with a larger diameter is required.

Checking the same system but with a clear diameter of 120 mm:

The back pressures per 1 m of pipe and a 90

˚

manifold can be gathered from the following

tables.

The total back pressure

Δ

p is calculated as follows:

Δp = 3.0hPa x 7 + 5.1 hPa x 4 = 41.4 hPa(mbar)

The calculated value is in the permissible area. Downstream of the sea water inlet into the

exhaust pipe the diameter is to be enlarged by 25% . From there onwards it must be 150

mm.

The calculation method is an aid to designing the exhaust system. However, when an engine

is commissioned an exhaust back pressure check is necessary in any event.

4.7. Measuring the Pressure Drop

4.7.1. Unit of measurement

1 hPa = 1 mbar = 10 mm water column

4.7.2. Measuring instrument

The simplest measuring instrument is a U-pipe manometer filled with water. If the U-pipe

manometer is filled with mercury, the reading of the liquid’s difference in height given in mm

is to be multiplied by 13.6 to obtain the result in mm head of water.

1 mm Hg = 13.6 mm head of water = 1,333 mbar

4.7.3. Measuring arrangement

- 26 -

The quantity to be measured is the static pressure, i.e. the measuring connection must fit on

the inside flush with the pipe wall.

Select a straight part of the pipe or the neutral fiber of the pipe bend for the measurement.

This can be nothing more than a piece of clear plastic tubing of any diameter greater than

1/4”, fixed in a U-shaped loop to a board about 4 feet long. The board is marked off in inches

as below figure. Set up the board on end and half fill the tubing with water.

If the overall pressure drop of the exhaust system is to be measured, a point immediately

downstream of the engine’s exhaust gas collecting pipe or the turbocharger is to be selected

for the measurement.

Note : During the measuring operation the engine must run at continuous maximum power

and speed.

Note the level of the water in the tube with the engine at rest. Then crank the engine and the

exhaust back pressure will push the water down one side of the tubing and up the other. The

difference between two levels, measured in inches, is the back pressure in inches of water

column.

- 27 -

EB0O4013

Exhaust gas

outlet pipe

1/4" Plastic tubing

48"

40"

36"

24"

12"

32"

8"
0

Average back pressure(pressure drop) in kPa per 1 m exhaust pipe, depending on the

Fexhaust gas mass flow in kg/h and the clear diameter in mm ( 1 kPa = 10 mbar)

< Average back pressure (pressure drop) >

in kPa per 1 m of exhaust pipe (1 kPa =10 hPa = 10 mbar)

For mass flow values, see each engine technical data of the appendix page in this manual.

- 28 -

Exhaust gas Diameter in mm

mass flow * (kg/h) 80 100 120 140 160 180 200

200 0.06 0.02 0.01 - - - ­300 0.14 0.04 0.02 0.01 - - ­400 0.25 0.08 0.03 0.01 0.01 - ­500 0.39 0.12 0.05 0.02 0.01 - ­600 0.56 0.17 0.06 0.03 0.01 0.01 ­700 0.76 0.23 0.09 0.04 0.02 0.01 0.01
800 0.99 0.30 0.12 0.05 0.03 0.01 0.01
900 1.26 0.38 0.15 0.06 0.03 0.02 0.01

1000 1.55 0.47 0.18 0.08 0.04 0.02 0.01

1100 1.88 0.57 0.22 0.10 0.05 0.03 0.02
1200 2.23 0.68 0.26 0.11 0.06 0.03 0.02
1300 - 0.80 0.30 0.13 0.07 0.04 0.02
1400 - 0.93 0.35 0.16 0.08 0.04 0.02
1500 - 1.07 0.40 0.18 0.09 0.05 0.03
1600 - 1.21 0.46 0.20 0.10 0.05 0.03
1700 - 1.37 0.52 0.23 0.11 0.06 0.04
1800 - 1.53 0.58 0.26 0.13 0.07 0.04
1900 - 1.71 0.65 0.29 0.14 0.08 0.04
2000 - 1.89 0.72 0.32 0.16 0.08 0.05
2100 - 2.01 0.79 0.35 0.17 0.09 0.05
2200 - 2.29 0.87 0.38 0.19 0.10 0.06
2300 - - 0.95 0.42 0.21 0.11 0.06
2400 - - 1.04 0.46 0.22 0.12 0.07
2500 - - 1.12 0.50 0.25 0.13 0.08
2600 - - 1.22 0.54 0.26 0.14 0.08
2700 - - 1.31 0.58 0.29 0.15 0.09
2800 - - 1.41 0.62 0.31 0.16 0.09
2900 - - 1.51 0.67 0.33 0.18 0.10
3000 - - 1.62 0.71 0.35 0.19 0.11
3100 - - 1.73 0.76 0.38 0.20 0.11
3200 - - 1.84 0.81 0.40 0.21 0.12
3300 - - 1.96 0.86 0.42 0.23 0.13
3400 - - 2.08 0.92 0.45 0.24 0.14
3500 - - 2.20 0.97 0.48 0.26 0.15
3600 - - - 1.03 0.50 0.27 0.15
3700 - - - 1.08 0.53 0.29 0.16
3800 - - - 1.14 0.56 0.30 0.17
3900 - - - 1.20 0.59 0.32 0.18
4000 - - - 1.27 0.62 0.33 0.19
4100 - - - 1.33 0.65 0.34 0.20
4200 - - - 1.40 0.68 0.36 0.21

Table 1)

< Average back pressure (pressure drop) >

in kPa per 90˚bend (R/d = 1.5) :1 kPa =10 hPa = 10 mbar

For mass flow values, see each engine technical data of the appendix page in this manual.

- 29 -

Exhaust gas Diameter in mm

mass flow * (kg/h) 80 100 120 140 160 180 200

200 0.06 0.03 0.01 0.01 - - -

300 0.14 0.06 0.03 0.02 0.01 - -

400 0.24 0.10 0.05 0.03 0.02 0.01 -

500 0.38 0.16 0.08 0.04 0.03 0.02 0.01

600 0.55 0.23 0.10 0.06 0.04 0.02 0.02

700 0.75 0.31 0.15 0.08 0.05 0.03 0.02

800 0.98 0.40 0.19 0.11 0.06 0.04 0.03

900 1.23 0.51 0.25 0.13 0.08 0.05 0.03

1000 1.52 0.62 0.30 0.16 0.10 0.06 0.04

1100 1.84 0.76 0.36 0.20 0.12 0.07 0.05

1200 2.19 0.89 0.43 0.23 0.14 0.09 0.06

1300 - 1.06 0.51 0.28 0.16 0.10 0.07

1400 - 1.22 0.59 0.32 0.19 0.12 0.08

1500 - 1.41 0.68 0.37 0.22 0.13 0.09

1600 - 1.60 0.77 0.42 0.24 0.15 0.10

1700 - 1.80 0.87 0.47 0.28 0.07 0.11

1800 - 2.02 0.98 0.53 0.31 0.19 0.13

1900 - - 1.09 0.59 0.34 0.22 0.14

2000 - - 1.20 0.65 0.38 0.24 0.16

2100 - - 1.33 0.72 0.42 0.26 0.17

2200 - - 1.46 0.79 0.46 0.29 0.19

2300 - - 1.59 0.86 0.50 0.31 0.21

2400 - - 1.73 0.94 0.55 0.34 0.23

2500 - - 1.88 1.02 0.06 0.37 0.24

2600 - - 2.04 1.10 0.65 0.40 0.26

2700 - - - 1.18 0.69 0.43 0.28

2800 - - - 1.27 0.75 0.47 0.31

2900 - - - 1.37 0.80 0.50 0.33

3000 - - - 1.46 0.86 0.54 0.35

3100 - - - 1.56 0.91 0.57 0.37

3200 - - - 1.66 0.97 0.61 0.40

3300 - - - 1.77 1.04 0.65 0.42

3400 - - - 1.88 1.10 0.69 0.45

3500 - - - 1.99 1.17 0.73 0.48

3600 - - - 2.10 1.23 0.77 0.50

3700 - - - 2.22 1.30 0.81 0.53

3800 - - - - 1.37 0.86 0.56

3900 - - - - 1.45 0.90 0.59

4000 - - - - 1.52 0.95 0.62

4100 - - - - 1.59 0.34 0.65

4200 - - - - 1.66 1.00 0.68

Table 2)

CHAPTER 5 INTAKE SYSTEM

5.1. Air Intake

With both engine mounted and remote mounted air cleaners, there should be enough

ventilation to keep the engine room temperature below 60

˚

C (140 ˚F). Temperatures above

this may cause a deterioration in the hoses and / or wiring on the engine.

Maintaining reasonable engine room temperatures can be aided by insulating as many hot

surfaces as possible (i.e. exhaust piping, turbocharger, muffler, heating system).

Any breaks or leaks in the air system after the air cleaner will allow dirt to enter the engine and

decrease engine life.

Relative movement between the engine air cleaner and air inlet requires flexibility in the pipe

components and flexible connections. Any deflections must occur in the rubber components

and not in the rigid piping.

DOOSAN marine engines have air filter with urethane rubber type as below figure.

After the installation of the engine if a work that produces dust is carried out on the interior

ship fittings, the air filter must be cleaned before the engine is commissioned.

EB0O9012

EB0O5002

1.5m(5ft)

Maximum

Support

Flexible

rubber elbow

On turbocharger engines a flexible

connection must be provided between the

compressor casing and the first piping

support. The first support should be less

than 1.5 meters (5 feet) from the

turbocharger.

If it is not possible to install sufficient

ventilation ports to maintain the required

engine room temperature, blowers and

exhaust fans can be used to circulate fresh

air through the engine room. The inlet

blowers must have a capacity of two times

the engine’s rated air consumption listed on

the engine technical data of the last sheet in

this manual. Exhaust fans should be from

one-half to one times the rated air

consumption of the engines to carry away

the excess heat.

- 30 -

(2) Vacuum after air filler

The maximum permissible partial vacuum at maximum power and rated engine speed is:

•

when filter is new : 0.08 kg/cm2(80hPa[mbar], 800 mm water column)

•

when filter is contaminated : 0.12 kg/cm2(120hPa[mbar], 1200 mm water column)

If this value is exceeded, the filter element must be cleaned or the filter element must be

replaced new one.

5.2. Engine Room Ventilation

During engine operation the component surfaces become hot and dissipate radiant heat,

which must be removed by means of an effective ventilation system.

An indication for sufficient engine room ventilation is:

Engine room temperature = ambient temperature + 15

˚

C (max. 20˚C)

Even in the worst conditions an engine room temperature of 60

˚

C (140 ˚F) must never be

exceeded to ensure that temperature - sensitive components, e.g. hoses and wires may cause

a deterioration.

To avoid power drops, especially attention to the intake air and fuel temperature heating up.

In classified systems the regulations of the classification associations concerning the

maximum permissible engine room temperature must be heeded.

5.3. Radiant Heat to be Removed

Depending on the engine model, the amount of heat to be removed is up to 5% of the heat

input supplied with the fuel. If silencers or long exhaust pipes are also located in the engine

room, the heat dissipation of these components must be taken into consideration too.

High air inlet temperatures will lead to high thermal stresses, high exhaust temperatures, poor

engine performance, worse fuel economy and shorter engine life. Inlet air temperatures above

27

˚

C (81 ˚F) will reduce engine power by approximately 1% for every additional 5.6

˚

C (10 ˚F)

temperature rise.

- 31 -

EB0O5003

(1) For air filters only:

In the event of heavy dust generation

remove air filter and rinse it out in fuel or

washing oil. To dry it, shake it out

thoroughly.

Apply an even and thin coat of engine oil

to the filter element surface.

If do this coat you can confirm better

filtering effect.

5.4. General Note on Air Guidance

High air inlet restriction will lead to decreased airflow through the engine for combustion. This

in turn will lead to a decrease in power, performance and engine life as well as an increase in

smoke.

The air inlet location, air piping and engine room ventilation must be designed so that

the air inlet temperature measured at the inlet connection to the manifold or

turbocharger is not more than 17

˚

C (30 ˚F) above the outside ambient temperature at

rated speed and load.

5.4.1. Guidance of the air filter for engine room outside installation

The air cleaner should be mounted in an area that is free of dirt, dust, fish scales or other

debris that may clog the filter during regular operation, net handling or deck operations.

If the exhaust and air Intake are both above the vessel, the exhaust should be located higher

and aft of the intake. If the exhaust gas is drawn back into the intake, the air cleaner can quickly

become clogged.

If the air cleaner is to be remote mounted,

the inlet location should be outside the

engine room. The inlet should be located

so that a supply of fresh air or near the

ambient temperature is always available.

Locations with high inlet air temperature

should be avoided. Areas to consider as

heat sources are exhaust components,

mufflers, air conditioner and refrigeration

condensers, boilers and heating system

components and auxiliary engines. Air

inlets should be louvered or pointed

forward to increase air circulation through

the engine room.

5.4.2. Intake & exhaust ventilation ports of the engine room

Marine engines with engine mounted air cleaners may draw air from the engine room.

Engine rooms with natural draft ventilation must have vent openings of adequate size

and location to insure an ample supply of air at a reasonable temperature to the

engine, and carry away heat from the machinery in the engine room.

A water or condensation trap should be located prior to the air cleaner on remote mounted

systems. The air cleaner should be easily serviced without removing other parts of the air

system and should be checked at air cleaner service intervals or if the air inlet restriction

increases unexpectedly.

Good circulation in the engine room is a key factor in keeping down the engine room

temperature at a low level.

EB0O5004

Exhaust

BAD

GOOD

- 32 -

The inlet vents should be ducted to the

bottom of the engine room to promote

bottom up circulation of the fresh air and to

clear fumes and moisture from the bilge.

The exhaust vents should be located near

the top of the engine room to carry away

the hot air in the engine room.

Note : In planning the ventilation ports,

two-thirds of the area should be

used for intake air and one third of

the area should be for exhaust

ventilation.

5.5. Clear Cross Section

<Clear cross sections>

In fast vessels ventilators switched on via a thermo-switch once the critical engine room

temperature has been reached may be additionally necessary for ventilation with the back

pressure from the headwind.

- 33 -

1

3

2

EHO7003I

A

A : Clear cross section

1. Deck

2. Air guidance

3. Ship's side

A

The clear cross section A of the air inlet

orifice refers to the narrowest point in the

entire air-guiding system.

The table on shows the guideline values for

the clear cross section A of the air inlet

orifice. They are based on an assumed flow

rate of 1.5 m/s.

The ventilation cross sections can be further

reduced by means of electric fans switched

on above a certain engine room temperature

by electrical temperature switches.

EB0O5005

Engine Rated Clear cross

model output(kW/ps) section A (m2)

L034 51 / 70 0.07

L034TIH 88 / 120 0.11

L034TIM 107 / 145 0.12

L066TIH 132 / 180 0.15

L136 118 / 160 0.12

L136T 147 / 200 0.16

L136TL 177 / 240 0.17

L136TI 169 / 230 0.18

L086TIH 210 / 285 0.22

L086TIM 232 / 315 0.27

L086TIL 265 / 360 0.32

MD196T 206 / 280 0.20

Engine Rated Clear cross

model output(kW/ps) section A (m2)

MD196TI 235 / 320 0.29

L126TIH 265 / 360 0.30

L126TIM 294 / 400 0.32

V158TIH 353 / 480 0.38

V158TIM 397 / 540 0.44

V158TIL 500 / 680 0.52

V180TIH 441 / 600 0.47

V180TIM 478 / 650 0.50

V180TIL 603 / 820 0.62

V222TIH 530 / 720 0.55

V222TIM 588 / 800 0.60

V222TIL 736 / 1000 0.72

CHAPTER 6 COOLING SYSTEM

6.1. Marine Installation Requirements

•

Remote mounted expansion tanks must be mounted above the highest point in the cooling

system.

•

The cooling system must be designed and installed so that the maximum jacket water

temperature does not exceed 96

˚

C (205 ˚F) under any operating conditions.

•

The engine cooling system must be properly treated with an ethylene or propylene glycol /

water solution and / or DCA-4.

•

The pressure at the water pump inlet must be greater than atmospheric when the engine is

run at rated speed with a coolant temperature of 76

˚

C to 90 ˚C (169 ˚F to 194 ˚F), and the

system filler cap removed.

•

The engine must have a closed cooling system that will maintain the system pressure

between 1.0 and 1.4 kg/cm

2

(15 psi and 20 psi).

•

The expansion tank volume must provide for a minimum excess coolant volume that is

equal to 20% of the engine coolant capacity listed on the "Engine technical data" of the last

sheet in this manual and 5% of the total coolant in keel cooler system volume.

•

The system must vent during initial fill to allow filling of the total cooling system volume to

95% of its full capacity.

•

The pressure drop from the coolant outlet to the coolant inlet must not exceed 0.35 kg/cm

2

(5 psi).

•

Cooling system vent lines must not be fed together.

•

The cooling system must remove entrained air at engine start-up, and must continuously

remove air traps entering the cooling system during normal operation.

6.2. Selection of Piping Materials

Dissimilar metals must not be combined randomly. If a precious metal is combined with base

metal, the base metal is destroyed by galvanic corrosion. Moist or even salty atmosphere

accelerates this process.

The baser a metal, the more negative is its electrical potential. Two different metals have a

galvanic difference in potential which strives to be cancelled out if a connection is established

between the metals (direct contact or conductive water). The metals listed below are arranged

according to their difference in potential, starting off with the most precious metal (platinum)

down to the basest metal (magnesium).

The farther apart two metals appear in this list the greater are the problems to be expected

owing to galvanic corrosion.

- 34 -

6.3. Cooling Circuit

All DOOSAN marine engines have indirect cooling circuit cooled the engine coolant in the

heat exchanger by sea water.

The temperature of engine coolant is ususlly normal between 76

˚

C and 90˚C.

And the sea water entry temperature is designed up to 32

˚

C(305 K).

River/sea water is sucked in by the sea water pump and fed through the heat exchanger,

where it absorbs the heat conducted away by the engine coolant.

After that, the sea water flows to the outside of the boat through inter-cooler and reduction

gear oil cooler. In case of most inter-cooled engines, sea water flows to inter-cooler at first and

heat exchanger and then gear box oil cooler, finally flow out the vessel outside.

6.4. Engine Cooling System

6.4.1. Expansion tank

Cooling water expands owing to the heat caused by engine operation. The engine coolant will

expand approximately 5% between its high and low temperatures. In order to compensate this

expansion, an expansion tank must be installed.

The expansion tank volume must have enough capacity to accommodate this plus

additional capacity for any evaporation or minor leaks. That is equal to 20% of the

engine coolant capacity listed on the “Engine technical data" of the appendix page in

this manual” and 5% of the total coolant in keel cooler system volume.

- 35 -

GRADE METAL

Precious

Platinum

Titanium

Silver

Nickel

Cupro-nickel

Lead

Stainless steel

Tin bronze

Copper

Tin

Brass alloys

Nickel cast-iron

Low-alloy steels

Shipbuilding steel

Aluminum alloys

Zinc

Base Magnesium

The following formula is used to calculate the minimum required deaeration expansion tank

size:

V = T+

E

18 4.5

Where : V = Minimum Expansion Tank Volume (Lit.)

T = Total System Coolant Volume including engine (Lit.)

E = Engine Coolant Volume (Lit.)

For the heat exchanger cooled engines, the expansion tank system has been properly sized

for DOOSAN supplied heat exchanger. If a customer is using a different heat exchanger or

wishes to build their own expansion tank, the equation shown above should be used.

6.4.2. Air vents system(Keel cooler type)

All DOOSAN engines have venting

provisions at the thermostat housing and

water outlet connection. 0ther vent locations

on a particular engine are shown on some

engine installation drawings. These include

the turbocharger(water cooled), exhaust

manifold, inter-cooler and any other

locations requiring vents.

Additional vents are also required to allow

air to escape from the top of the keel cooler

during initial engine coolant filling.

Expansion tanks more than 5 meters (16

feet) above the engine crankshaft are not

recommended.

Expansion tanks that do not require a

pressure cap must have a vent tube from

the top of the tank to allow air and gases to

escape from the cooling system and a fill

cap. The vent must have a gooseneck to

prevent dust and debris from contaminating the cooling system.

The engine vent system provides a continuous flow of water through the expansion tank as a

method of removing air and gases from the engine coolant. The highest points in the engine

coolant circuit are the best vent locations,

Since air will always travel to the highest point in the cooling system, it is necessary to have

the bottom of a remote mounted expansion tank above any other point in the cooling system.

The bottom of the tank must be above all vent locations on the engine at any vessel trim and

operating angle and all vent lines must have a continuous upward run to prevent air traps from

forming.

- 36 -

Vent

Fill cap

EB0O6003

Up to 5m

(16 feet)

If air becomes trapped in the engine

cooling system it can lead to isolated hot

spots in the engine and water pump

cavitation. This will decrease engine life

and may cause engine or component

failures. A deaeration system consists of a

properly designed expansion tank, vents

and make-up line.

All vent lines must be installed with a

continuous upward run from the engine or

keel cooler to the expansion tank at all

vessel operating angles.

Engine power levels must be reduced if

high ambient temperatures raise the engine

coolant temperature above 93

˚

C (199 ˚F).

Cooling system vent lines must not be

fed together.

Since vent lines run from points of different

pressures, teeing the vent lines together

may result in reduced vent water flow and

inadequate venting of the system.

Each vent line must be connected to the

expansion tank without using Tee’s or other

fittings that would join the vent line together

in a common vent. Joining the vents into a

common line will reduce the total vent

water flow and may result in aerated water

flowing back into the engine.

- 37 -

EB0O6004

Vent lines

Expansion tank

Make-up line

To keel cooler

From keel cooler

EB0O6005

BAD

GOOD

BAD

EB0O6007

Vent
lines

- 38 -

The engine must have a closed cooling system.

Dirt or debris must not be allowed to enter the engine cooling system. All cooling systems on

DOOSAN marine engines should have a 0.9 kg/cm

2

(13 psi) pressure cap unless the

expansion tank is more than 1.5 meters (5 feet) above the engine. This will maintain the

proper pressure in the cooling system which will in turn raise the boiling point of the coolant

and help prevent overheating and cavitation. The recommended combinations of pressure

caps and expansion tank height are as follows:

6.4.3. Make-up lines

The deaerated water return, or make-up line, connection is located in the bottom of the

expansion tank. The purpose of the make-up line is to provide a means for filling the engine

water line and to feed the water from the vent lines back to the engine after it has been

deaerated during operation.

The make-up line is plumbed from the bottom of the expansion tank to the engine water inlet

line. The make-up line should not be plumbed to the water pump housing or body.

When the make-up water enters the engine water inlet line, the turbulence created in the flow

may cavitate the water pump. Therefore, the line should be plumbed at least 450 mm (18

inches) from the engine water pump inlet connection and at least 150 mm (6 inches) from

any bends or elbows in the piping. This will reduce the chances of pump cavitation .

The size of the make-up line is also important. The line must be large enough to allow proper

coolant fill and to provide adequate return flow from the expansion tank without allowing air

back into the system. The size of the make-up will depend on the number and size of the

vent lines. In general, the cross-sectional area of the make- up line should be 3 ~ 4 times the

sum of the vent line areas.

Cooling system vent lines must not be fed together.

Expansion Tank height

Above Engine Meter(feet) Minimum Pressure Cap Kg/cm

2

(psi)

0 to 1.5 (0 to 5) 0.9 (13)

1.5 to 4 (5 to 13) 0.5 (7)

3 to 7 (10 to 23) 0.3 (4)

6 to 9 (20 to 30) Fill Cap & Vent

6.5. Engine Coolant

Correctly prepared coolant is of particular importance for trouble-free engine operation.

Coolants that are unsuitable or inadequately or wrongly prepared may cause failure of coolant

circuit units and components as a result of cavitation and / or corrosion damage.

6.5.1. Antifreeze agent

DOOSAN recommends to use a coolant

that is 50% water and 50% ethylene or

propylene glycol antifreeze. This mixture

raises the boiling point of the coolant and

prevents vapor pockets from forming in the

engine as well as lowers the freezing

temperature. The antifreeze will also

provide additional protection from

cavitation and liner erosion.

The engine cooling system must be treated with an ethylene or propylene

glycol/water solution and/or DCA-4.

The antifreeze concentration may be increased to 60 % ethylene / propylene glycol for operation

below -37

˚

C (-34 ˚F).

DOOSAN recommends to use the pre-charge DCA elements for cooling system. Since keel-

cooling systems have a much larger coolant volume, an additional DCA charge must be added

at initial fill. The following table lists the additional amounts of DCA4 required for various sized

systems. Spin-on cartridges are available with 2 to 23 units of DCA. Larger coolant volumes are

treated with DCA liquid or powder.

- 39 -

EB0O6006

450mm

(18 in)

150mm

(6 in)

Keel cooler

return

Expansion tank

make-up line

EB0O6014

Water

Antifreezer

DCA Concentration with 50% water / 50% anti-freeze mix.

6.5.2. Anti-corrosion agent

At this moment only the “Fleetguard DCA 4 Fluid” agent is cleared in accordance with this

standard. Notwithstanding the manufacturer’s data the following instructions must be

adhered to :

•

Keeping a concentration of 0.8 to 1.5 DCA 4 units per 4 liters of water; this corresponds

to 240 ~ 450 ml fluid per 10 liters of water (2.4 to 4.5 % by volume).

•

Change of the entire coolant after one year or after 1500 operating hours, depending on

which limit has been reached earlier.

•

A mixture of antifreeze and DCA 4 is not permissible. When changing from antifreeze to

Fleetguard DCA 4 Fluid or vice versa, the entire coolant must be drained. Flushing is not

necessary.

The Fleetguard DCA 4 Fluid concentration must be checked with the Fleetguard test kit,

DOOSAN part no. 60.99901-0038, after every 300 operating hours:

- 40 -

Cooling System Size Required Liquid or Units of DCA4

Liters US Gallons Pints or US Gallons Units

19 ~ 25 5 ~ 7 2 pints 10

26 ~ 40 8 ~ 11 3 pints 15

41 ~ 55 12 ~ 15 4 pints 20

56 ~ 75 16 ~ 20 5 pints 25

76 ~ 115 21 ~ 30 1.00 40

116 ~ 190 31 ~ 50 1.50 60

191 ~ 285 51 ~ 75 2.25 90

286 ~ 380 76 ~ 100 3.00 120

381 ~ 570 101 ~ 150 4.50 180

571 ~ 760 151 ~ 200 6.00 240

761 ~ 950 201 ~ 250 7.50 300

951 ~ 1140 251 ~ 300 9.00 360

1141 ~ 1330 301 ~ 350 10.50 420

1131 ~ 1515 351 ~ 400 12.00 480

6.5.3. Test kit instructions

1) Collect coolant sample from the drain device of heat exchanger or cylinder block. Do not

collect from the coolant recovery or overflow system. Coolant must be between 10

˚

C and

55

˚

C when tested. Room temperature is preferred.

2) Remove on strip from bottle and replace cap immediately. Do not touch the pads on the end

of the strip. Discard kit if unused strips have turned brown for the nitrite test pad.

3) Dip strip in coolant sample for one second, remove, and shake strip briskly to remove

excess liquid.

4) 45 seconds after dipping strip compare and record results in the following order.

c) b) a)

a) Compare FREEZEPOINT (end pad) to color chart and record result.

b) Next compare MOLYDATE (middle pad) to color chart and record result.

c) Finally compare NITRITE test to color chart and record result.

- 41 -

EB0O6015

1 ml 10 ml

- 42 -

6.5.4. Treatment instructions (Not for ES coolant)

•

Below 0.3 units per liter

Replace service filter and add the specified amount of DCA4 liquid as stated in service chart.

Follow precharge instructions.

•

0.3 to 0.8 units per liter

Continue to replace service coolant filter and add specified amount of DCA4 liquid as stated

in service chart.

•

Above 0.8 units per liter

Do not replace service filter or add DCA4 liquid until the concentration falls below 0.8 units

per liter. Test at every subsequent oil drain interval.

% GLYCOL/FREEZEPOINT (oC) (End Pad)

25%

-12o-15o-18o-21o-23

o

EB0O6016

-29o-34o-43o-51oC

33% 40% 50% 60%

SCA Units per Litre

0.0 0.4 0.7 0.9 1.0 1.1 1.3 1.5

0.0 0.4 0.6 0.7 0.9 0.9 1.1 1.3

0.0 0.4 0.5 0.5 0.6 0.7 1.0 1.2

0.0 0.3 0.4 0.4 0.6 0.7 0.9 1.1

0.0 0.2 0.3 0.4 0.5 0.6 0.8 1.0

0.0 0.2 0.2 0.2 0.4 0.5 0.7 0.9

0.0 0.1 0.2 0.2 0.3 0.4 0.6 0.9

Row 6

1200 PPM 600 PPM 300 PPM 150 PPM 0 PPM

0 PPM 300 PPM 800 PPM 1600 PPM 3200 PPM

Row 4

Row 2

Row 1

Row 0

A

B D F HGEC

Row 5

Row 3

NITRITE

MOLYBDATE

(MIDDLE PAD)

TEST

SERVICE

PRE CHARGE

5) All three readings must be completed

no later than 75 seconds after dipping

strip.

6) It is okay to estimate a value between

color blocks, but if uncertain about the

color match, pick the lower numbered

block. (example: if nitrite color is not F,

use column E)

7) Determine where the MOLYDATE level

intersects the NITRITE level on the

chart. The amount of SCA units per liter

in the cooling system is given where the

MOLYBDATE row intersects the

NITRITE column.

8) For best results follow test times

carefully. Use a stopwatch or clock with

a sweep second hand. Comparing the

test strip to the color chart too soon

before, or too late after, the required test

time will result in incorrect readings and

improper treatment and could result in

liner pitting and engine damage.

9) All readings should be recorded on the

truck maintenance record for future

reference.

6.5.5. Maintenance and repair

Any coolant loss must be replenished with a mixture of antifreeze and water with the

same concentration required for summer and/or winter operation.

Every other year coolant must be replaced. It is essential that during this period of time the

antifreeze concentration does not sink below 35~40% by coolant volume.

6.5.6. Engine coolant treatment

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.

6.6. Sea Water Lines

6.6.1. Sea water pump

DOOSAN marine engines have two kinds of sea water pump impeller used in each model:

•

Rubber impeller type : L034 / L034TI / L066TI / L136 / L136T / L136TI / L086TI

MD196T / MD196TI / L126TI - - - - - - In line type

•

Bronze centrifugal type : V158TI / V180TI / V222TI - - - - - - V series type

Note : Sea water pump of bronze type have to install a sea water strainer to prevent small

debris from clogging bronze impeller side gap. Also we recommend to install the sea

water strainer for our all engines.

The sea water pumps have a limited suction lift capability with straight pipe that is listed in the

table below.

- 43 -

Engine model Maximum Sea Water Pump Suction Lift

L034 / L034TI / L066TI 3m (10 ft)

L136 / L136T / L136TI / L086TI 4m (13 ft)

MD196T / MD196TI / L126TI 4.5 m (15 ft)

V158TI / V180TI / V222TI 4 m (13 ft)

6.6.2. Sea water entry

In most cases sea water enters the vessel through a scoop whose entrance port must be

minimum two times the cross section of the suction pipe. The entrance port must be located

so far below the water line that the sea water pump does not suck in air under any

circumstances.

An indication of sufficient sea water supply in high speed planing boats is the reduction in

partial volume in the suction line as the boat gains speed, ideally, until overpressure is reached.

If the partial volume increases while the vessel is in motion, the sea water supply is inadequate.

Guideline values for the maximum permissible partial volumes are:

•

while the vessel is stationary : 0.3 kg/cm2(0.3 bar) at set nominal speed

•

at maximum speed : 0.05 kg/cm2(0.05 bar)

The sea water inlet must be in a location

that provides a solid water flow to the sea

water pump at all times and in all operating

conditions. If air is ingested in the sea

water system it can cause failure of the sea

water pump and result in overheating the

engine.

- 44 -

X

X

Section X-X

EHO1501S

Water line

Scoop

EB0O6001

GOOD BAD

If a scoop is used on the bottom of the hull

at the sea water inlet it should be

positioned as shown in the right figure.

Note : The cooling system must remove

entrained air at engine start-up,

and must continuously remove air

that enters to the cooling system

during normal operation.

6.6.3. Sea water filter

In many places (harbors, rivers, coastal

waters) water contains sand and

suspended matter. To prevent that matter

from clogging the heat exchanger and the

intercooler and to prolong the service life of

the sea water pump, a sea water filter must

be Installed between shut-off valve and

sea water pump.

Debris in the sea water system can lead to

sea water pump damage or clogging of the

heat-exchanger. This will in turn result in

overheating and possible failure of the engine.

DOOSAN recommends selecting a filter whose pressure drop in the new condition is not above

0.1 kg/cm

2

(100 mbar) and using of strainer in the sea water system prior to the sea water

pump in addition to a scoop on the bottom of the hull. This strainer can be checked for clogging

and must be serviced more easily.

If a scoop is used on the bottom of the hull it must be able to handle the volume of sea water

flow listed on the “Engine technical data" of the appendix page in this manual.

6.6.4. Piping of sea water line

All components of DOOSAN marine engines carrying sea water are made of copper & bronze

and hoses. In order to prevent galvanic corrosion, material for the sea water pipes along the

hull must be selected accordingly

The minimum sea water piping sizes are listed below. The line size may have to be larger if the

piping is especially long or has several bends that would increase the intake restriction.

- 45 -

EB0O6002

Bow

EB0O6013

1.6mm
(1/16")
Maximum

DIA.

Note : Although a boat has two engines, each engine should have its own sea water inlet or

outlet individually. This will prevent all engines from overheating in the vessel if a sea

water inlet should become plugged.

<Suction side>

The piping from the sea water inlet on the

bottom of the hull to the sea water pump

should be short and as free of sharp bends

as possible. Any sharp bends will cause an

increase in the inlet restriction.

Immediately downstream of the sea water

entrance port in the hull a shut off valve

must be fitted to allow repairs or the

replacement of components of the sea

water pipe line below its water line.

The clear cross sections of both the sea

water suction lines and the shut off valve

must not be smaller than the inlet cross

section at the sea water pump inlet.

The through keel fittings and shut-off valve

connections should be at least as large as

the sea water piping and any scoop used

on the bottom of the hull should be sized

for the sea water flow of the engine.

The suction line from the sea water inlet to

the sea water pump must be absolutely

tight and stable, i.e. it must not contract

under the low suction pressure of the sea

water pump. The line is to be kept as short

as possible.

<Deliver side>

DOOSAN marine engines (except L034 / L034TI / L066TI / L136 / L136T / L136TI / L086TI

marine engine) must install two kinds of the sea water outlet pipes, that is, for heat exchanger

(or inter cooler) and for marine gear oil cooler respectively

The heated sea water can be pumped out through outlets in the hull after cooling the coolant

in heat exchanger or the hot air in inter-cooler and the oil in marine gear oil cooler.

- 46 -

Engine model

Max. Inlet Restriction Min. Sea Water Piping Line Size

(mmHg) (

diameter

mm)

L034 / L034TI / L066TI 85 35

L136 / L136T / L136TI /

127 50

L086TI

MD196T / MD196TI / L126TI 135 60

V158TI / V180TI / V222TI 160 75

EB0O6012

BAD

Collapsed hose

EB0O6017

6.7. Keel Cooler

Keel cooling is a cooling system that uses a

group of tubes, or channels in direct contact

with the surrounding water to transfer heat

from the coolant to the water. Keel cooling is

widely used in river pushing boats and

fishing boats, especially in areas of heavy

silt, ice or other debris which may clog fresh

water inlets or erode heat exchanger tubes.

An alternative to keel cooling is the use of

keel pipe cooling, with the cooling containers

being replaced by pipes fixed to the outboard side of the hull. These pipes can run either parallel

to the keel or be designed similar to bilge keels.

As in keel cooling systems, avoid sharp edges and turns as well as reductions in pipe cross

sections to minimize pressure drops in the system.

A drawback of keel cooling is its proneness to destroy when hitting the sea- or riverbed and the

ship’s increased resistance coefficient. As all pipes are located on the outer side of the keel, the

system must be checked for leaks before the ship is launched.

Keel coolers may be manufactured units or fabricated. The manufactured type of keel cooler, or

grid cooler, is generally much more compact and efficient than a fabricated unit. They are made

of a “grid” of tubes that is attached to the bottom of the hull with an Inlet and outlet connection

for the engine fresh water. The manufacturer of the unit should be consulted for proper siting and

installation.

6.7.1. Kinds of keel cooler

<Fabricated Keel Cooler>

Fabricated keel coolers will generally be a

series of pipes or channels that are welded

to tile bottom of the keel. This is used

instead of a heat exchanger. The engine

coolant pump feeds engine coolant

through the keel cooling sells where it

gives off heat to the surrounding river or

sea water. These types tend to be less

efficient and therefore, larger than a

manufactured unit.

- 47 -

EB0O6008

Engine water

Out

In

Hull

Grid cooler

EB0O6009

In

Out

Hull

Fabricated keel cooler

<Box Type Keel Cooler>

The other type of keel cooler that is used is

a box cooler. This type uses a box or sea

chest that sits inside the keel with openings

to allow sea water to flow through it. The

tube bundle sits inside the box and carries

the engine water. These units are useful

since they can be checked or serviced

without pulling the boat out of the water

and the cooler is protected from any impact

with foreign objects.

The manufacturer of the box cooler should

be consulted for proper sizing and

installation of the unit.

6.7.2. Keel cooler location

The keel cooler should be installed below the waterline far enough to avoid the aerated water

close to the surface. Good keel cooler performance requires a constant water flow over the

cooler. Locations that are in the water flow and flush on the keel are preferred over side

locations and recessed installations. Recessed and shielded installations must allow for

unobstructed sea water flow over the keel cooler tubes.

Slow moving boats should have the keel coolers installed close to the propeller to benefit from

movement of water through the propeller. Dredges and other vessels that will be operated with

little movement through the water should have the keel coolers installed on an incline or

vertically to promote water circulation by convection.

Keel coolers should not be located in areas that at exposed to pounding seas, keel flexing or

excessive vibration. The bow of a ship is subjected to tremendous water forces and is generally

a poor location for a keel cooler. The area of the ships bottom adjacent to the keel is the

strongest section and is the best keel cooler location.

6.7.3. Design of keel cooler system

The keel cooling area must be of a certain size to ensure that coolant heat is conducted away

under all operating conditions.

This cooling area depends, among other things, on the planned top speed of the vessel which,

for a given engine rating, results from the propeller system installed and the size and design of

the hull.

Guideline values for the design of the keel cooling area as a function of the amounts of coolant

heat to be dissipated and the speed of the ship can be found in tables on the following pages.

The amounts of heat to be dissipated at maximum power output can be obtained from the

“Technical data “ sheet in the appendix page of this manual.

- 48 -

EB0O6010

Sea chest

Box cooler

Openings

(Allows water flow through the

sea chest and around cooler)

Guideline values for cooling areas in keel cooling systems in m

2

for the engine coolant

circuit. (River or sea water temperature = 32

˚

C)

*

see Engine technical data of the appendix page in this manual.

Design data : a) River or sea water temperature: 32

˚

C

b) Cooling cell height: 20 mm

c) Cooling flow rate in cooling system: 1 ~ 2 m/s

d) Keel made of steel with thermal conductivity: 50 W/K x m

e) For safety reasons (influence of paint layers, encrustation of keel with

foreign matter, deposits in cooling system) only 60 % of the cooling areas

were utilized.

- 49 -

Amount of heat to be dissipated from Cooling area in m

2

for ships at a top speed of :

the engine coolant circuit in MJ/h* 0815≥20 (knots)

0 15 28 37 (km/h)

200 5.5 1.0 0.9 0.8

400 11.0 1.9 1.75 1.6

600 16.5 2.8 2.6 2.3

800 22.0 3.75 3.5 3.1

1000 27.4 4.75 4.3 4.0

1200 - 5.6 5.25 4.7

1400 - 6.5 6.0 5.5

1600 - 7.5 7.0 6.25

1800 - 8.5 7.75 7.0

2000 - 9.5 8.75 8.0

2200 - 10.3 9.1 8.7

2400 - 11.2 9.9 9.5

2600 - 12.2 10.7 10.3

Guideline values for cooling areas in keel cooling systems in m

2

for the engine coolant

circuit. (River or sea water temperature = 20

˚

C)

*

see Engine technical data of the appendix page in this manual.

Design data : a) River or sea water temperature: 20

˚

C

b) Cooling cell height: 20 mm

c) Cooling flow rate in cooling system: 1 ~ 2 m/s

d) Keel made of steel with thermal conductivity: 50W/K x m

e) For safety reasons (influence of paint layers, encrustation of keel with

foreign matter, deposits in cooling system) only 60 % of the cooling areas

were utilized.

<Design of keel cooler>

Keel coolant cell heights of over 20 mm are to be avoided, as the heat transfer occurs only

within a small boundary layer. In addition, great heights result in large cross sections and,

consequently, in flow rates that are too low, which leads to a deterioration of the heat transfer.

Not any small value for the free cross section of the cooling system can be chosen, as

otherwise the pressure drop will be too high. Flow resistance in the cooling system can be

effectively reduced by the use of deflectors at the turns. The coolant is usually circulated by

engine water pump.

- 50 -

Amount of heat to be dissipated from Cooling area in m

2

for ships at a top speed of :

the engine coolant circuit in MJ/h* 0815≥20 (knots)

0 15 28 37 (km/h)

200 4.5 0.8 0.7 0.65

400 9.0 1.6 1.4 1.3

600 13.4 2.4 2.1 2.0

800 17.9 3.2 2.8 2.6

1000 22.3 4.0 3.5 3.3

1200 - 4.8 4.2 4.0

1400 - 5.6 4.9 4.7

1600 - 6.5 5.6 5.3

1800 - 7.25 6.3 6.0

2000 - 8.0 7.0 6.7

2200 - 8.8 7.7 7.25

2400 - 9.6 8.4 8.0

2600 - 10.4 9.1 8.7

<Example: Schematic diagram of a keel cooling system>

Note :

Good bleeding of each and every cell section to the expansion tank is decisive

for system’s reliability.

6.7.4. Commissioning the keel cooling system

Before commissioning, remove any kind of dirt from the cooling system (forging scales, welding

beads etc.) and check for leaks.

Ensure that the system is thoroughly bled when filling it up.

- 51 -

1

A

2

3

A

4

5

4

6

4

4

4

4

4

4

8

A-A

B

B

7

8

4

B-B

EHO1601S

1. Coolant inlet 5. Guide plate

2. Breather to expansion tank 6. Drain device

3. Coolant outlet 7. Passage

4. Rib 8. Hull

6.7.5. Engines with inter-cooler

A second cooling system with a separate pump must be installed for the keel-cooler.

The circulating pump may be procured by the shipyard itself but must meet the following

minimum delivery requirements:

Note : Refer to "engine technical data" of the appendix page in this manual for

"Amounted of heat to be dissipated from Intercooler" each model.

Alternatively, the sea water pump only can be used for inter cooler cooling separately.

The below figure shows the cooling circuits of the keel cooled engine (Example 1) & (Example

2). Owing to the tremendous amounts of heat to be dissipated in the inter-cooler, the most

powerful engines require very large cooling surfaces which in practice are hardly feasible. A

25% reduction of the cooling surfaces is possible by increasing the flow rate from 1 m/s to 2

m/s (which can be achieved by installing a higher capacity pump),

The air bent lines for the keel cooler circuit must be routed to each expansion tank for the

engine coolant circuit.

- 52 -

Keel cooler Keel cooler

Bypass line

Thermostat

Water Water

Air bent

Air bent

Example 1

Bypass line

Control valve

Example 2

EB0O6011

Guideline values for cooling areas in keel cooling systems in m

2

for the inter-cooling

agent circuit. (River or sea water temperature = 20

˚

C)

*

see Engine data of the appendix page in this manual.

Design data : a) River or sea water temperature: 20

˚

C

b) Cooling cell height: 20 mm

c) Cooling flow rate in cooling system: 1 ~ 2 m/s

d) Keel made of steel with thermal conductivity: 50 W/K x m

e) For safety reasons (influence of paint layers, encrustation of keel with foreign

matter, deposits in cooling system) only 60 % of the cooling areas were

utilized.

- 53 -

Amount of heat to be dissipated from Cooling area in m

2

for ships at a top speed of :

intercooler circuit in MJ/h* 0815≥20 (knots)

0 15 28 37 (km/h)

50 5.7 1.3 1.2 1.1

100 11.4 2.5 2.25 2.15

150 17.0 3.8 3.4 3.2

200 22.7 5.0 4.5 4.3

250 28.5 6.3 5.6 5.4

300 - 7.6 6.7 6.5

350 - 8.8 7.8 7.5

400 - 10.1 9.0 8.6

450 - 11.3 10.1 9.7

500 - 12.6 11.2 10.7

550 - 13.9 12.3 11.8

600 - 15.1 13.4 12.9

650 - 16.4 14.6 14.0

<Calculation formula of rated power at inter-cooler system>

The maximum permissible inlet temperature of the inter-cooling agent into the inter-cooler is

32

˚

C. If this requirement cannot be met, proceed as follows:

The output must be reduced as per the formula below:

P= - 1 x t

a3

+ 110

3

Key : P = Power in % of rated power

ta3= Inlet temperature of the coolant into the inter-cooler in

˚

C

Example : One engine with a maximum output of 300 kW at 2,000 rpm

The coolant inlet temperature into the inter-cooler is 60

˚

C.

P= - 1 x 60 + 110 = 90

3

The engine can now be operated with only 90% of its max. output, i.e. 0.9 x 300 = 270 kW.

The above formula does not apply to these engine models. If an inter-cooling agent entry

temperature of 32

˚

C cannot be achieved, a heat exchanger cooling system must be installed

greater

- 54 -

CHAPTER 7 LUBRICATING SYSTEM

7.1. Marine Installation Requirements

•

When oil filter is changed, DOOSAN genuine parts are to be used.

•

The oil dipstick must be marked with the high and low oil level when the boat is in the water

and at its normal trim if the engine installation angle is over 6 degree.

•

The lubricating oil used in the engine must meet the specifications listed in “engine technical

data” of the appendix page in this manual.

All DOOSAN marine engines have full flow lubricating oil filter type. Engine oil filter should not

be modified from engine.

7.2. Engine Blow- By Gas Vent

During normal operation a small amount of combustion gas escapes past the piston

compression rings into the crankcase. This blow-by gas is vented out through the engine

breathers. Most of the oil mist and vapor is removed by the breathers and drains back into the

engine.

However, some oil vapor is carried through the breathers by the blow-by gases. Engines that

operate in an open area just allow the gases and oil vapor to escape at the breather.

On boats the gases and oil vapor should be piped out of the engine room. Vessels with dry

exhaust systems can vent the blow-by into the exhaust flow. The blow-by should be vented

into the exhaust at the outlet of the exhaust piping. Routing the blow-by too close to the

turbocharger outlet will pressurize the crankcase and result in excessive blow-by gas.

- 55 -

EB0O7001

BAD GOOD

Crankcase
breather

Exhaust
outlet

Air intake

Crankcase
breather

Condensation
trap

Drain

Crankcase vent plumbing should have a continuous upward slope to prevent oil build-up in the

vent lines. Drain fittings are required at the bottom of long vertical runs to remove accumulated oil.

Blow-by gases should not be vented to the atmosphere near the engine all intake or directly

into air cleaners or turbochargers. The oil build-up that occurs will plug the air cleaner element

and may cause turbocharger failures, loss of power and decrease the effectiveness of the

inter-cooler air fins.

7.3. Lube Oil Drain Pump

The engine oil pan is normally not accessible in a marine application of boat. Lube oil drain

pump is mounted on all DOOSAN marine engines to a standard part because the drain plugs

of oil pan and marine gear are difficult to access in the boat.

7.4. Oil Dipstick Level Gauge

Since the installation angle of a marine

engine may vary greatly among vessels,

the high and low oil levels on the dipstick

will also vary as the engine angle changes.

The capacity of lube oil can be referred to

"Engine technical data" of the appendix

page in this manual.

<Oil capacity and Difference between maximum and minimum oil level>

- 56 -

The lubricating oil dipstick must be

marked with the high and low oil level

when the vessel is in the water and at

its normal trim if the engine

installation angle is over 6 degree.

Dipstick should be re-marked by engraving

on the lube oil capacity of each engine. Be

sure to check and mark the oil levels

between Max. and Min. when the boat is

commissioning at first. Please note that

stamping or notching will weaken the

dipstick and the tip of the dipstick may break

off in the oil pan.

EB0O7002

EB0O7003

Engine model

Oil Capacity (Liter) Difference (mm)

Maximum minimum Max.-Min

L034 / L034TI 6.5 5.5 18

L066TI 19 14 33

L136 / L136T / L136TI / L086TI 23 17 28

MD196T / MD196TI / L126TI 24 19 31

V158TI 31 25 30

V180TI 35 28 46

V222TI 40 33 63

CHAPTER 8 FUEL SYSTEM

8.1. Fuel Circuit

Fuel is sucked from the tank by the supply pump and fed to the inlet chamber of the injection

pump via the fuel water separator filter.

The fuel supply pump supplies more fuel than is actually needed for the combustion.

The delivered surplus fuel flows back to the tank via a fuel return line.

8.1.1 Fuel lines

Should prevent the fuel against heating up. Heated fuel is expanded and especially lighter.

As a result, less fuel mass is injected, which causes the power to drop. For this reason fuel

line from the tank to the engine must not be laid near or attached to hot engine parts.

The inner line cross sections must not be smaller than that of the injection pump inlet pipe

and should select the flame-resistant material for this fuel lines.

Prior to commissioning the fuel system (tank and pipe-work) the entire system must be

flushed out with diesel fuel.

If the fuel return restriction is too high, excess fuel will be put in the cylinder. This will cause

high cylinder pressures, high temperatures, increased smoke, poor performance and a

decrease in the engine life.

Note : The fuel return line size required for an engine will depend on the engine return flow

rate, the length of the line, the number of bends and the number and type of fittings.

The following table lists the minimum line sizes which will NORMALLY meet the maximum

allowable return line restriction limit. However, larger line sizes may be required when several

bends, valves or fittings are used in the fuel plumbing. Whatever line size is used, the fuel

return line restriction must not exceed the 102 mm Hg (0.14 kg/cm

2

).

The fuel system must deliver adequate clean fuel that is free of air and water to the engine.

Fuel is sucked from the fuel tanks through a fuel water separator, into the fuel pump. The

suction vacuum at the suction connection of the pump should not exceed 0.2 bar (0.204

kg/cm

2

) at maximum engine speed.

The fuel is also used to lubricate the Injection nozzles and fuel pump as well as cool down

some combustion heat from the Injection nozzle tips.

- 57 -

Engine model Supply Line O.D. Return Line O.D.

L034 / L034TI / L066TI

N

10mm

N

10mm

L136 / L136T / L136TI / L086TI

N

10mm

N

10mm

MD196T / MD196TI / L126TI

V158TI / V180TI / V222TI

N

12mm

N

10mm

Note : A fuel/water separator is required

before the fuel pump

All of the fuel pumps used on the engines

in this manual are fuel lubricated. Water in

the fuel will decrease the lubrication in the

pump and possibly cause a failure of the

pump. Injection nozzles are also

lubricated by fuel and can also fail as a

result of water in the fuel. Therefore, it is

necessary to remove any water from the

fuel before it reaches the fuel pump by

using a fuel water separator.

Fuel water separators that are available

from DOOSAN are recommended. If

another fuel water separator is to be used,

it must be sized for the engine’s fuel

supply flow rate

8.1.2. Valves

Valves installed in the fuel supply should

have low flow resistance and not be a

source for the entry of air into the fuel

system. These requirements are best met

with a plug type valve. Globe valve and

other types of packed valves may be used,

but they require periodic repacking to

maintenance an air tight seal. Some valves

are not designed to seal in a suction line,

and therefore, cannot be used in the fuel

supply line.

When a manual shut-down valve is used,

the linkage should completely open and

close the valve under all conditions.

Selector valve ports should be at least as

large as the fuel supply line’s inner

diameter.

All values used in the fuel system should

be clearly marked as to their function and

position (open / close).

- 58 -

EB0O9004

Seal

Outlet

Clearbowl

Inlet

Check valve

(1) Primary stage
separation
(2) Secondary stage
coalescing
(3) Final stage filtration

Drain plug

Element

Engine 1

return

Return to

fuel tank

Area 3 = Area 1 = Area 2

Engine 2

return

EB0O8006

1

2

3

Engine 1

return

Return to

fuel tank

Area 3 = Area 1 + Area 2

Engine 2

return

1 2

3

BAD

GOOD

The fuel supply and return line must be routed without loops. Any loops in the fuel plumbing

will cause pressure surges in the line and result in engine speed instability.

Whenever multiple engines are used, each engine should have separate fuel supply and return

lines. Running two or more engines with common fuel lines can result in idle surge and speed

stability problems.

Pressure pulses in the return line of one engine may affect the operation of other engines that

share the common return line. This can be overcome by using a common return line whose

cross-sectional area is equal to the sum of the area of each of the individual return lines.

8.1.3. Arrangement of the fuel tank system on the vessel

The tank should be located at roughly the

height of the engine. If this is impossible

owing to the design of the ship, the

following points must be heeded:

The maximum suction height of the fuel

supply pump below is less than 1 m from

injection pump inlet The suction height is

reduced if an additional filter is installed in

the suction line or a longer pipe is

required for reasons of space.

- 59 -

EB0O8007

GOOD

BAD

Fuel tank

Fuel supply

Fuel supply

Return tank

Return tank

Fuel tank

EB0O8003

Max. 3m

Max. 1m

The fuel return system must have at least one return line that cannot be shut off. This prevents

accidental closure of all return lines. Since the fuel system will return up to 2~3 times the

amount of fuel that is burned, this will result in excessive fuel consumption, high cylinder

pressures and temperatures, increased smoke and failure of the fuel pump, injector or engine.

<1> Fuel tanks located under the engine

The fuel pump used on the engines in this

manual has a maximum lift capability of 1

meter (3.3 feet). Therefore, any fuel system

where the bottom of the main fuel supply tank

is more than 1 meter (3.3 feet) below the fuel

feed pump requires a fuel transfer pump to

deliver fuel to the engine.

A float tank should use a continuously

running transfer pump to deliver fuel to the

auxiliary tank at a regulated pressure of 0.6

kg/cm

2

(8 psi) maximum.

All auxiliary tanks must have vent and

overflow piping. The overflow piping returns

fuel to the main fuel supply tank if the float

valve or switch should malfunction and overfill

the auxiliary tank.

<2> Fuel tank located above the engine

If the fuel tank is 2~8 meters (6.6~26.2 feet)

above the fuel feed pump, the return line

should be run to the auxiliary tank.

In this case a shut-off valve must be installed

in the fuel supply and return lines to prevent

fuel from running out during maintenance

work.

- 60 -

EB0O9005

Fuel Return

Vent

Over flow

Aux.

tank

Transfer

pump

Filter

Fuel supply

More than

1 meter

Main

fuel

tank

> 2~8 m
(6.6~26ft)

EB0O9006

Return

Vent

Sight

glass

Aux.
tank

Filter or
strainer

Shut-off

valve

Fuel supply

Main

fuel

tank

<Air Vent Line>

The vent line should terminate above the deck in a protected location. A gooseneck at the top

is recommended to keep dirt and water from entering the fuel tank through the vent line.

Fuel tanks can be made of terneplate or phosphate coated steel, aluminum or fiberglass.

Galvanized or zinc plated steel tanks or piping should never be used in a diesel fuel system.

All auxiliary tanks should have vents routed to a point that is above the highest possible fuel

level in the main tanks. This will prevent accidental flooding of the bilge if the float tank (No. 1)

is overfilled.

- 61 -

EB0O8009

Tank

No. 2

Tank
No. 1

Auxiliary tank

Return

Supply

Deck

8.2. Fuel Tank

8.2.1. Tank capacity

The required fuel tank capacity is determined by the engine power, the fuel consumption and

the required radius of action. The following equation can be used for a rough-and-ready

estimate. In addition, a sufficiently large amount of reserved fuel must be taken into

consideration too.

V =

Px b

e

x t

830

where : V = Tank capacity in liter (lit.)

P = Engine power in kilowatt at cruising speed (kW)

t = Operating period in hours (hr)

b

e

= Specific fuel consumption at full load in gram per kilowatt and hour.(g/kW.h)

A guideline value of 220 g/kWh is sufficiently precise for the estimate.

8.2.2. Tank manufacturing

The tank must be made of fuel- and corrosion-resistant material. We recommend special

sheet steel as tank material. Under no circumstances must galvanized sheet metal be used.

The tank must be made stable. We recommend the use of baffles to prevent fuel from

sloshing when the ship is pitching through rough waters and air from being sucked in. The

tank bottom must have a depression with a drainage device where dirt and condensation

water can collect.

Condensation water in the fuel tank provides the basis for the growth of micro-organisms in

- 62 -

300mm

50mm

60

o

EB0O8001

diesel fuel. These micro-organisms cause premature filter blockages and corrosion damage,

which is why condensation water collected in the tank and in the filter must be drained

regularly.

The suction line inlet to the engine should be approx.50 mm above the tank bottom.

We recommend that the fuel return line from the engine to the tank be located as far away

from the suction line as possible and extend as far into the tank as the suction line.

The filling line must have an adequate cross section, lead to the tank without sharp turns and

close securely.

In addition, the tank must be equipped with a bleeding line to the deck. Ensure that even in

adverse conditions no water (spray, rain) can penetrate.

Having completed the tank assembly, remove all dirt, forging scales and welding beads from

the tank and check it for leaks.

8.2.3. Fuel requirements

Fuel quality is an important factor in obtaining satisfactory engine performance, long engine

life, and acceptable exhaust emission levels. DOOSAN engines are designed to operate on

most diesel fuels marketed today. In general, fuels meeting the properties of ASTM

Designation D975 (grades 1-D and 2-D) have provided satisfactory performance.

DOOSAN recommends to use Number 2-D diesel fuel for maximum fuel economy whenever

possible. When temperatures are below -7

˚

C (20 ˚F), use Number 1-D fuel. If Number 1-D

fuel is not available, the mixture of one kerosene to two gallons of Number 2-D fuel can be

used. Once kerosene has been added, the engine should be run for several minutes to mix

the fuel.

- 63 -

CHAPTER 9 PROPULSION SYSTEM

9.1. Marine Gear Ratio Selection

•

Marine gear ratio selection is important and will affect both engine life and vessel

performance. Propeller speed must be properly balanced with the power applied to it like

vessel speed, propeller size, and propeller pitch and the secondary loads.

•

Another important part of proper engine application is to choose the proper marine gear

ratio and propeller size. Therefore, the marine gear ratio and propeller size must be chosen

to allow the engine to achieve rated speed under fully loaded conditions.

Note : DOOSAN recommends to install the gearbox ratio as next application.

•

Heavy Duty : 2.5 ~ 6, Medium duty : 2 ~ 3.5, Light Duty : 1 ~ 2.5

•

Engine movement must be restrained sufficiently to prevent damage from physical contact

between the engine components and adjoining structures; and the movement must not

exceed the flexural limits of connecting systems.

•

The propeller shaft flange bore and face alignment must be within the marine gear

manufacturer’s limits.

9.2. How to Select the Right Propeller System

If you want to get the best performance out of your boat, you need to select the propeller and

the gear ratio that will suit your particular boat, engine and speed range.

Below you will find a brief description of how propeller systems are designed. It is not just the

engine capacity which determines the speed of the boat ; it depends just as much on the

efficiency of the reverse gear and the propeller system.

Using the right propeller system will not only give you good fuel economy and higher speed ;

you will also experience greater comfort, with less noise and vibration.

9.2.1. Planing boats

In planing boats over 20 knots, the size of the propeller depends on the engine power. To

transfer the power from the engine to the water, you need approximately 7 ~ 8 cm

2

propeller

blade surface per kW shaft power. If the shaft is at an angle in relation to the flow of the

water, this requirement may be considerably greater : 8 ~ 15 cm

2

/kW is reasonable,

depending on the angle of the shaft and the water flow.

At a shaft power of 400kW, therefore, the propeller blade surface may need to be 400 kW x

9 cm

2

/kW = 3600 cm2.

This surface may be divided over three, four or five blades.

This efficiency of a propeller blade diminishes when it becomes far too wide in relation to its

length. This means that if the propeller diameter is limited in size (as is often the case), it is

better to select several narrower blades (four of five) rather than three wide ones, for

example.

The angle of the propeller shaft should be as small as possible. Shaft angles of less than 12˚

- 64 -

do not usually cause any major problems, but shaft angles of more than 14 ~ 15˚ should be

avoided. The distance between the bottom of the boat and the propeller blades should be at

least 12 ~ 13% of the diameter of the propeller. When you have selected the diameter of the

propeller, you are ready to go on to select the pitch. Propeller blades should no travel faster

than 60 ~ 70 knots through the water at 70% of the maximum propeller diameter.

This means that the speed of the propeller revolutions must be reduced when the engine

capacity is greater, which requires a larger blade surface and therefore a greater diameter.

The relations between pitch and diameter should be :

Pitch =

pitch ratio

diameter

0.9 ~ 1.15 at 20 knots

1.0 ~ 1.3 at 30 knots

1.05 ~ 1.35 at 35 knots

Generally, a larger propeller with narrow blades and low revolutions is more efficient than a

small, high - speed revolving propeller. When the boat’s speed goes above 24 ~ 28 knots,

the resistance of the shafts, rudders and propeller supports starts to become so great that

the greater efficiency of the propeller is not beneficial.

The resistance on the propeller system can be reduced by reducing the shaft diameter,

selecting stronger materials and reducing the rudders and surfaces of the propeller supports.

Lower gear ratios also mean thinner shafts. It is necessary to find a balance between

propeller efficiency, water resistance of the shaft, etc.

9.2.2. Displacement and semi-planing boats

Boats of less than 15 knots need propellers which are as large as possible.

For example, in a trawler it is possible to save 20 ~ 30% fuel or to gain 20% greater thrust

when trawling by increasing the propeller diameter by 50% and reducing the propeller speed

by 40%.

The blade surface of the propeller is designed according to the minimum of 0.17m

2

perton of

thrust.

As described above, a large, slow - moving propeller is preferable. At a speed of 12 knots,

for example, a three - blade propeller with a 50% blade area will achieve an efficiency rate of

approximately 57% if the propeller blade cuts through the water at 50 knots with 70% of its

diameter. At a blade speed of 70 knots, approximately only 47% efficiency is achieved.

The formula :

T Newton =

propeller efficiency x shaft output in kW x 1944

speed of boat

Can be used to calculate the thrust and, therefore, the blade surface.

- 65 -

Three - blade propellers are often more efficient for large, solw - moving propellers than four

- blade or five - blade propellers.

However, four - blade propellers usually produce less vibration, which is often preferable.

In general, there is a tendency towards four - blade propellers.

A suitable pitch ratio at 10 knots is 0.7 ~ 0.9 and at 15 knots 0.8 ~ 1.05.

As the best pitch ratio varies according to the speed of the boat, it is necessary to decide

whether the propeller should be at its best when trawling, e.g. with a pitch ratio of 0.7, or

whether it should be better when not trawling with a slightly higher pitch ratio.

Adjustable propellers are an excellent solution for trawlers, tugs and freighters.

As a very rough estimate, the bollard pull thrust can be calculated using the formula

Adjustable propeller (kp)’ 13 ~ 14 x hp

Fixed propeller (kp)’ 11 ~ 12 x hp

An adjustable propeller fitted to “ the right boat” (up to 10 knots) can therefore save a lot of

fuel.

9.2.3. Speed range between 15 and 20 knots

Within this speed range, a large slow propeller is preferable to a small, fast one.

The blade surface is designed as a compromise between kW/cm

2

and m2/ton of tractive

force.

The above description is very general and describes only superficially how propellers are

designed.

9.2.4. Controllable pitch propellers

If controllable pitch propellers are to be used, the maximum pitch on the propeller should be

determined under fully loaded conditions. The vessel should be taken out fully loaded and

the pitch slowly increased until the engines are operating at rated speed at full throttle. This

is the maximum amount of pitch that should be used under any operating conditions.

- 66 -

9.3. Propeller Selection

Your dealer has chosen a propeller designed

to deliver top performance and economy

under most conditions. To obtain the

maximum percentage of available

horsepower (A), the engine rpm at full

throttle should be in the specified full throttle

operating rage (B).

Refer to specifications in Performance

Curve.

If the engine’s full throttle RPM with a normal

load is below the specified on the low side of

the range(C), use a propeller with less pitch to increase the RPM. Should the engine’s full throttle

RPM want to exceed the specified range(D), the engine RPM is limited by the governor. Use a

propeller of higher pitch to stop the limiting by the governor.

Note : Engine damage can result from incorrect propeller selection which;

•

(C) Prevents engine RPM from attaining the specified “Full Throttle

Operating Range”. When the engine is laboring, install lower pitch propeller.

•

(D) Allows engine RPM above the specified “Full Throttle Operating Range”.

Engine RPM can be limited by the governor, install a higher pitch propeller.

9.4. Power Drive with Fixed Pitch Propeller

The power of a marine diesel engine varies as shown by the power curve approx. in

proportion to the engine speed.

The power take-up of a propeller, however, varies according to the propeller law

P1: P2= n

1

3

: n

2

3

with the third power of the engine speed, i.e. if the propeller speed and, consequently, the ship

speed(P) is to be doubled, the power input(n) has to be increased eightfold (2

3

= 8).

The diagram and the table on the next page give in percent the power ratings and the engine

speeds which belong together according the propeller law. These figures are theoretical values

which allow only rough-and-ready estimates and apply to ships with displacement hulls without

trawling device (trawl nets for fishing, barges) in calm, deep shipping channels.

This means that a ship’s curve of resistance depends on the overall tractive resistance of the

ship, the propeller design and the individual water conditions.

<Example>

According to the model plate the power of an engine is 185 kW at 1,800 rpm.

What is the power that can be transmitted by the propeller if the engine speed is reduced by

200 rpm to 1,600 rpm?

- 67 -

EB0O9001

30%

40%

50%

60%

70%

80%

90%

100%

RPM

B

C

A

D

Output

Power

<Solution>

The rated engine speed of 1,800 rpm is 100%. Consequently, the engine speed of 1,600 rpm

is 89% of the rated speed. Both the diagram and the table on the next page show that with

89% of the rated engine speed 70% of the power i.e. 10% of 185 kW, which equals 130 kW,

can still be transmitted by the propeller.

•

Engine power as a function of engine speed with propeller drive

(theoretical propeller curve)

1. Engine power curve

2. Power take - up of propeller

3. Breakaway curve

- 68 -

EHO1701I

100

90

80

70

60

50

40

30

20

10

0

40 50 60

70 80 90

100 110 120

1

23

Engine speed in %

Power in %

Power Engine Speed

P (%) N (%)

75 91

80 93

85 95

90 97

95 98

100 100

Power Engine Speed

P (%) N (%)

15 53

20 58

25 63

30 66

35 71

40 73

Power Engine Speed

P (%) N (%)

45 77

50 79

55 82

60 84

65 87

70 89

In practice there can be considerable differences between the theoretical power take-up of the

propeller and the actual tractive resistance.

1. Engine power curve

2. Tractive resistance range of some high speed planing boats

3. Breakaway curve

The actual resistance curves show that, in contrast to the theoretical power requirement of the

propeller, a relative large amount of power is already transmitted in the lower engine speed

range, which in the case of light boats can produce high speeds even at idling speed.

This could render maneuvers in narrow harbors or travelling in canals at crawling speed

difficult.

There are several possibilities of reducing propeller speed independently of the engine speed,

thus improving the slow travelling properties of fast boats:

- 69 -

EHO1702I

100

90

80

70

60

50

40

30

20

10

0

40 50 60

70 80 90

100 110 120

1

2

3

Engine speed in %

Power in %

•

Reduction

gear with trolling device :

Propeller speed is reduced by the clutch discs slip. The clutch oil pressure (for pressing the

clutch discs against one another) is lowered during the trolling operation while at the same

time an increased amount of oil for lubrication and removing friction heat is pumped through

the clutch discs.

Trolling device can be only supplied to all models optionally by gear box maker.

These models as follows : L034 / L034TI / L066TI / L136 / L136T / L136TI / L086TI /

MD196T / MD196TI / L126TI / V158TI / V180TI / V222TI.

9.5. Designing of the Propeller

The propeller design is of paramount importance for achieving the highest ship speed or thrust

possible at a given power output. It depends on the type of ship (displacement, planing or

semi-planing), the shape of the hull and the operating conditions (non-towing ship or tug).

More detail design of the propeller can be made by the propeller maker.

The propeller should be planned for 90% of the rated power and must be designed in such a

way that in a trial run with the new, fully equipped ship in laden condition the engine speed is

100 rpm above the rated speed.

This guarantees that rated engine speed is achieved if the tractive resistance (encrustation)

increases any further.

- 70 -

Engine speed in %

Power in %

100

90

80

70

60

50

40

30

20

10

0

40 50 60

70 80 90

100 110 120

1

23

4

5

EHO1703I

1. Engine power curve

2. Tractive resistance curve

3. Breakaway curve

4. Operating point, new condition (inspection, trial run)

5. Operating point, with further increase in tractive resistance

9.5.1. Propeller too small

Incorrect propeller design results in the following operating conditions:

The propeller cannot take up and transmit the engine power available. Thrust and ship speed

may be too low.

Owing to the engine load being lower than the rated power at rated speed, the operating

point is on the breakaway curve. The engine speed is markedly higher than the rated speed

as per model plate.

There is no danger of the engine getting damaged.

1. Engine power curve

2. Tractive resistance curve

3. Breakaway curve

4. Operating point if the propeller is too small

- 71 -

EHO1704I

Engine speed in %

Power in %

100

90

80

70

60

50

40

30

20

10

0

40 50 60

70 80 90

100 110 120

1

2

3

4

9.5.2. Propeller too large

The power take-up of the propeller is higher than the engine power. Consequently, the

engine cannot achieve its rated speed and is therefore overloaded.

Overloading may result in the development of black smoke, which in the long run is likely to

cause damage to the engine and excessive wear.

1. Engine power curve

2. Tractive resistance curve

3. Breakaway curve

4. Operating point if the propeller is too big

- 72 -

EHO1705I

Engine speed in %

Power in %

100

90

80

70

60

50

40

30

20

10

0

40 50 60

70 80 90

100 110 120

1

2

3

4

9.6. Propeller Tip Clearance

Sufficient propeller tip clearance is

necessary to prevent water hammering

against the bottom of the hull. Inadequate tip

clearance will result in noise vibration, and

cavitation throughout the vessel. Most boats

typically require tip clearance between 10 to

15% of propeller diameter.

•

Typical Propeller Diameters

units : mm (Inch)

•

Max allowable propeller diameter =

Max. Propeller swing without tip clearance

1 + [2 (Tip clearance percentage/ 100) ]

EB0O9003

Tip clearance

- 73 -

Max. Propeller Swing without Maximum Allowable Propeller Diameter

Tip Clearance 10 % Tip Clearance 15 % Tip Clearance

381 (15) 279 (11) 305 (12)

406 (16) 305 (12) 330 (13)

432 (17) 330 (13) 356 (14)

457 (18) 356 (14) 381 (15)

483 (19) 356 (14) 406 (16)

508 (20) 381 (15) 406 (16)

533 (21) 406 (16) 432 (17)

559 (22) 432 (17) 457 (18)

584 (23) 432 (17) 483 (19)

610 (24) 457 (18) 508 (20)

635 (25) 483 (19) 533 (21)

660 (26) 508 (20) 533 (21)

686 (27) 533 (21) 559 (22)

711 (28) 533 (21) 584 (23)

737 (29) 559 (22) 610 (24)

762 (30) 584 (23) 635 (25)

9.7. Propeller Rotation in Twin Engine Applications

Engine rotation is viewed from the front of

the engine, looking at the engine crank

pulley side. Propeller rotation is viewed

from behind the boat, looking forward at the

propeller. Therefore, a right hand rotation

engine and a left hand rotation propeller are

turning in the same direction.

DOOSAN marine engines are available in

standard right hand rotation only. Twin

engine installations should have the

propellers turning in opposite directions.

The normal recreational boat arrangement has the right hand (clockwise) turning propeller on

the starboard (right) side of the boat and the left hand (counterclockwise) turning propeller on

the port (left) side of the boat.

The propeller rotation is determined by the marine gear. Some gears allow for full power in either

direction of rotation. The rotation in forward is set at the marine gear. Marine gears that are

designed for a specific direction of rotation must be installed on the proper side of the boat.

DOOSAN marine gears have the strength fully that they can be used for long periods of time in

reverse position of the gear shift lever under full load at rated rpm because of designing both

forward gear/shaft and reverse gear/shaft equally.

So all marine gears supplied by DOOSAN can be used for the port propeller.

- 74 -

EB0O9002

CHAPTER 10 ELECTRICAL SYSTEM

10.1. Electric Circuit

The circuit diagrams depend on the engine models and the extent of delivery and are tailor-

made for orders and dispatched together with the usual documents such as wiring diagram

etc. while the order is processed but on some available models.

•

The installed battery capacity must not be less than that specified for that particular

engine.

•

The maximum resistance in the starting circuit must not exceed 0.002 Ohms.

•

If the alternator is not supplied with the engine, the installer must assume responsibility for

adequate mounting.

•

A functioning hour meter must be maintained on the engine.

Note : When you work like any repairing jobs in the engine room you should pay

attention to not occurring any electric circuit shortage (spark).

10.1.1. Electrical wiring

Overcharging or undercharging reduces

battery life.

Because of operating and environmental

conditions, wiring on marine applications

needs special precaution. Connections

should be made with corrosion resistant

hardware and be shielded as much as

possible. All wiring should be in protective

looms, conduit or tape and be routed away

from heat sources, such as the exhaust

piping, and above bilge water level.

Proper routing arid clipping of electrical

wiring is extremely important. Leads

should be routed away over 127 mm from

heat sources such as the exhaust piping and should be above the bilge water level.

Listed below are basic guidenlines which should be followed when designing or installing

wiring systems.

•

On any surface likely to see movement

from vibration or normal deflections,

such as the frame or stringer to engine,

wires must not rub against surrounding

parts or each other. If they must rub a

surface, they should be banded or

clipped to it.

•

Under no circumstances should the

wire contact sharp edges, screw, bolts

or nuts.

- 75 -

EB0O9011

Protective
loom

127mm(5 in)

Minimum

EB0O1106

BAD

10.1.2. Cause of electrolytic corrosion

One of the most important causes of corrosion of metal parts in salt water is interference

current from the ship’s electrical system. These currents may be very weak and are often

hard to detect. However, if they are active over prolonged periods of time, they may cause

heavy corrosion.

Electrolytic corrosion may be prevented by a suitable electrical wiring.

Marine engine installations require special grounding of electrical system components to

minimize electrolytic corrosion from stray currents and to minimize radio interference.

On metallic the boats the hull may serve as the common bonding conductor and a separate

bonding system may not be required.

10.2. Electric Components

10.2.1. Gauge panel

All DOOSAN marine engines covered in this manual are available with remote mounted

instrument panels and some kinds of different gauge panels on each model that is standard,

deluxe, dual type also one pole(earth return), two pole(insulated return) type engine electric

wires optionally.

Note :

Instrument panels should not be mounted on the engine due to engine

vibration.

10.2.2. Battery

The starting and electrical system must be designed so that the engine will start readily

under the most severe ambient conditions ordinarily encountered. In order to achieve this

objective, the installer must exercise good judgment in the selection and application of the

electrical system components. These recommendations are offered as a guide to obtain a

reliable system.

Note : The installed battery capacity must not be less than that specified for that

particular engine.

On any engine there must be enough power available to the starter to ensure quick, reliable

starts under any operating condition. The temperature of the environment in which the

vessel operators will greatly affect the power required for starting, so the worst case

condition for the vessel should be used and considered.

Note : The battery capacity must meet the cold cracking ampere limits.

Battery voltage or current capacity can be increased by connecting batteries in different

combinations of series and parallel arrangements.

- 76 -

1) The batteries in parallel

If the batteries are connected in parallel, the

system current will be equal to the sum of the

current for the two batteries and trip system

voltage will be the same as the individual

voltages of the batteries. (Refer to the figure.)

2) The batteries in series

Connecting the batteries in series will

increase the system voltage, but not the

current. The voltage will be equal to the sum

of the two battery voltages and the current will

be equal to the current of either individual

battery.

3) The batteries in series and parallel

If the batteries are connected in series and

parallel, then both the system voltage and

current will increase.

Note : The maximum resistance in the starting circuit must not exceed 0.002 Ohms.

If the circuit resistance is too high, the starting motor will not receive an adequate supply of

electrical energy and will not provide reliable cranking over the range of conditions

- 77 -

EB0O1103

-

-

+

+

12V

1

2

3

4

­+

12V

­+

12V

­+

12V

24V

Starter

Series - Parallel circuit

V = V1 + V2 = V3 + V4,

1= 1

1 + 13 = 12 + 14

EB0O1101

-

-

+

+

12V

12V

Starter

­+

12V

Parallel circuit

V = V1 = V2,

1 = 1

1 + 12

EB0O1102

-

-

+

+

12V

­+

12V

24V

Starter

Series circuit

V = V1 + V2,

1 = 1

1 = 12

encountered in service. The maximum starting circuit resistance for the engines covered in

this manual is 0.002 Ohms. The table below lists the maximum length of typical cables in

the cranking circuit necessary to meet this requirement.

<Battery to Cranking motor Cable Sizes>

This table lists the cable diameter and cross - sectional area for the sizes listed above.

Starting motor circuit resistance will be affected by cable size and length, the number of

connections in the system and the possible presence of additional contactors in the wiring

arrangement.

10.2.3. Starter circuit wiring

The starter cable terminals should have soldered connections. Rosin flux should be used

for soldering electrical connections. Acid flux solders will cause deterioration of the

electrical connection.

Connecting two strands of cable, such as two #00 or two #000 should be carefully done in

order to assure that both wires have a good connection with the battery. Next figure shows

one method used to connect two cables to a battery. Tinning the stainless steel washers

and cable connectors with solder will reduce the chances of problems due to corrosion. The

use of a non-conductive grease at the connection will also help prevent corrosion.

The cable to battery connections should

use the maximum available contact area

of the battery post. Clamps must be

positioned squarely on the battery post or

stud with clean surface and securely

fastened. Stacked terminal connections

which have only point or line contact will

not be satisfactory

- 78 -

Battery to Cranking motor Cable Sizes

Maximum Circuit

Maximum Length Cable in Cranking Circuit

Remarks

Resistance #00 #000

0.002 Ohm 6.1 m (20 feet) 8.23 m (27 feet) Single Cranking Motor

0.002 Ohm 6.1 m (20 feet) 8.23 m (27 feet)

Dual Cranking Motor

W/ Single Battery Bank

Cable size (AWG)

Cable diameter

Cable area (mm2)

mm in

#0 7.8 (.3065) 47.8

#00 8.4 (.3310) 55.4

#000 9.2 (.3625) 66.5

#0000 10.0 (.3938) 78.5

EB0O1104

Copper washers

Copper nut & bolt

Note : If the alternator is not supplied with the engine, the installer must assume

responsibility for adequate mounting.

Since the integrity of customer supplied alternator mounting cannot be assured, DOOSAN

is not responsible for any problems associated with an improperly mounted alternator that

was not supplied with the engine. If the customer wishes to supply and mount their own

alternator, they should contact the local DOOSAN distributor for assistance.

10.2.4. Alternator wiring

Unless special protective devices are used, an alternator system can be damaged by the

connection of a charged battery to the alternator in reverse polarity. If a reverse connection

is made while attempting to start an engine that has a dead battery or when connecting a

newly changed battery, the low resistance path through the rectifier will burn up the diodes.

It is recommended that one battery lead be shorter than the other so that once the battery

is properly set in place it is impossible to misconnect it.

Most alternators include heavy duty voltage regulators. Generally, the range will be as

follows:

10.2.5. Explanations on the subsequent wiring diagram

- 79 -

System voltage Low Normal High

12 Volt 13.1V 13.7V 14.3V

24 Volt 26.2V 27.4V 28.6V

32 Volt 34.2V 36.5V 38.5V

EB0O1112

The following wiring diagram depicts the wiring of the engine and its most important

components to prevent electrolytic corrosion. The earthing cables in the diagram are

indicated in bold print.

A copper band connected to the hull (1) runs in longitudinal direction along the hull and is

connected with zinc anodes (2). More anodes are located e.g. on the rudder blade.

The propeller shaft is connected with the hull via a slip ring (3).

Control cables (6) are laid from the adjusting lever of the Injection pump and from the

reversing lever of the gearbox to the deck control instruments (7) that are also to be

connected to the hull.

If a sea water injection system is fitted, that part of the exhaust gas pipe (4) that contains

sea water is in most cases connected with a hose connection (5) and must therefore also

be connected to the hull.

The pipe connections between the sea water pump (8), sea water filter (9), shut-off valve

(10) and scoop (11) must also be “earthed”.

For safety reasons (sparking owing to electrostatic charging) the steel tank (12) is also

connected to the hull.

In addition, the following is to be heeded for commissioning engines:

Only authorized specialist personnel must inspect the installation and commission the

engine.

•

Never operate the engine while it is dry, i.e. without lubricant or coolant.

•

Do not use any additional starting aids (e.g. start pilot) for starting the engine.

•

Only use operating materials (engine oil, antifreeze and anti-corrosion agents) approved

by DOOSAN. Ensure cleanliness. Diesel fuel must be free of water

•

Do not immediately switch off hot engine but let it idle for about 5 minutes without load so

that a temperature equalization can be brought about.

•

Never fill overheated engine with cold coolant

•

Do not fill up with engine oil above the max. level on the dipstick. Do not exceed the

engine’s maximum permissible operating inclination(12degree).

•

Non-compliance with these instructions may cause severe engine damage.

•

Always ensure that control and monitoring devices (charging, control, oil pressure,

coolant temperature) work faultlessly.

•

Never operate the sea water pump while it is dry in danger of frost empty sea water

pump when the engine is shut down.

- 80 -

APPENDIX

•

Conversion Tables (1/2)

- 81 -

Units To convert Into Multiply by Reference

mm inch 0.03937 I ft = 12 in.

cm foot 0.03281 I yd = 3 ft.

m yard 1.09361 = 36 in.

Length

km mile 0.62137

inch mm 25.4

foot cm 30.48

yard m 0.5144

mile km 1.6093

cm

2

in

2

0.155 1 ft2= 144 in.

2

m

2

ft

2

10.76 1 yd2= 9 ft

2

km

2

mile

2

0.3861 = 1296 in.

2

Area

are acre 0.0247

In

2

cm

2

6.4516

ft

2

m

2

0.0929

mile

2

km

2

2.59

acre are 40.4686

cm

3

in.

3

0.06102

•

Great Britain (UK)

dm

3

(liter) in.

3

61.0236 1 fl oz = 0.028413 dm

3

dm3(liter) ft

3

0.03531 1 pt = 4 gills

m

3

ft

3

35.315 = 0.56826 dm

3

m

3

yd

3

1.30795 1 qt = 2 pt

in.

3

cm

3

16.3871 = 1.13652 dm

3

in.

3

dm3(liter) 0.01639 1 gal = 34 qt

ft

3

m

3

0.02832 = 4.5461 dm

3

Volume

yd

3

m

3

0.76456

•

United States (US)

1 ft oz = 0.029574 dm

3

1 liq = 4 gills

= 0.47318 dm

3

1 liq qt = 2 liq pl

= 0.94635 dm

3

1 gal = 231 in.

3

= 4 liq qt

= 3.7854 dm

3

g oz 0.03527

Weight kg Ib 2.2046 1Ib =16 oz

(Units of mass) oz g 28.3495 = 453.592 g

Ib kg 0.45359 = 0.45359 kg

g

f

N (newton) 0.009807 1 pd MM(poundal)

kg

f

N 9.80665 = 0.138255N

Force

1b

f

N 4.44822 = force which

Ng

f

101.972 accelerates a mass

Nkg

f

0.101972 of Ib by 1 ft/s

2

N1bf0.224809

•

Conversion Tables (2/2)

- 82 -

Units To convert Into Multiply by Reference

kgf/cm

2

bar 0.98066 1 at = 1 kgf/cm

2

kgf/cm

2

N/m2(pa) 98066.5 1 Pa = 1 N/m

2

kgf/cm

2

Ibf/in.

2

14.2233 10m H2O = 1 kgf/cm

2

Pressure and Ibf/in.

2

bar 0.0689 1 mmHg = 1 Torr

stress 1b

f

/in

2

N/m2(pa) 6894.76 1 kg/cm2=98 kPa=980 hPa

Bar kg

f

/cm

2

1.01972 760mmHg =1,013mbar

N/m

2

(Pa) kgf/cm

2

1.0197 x 10

-5

=1,013 hPa

Ibf/in

2

kgf/cm

2

0.07031 1bar = 1,000hPa

Bar 1b

f

/in.

2

14.5037

N/m2(Pa) 1bf/in

2

1.4504 x 10

-4

J kcal 238.8 x 10

-6

J kWh 277.8 x 10

-9

Energy J BTU 947.8 x 10

-6

kcal BTU 3.9683
BTU kcal 0.252

kg

f

•

mN

•

m 9.80665

Ib

f

•

ft Nm 1.356

Work

kg

f

•

mIb

f

•

ft 7.233

Ib

f

•

ft kg

f

•

m 0.138

N

•

mkg

f

•

m 0.102

Nm Ib

f

•

ft 0.738
kW P.S 1.3596 1 PS = 75 kg-m/sec
kW HP 1.3410 1 HP = 550 Ib.ft/se

Power

PS kW 0.7355
HP kW 0.7457
PS HP 0.98632
HP PS 1.01387

m/sec ft/min 196.86

Velocity

ft/min m/sec 0.0051

km/h mile/h 0.62137

mile/h km/h 1.09361

Acceleration

m/sec

2

ft/sec

2

3.281

ft/sec

2

m/sec

2

0.3048

g/PS-h g/kW-h 1.3596

g/HP-h g/kW-h 1.3410

Ib/PS-h g/kW-h 599.96

Fuel consumption

Ib/HP-h g/kW-h 608.277

g/kW-h g/PS-h 0.7355
g/kW-h g/HP-h 0.7457
g/kW-h Ib/PS-h 0.00167
g/kW-h Ib/HP-h 0.00164

˚

C

˚

F

˚

C = 5/9 (˚F-32)

˚

C K (kelvin)

˚

C = K - 273.15

˚

F = 1.8 X ˚C+32

Temperature

˚

F

˚

C

˚

F = ˚R - 459.67

˚

F

˚

R(Ranfine)

˚

F = ˚R - 459.67

K

˚

CK = ˚C + 273.15

˚

R

˚

F

˚

R = ˚F + 459.67

•

DOOSAN Marine Engine Technical Data (1/3)

- 83 -

Engine Models

L034 L034 L034 L066 L136 L136 L136

Units

TIH TIM TIH T TL

Continuous Rating (B.H.P)

PS 70 120 145 180 160 200 240

kW 51 88 107 132 118 147 177

Engine Speed rpm 3000 3000 3300 2200 2200 2200 2500

Combustion air m3/h 220 410 480 700 450 770 1005

Fuel Inj. Timing (BTDC) deg 18 18 18 15 18 18 18

Fuel Consumption

g/ps.h 180 162 162 159 163 161 173

Lit./h 15 23 28 34.5 31 39 50

Coolant Capacity (Max/Min) Lit. 17/15 17/15 17/15 25/20 25/23 25/23 25/23

Oil Pan Capacity( Max/ Min) Lit. 6.5/5.5 6.5/5.5 6.5/5.5 19/14 23/17 23/17 23/17

Coolant Circulation Lit/min 130 130 140 150 250 250 290

Amounted of heat to be

MJ/h 120 135 148 325 276 312 338

dissipated from cooling circuit

Amounted of heat to be

MJ/h None 23 29 33 None None None

dissipated from inter cooler

Max. pressure loss in cooling

bar 0.6 0.6 0.6 0.7 0.7 0.7 0.7

system

Delivery rate, Sea water pump Lit/min 142 142 140 140 180 180 195

Exhaust gas temperature C 460 480 490 400 520 450 470

Exhaust gas mass flow kg/h 280 520 600 870 560 960 1260

Exhaust gas volume flow m3/h 340 630 730 1050 680 1170 1520

Radiation, convection MJ/h 42 62 70 78 68 76 92

Engine dry weight

kg 450 545 545 717 928 938 938

(with marine gear)

Engine dry weight

kg 372 402 535 743 748

(without marine gear)

•

DOOSAN Marine Engine Technical Data (2/3)

- 84 -

Engine Models

L136 L086 L086 L086 MD196MD196 L126 L126

Units

TI TIH TIM TIL T TI TIH TIM

Continuous Rating (B.H.P)

PS 230 285 315 360 260 320 360 400

kW 169 210 232 265 206 235 265 294

Engine Speed rpm 2200 2100 2300 2500 2000 2000 2000 2100

Combustion air m3/h 850 1050 1130 1470 865 1310 1344 1445

Fuel Inj. Timing (BTDC) deg 14 15 15 13 14 16 14 14

Fuel Consumption

g/ps.h 166 150 153 167 157 153 153 157

Lit./h 46 52 58 72 49 59 66 76

Coolant Capacity (Max/Min) Lit. 25/23 26/24 26/24 26/24 24/19 24/19 24/19 24/19

Oil Pan Capacity( Max/ Min) Lit. 23/17 23/17 23/17 23/17 25/19 25/19 25/19 25/19

Coolant Circulation Lit/min 250 250 260 270 342 342 342 342

Amounted of heat to be

MJ/h 356 387 450 540 430 510 580 610

dissipated from cooling circuit

Amounted of heat to be

MJ/h 47 54 64 77 None 66 73 82

dissipated from inter cooler

Max. pressure loss in cooling

bar 0.7 0.7 0.7 0.7 0.8 0.8 0.8 0.8

system

Delivery rate, Sea water pump Lit/min 180 180 190 200 260 260 260 260

Exhaust gas temperature C 410 450 500 500 510 470 370 415

Exhaust gas mass flow kg/h 1060 1310 1410 1840 1090 1300 1620 1751

Exhaust gas volume flow m3/h 1280 1580 1710 2200 1325 1575 3025 3269

Radiation, convection MJ/h 86 98 106 120 100 107 112 133

Engine dry weight

kg 773 790 790 790 975 1009 1410 1410

(with marine gear)

Engine dry weight

kg 994 1015 1015 1015 1225 1329 1060 1060

(without marine gear)

•

DOOSAN Marine Engine Technical Data (3/3)

- 85 -

Engine Models

V158 V158 V158 V180 V180 V180 V222 V222 V222

Units

TIH TIM TIL TIH TIM TIL TIH TIM TIL

Continuous Rating (B.H.P)

PS 480 540 680 600 650 820 720 800 1000

kW 353 397 500 441 478 603 530 588 736

Engine Speed rpm 1800 2100 2300 1800 2100 2300 1800 2100 2300

Combustion air m3/h 2350 2780 3970 2890 3190 4785 3450 4040 5995

Fuel Inj. Timing (BTDC) deg 24 24 24 24 24 24 24 24 24

Fuel Consumption

g/ps.h 155 163 185 153 156 185 152 160 190

Lit./h 90 106 152 111 122 183 132 154 229

Coolant Capacity (Max/Min) Lit. 85/78 85/78 85/78 90/81 90/81 90/81 95/87 95/87 95/87

Oil Pan Capacity( Max/ Min) Lit. 31/25 31/25 31/25 35/28 35/28 35/28 40/33 40/33 40/33

Coolant Circulation Lit/min 495 585 640 495 585 640 495 585 640

Amounted of heat to be

MJ/h 890 1060 1405 1130 1320 1690 1340 1570 2070

dissipated from cooling circuit

Amounted of heat to be

MJ/h 111 134 169 141 159 209 167 209 271

dissipated from inter cooler

Max. pressure loss in cooling

bar 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0

system

Delivery rate, Sea water pump Lit/min 375 460 510 445 530 580 445 530 580

Exhaust gas temperature C 320 320 390 340 330 350 330 320 400

Exhaust gas mass flow kg/h 1842 2168 2821 2347 2643 3383 2786 3214 4153

Exhaust gas volume flow m3/h 3610 4250 5530 4600 5180 6630 5460 6300 8140

Radiation, convection MJ/h 139 171 225 182 204 256 215 242 328

Engine dry weight

kg 1710 1710 1710 2065 2065 2065 2460 2460 2460

(with marine gear)

Engine dry weight

kg 1300 1300 1300 1550 1550 1550 1750 1750 1750

(without marine gear)