Daewoo Doosan DB58S Diesel Engine Service Repair Manual

65.99897-8079

OPERATION and MAINTENANCE MANUAL

DIESEL ENGINE

DB58 DB58S DB58T DB58TI DB58TIS

Printed in Jan. 2003

PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

FOREWORD This maintenance manual is designed to serve as a reference for DAEWOO Heavy Industries Ltd's (here after DAEWOO’s) customers and distributors who wish to gain basic product knowledge on DAEWOO's DB58, DB58S, DB58T, DB58TI and DB58TIS Diesel engine.

This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has been so designed and manufactured to be used for the overland transport or industrial purpose. That meets all the requirements such as low noise, fuel economy, high engine speed, and durability.

To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT OPERATION and PROPER MAINTENANCE are essential.

In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal

Adjustment

Installation

Cleaning

Disassembly

Pay close attention-Important

Reassembly

Tighten to specified torque

Align the marks

Use special tools of manufacturer's

Directional Indication Inspection

Lubricate with oil Lubricate with grease

Measurement During engine maintenance, please observe following instructions to prevent environmental damage; Take old oil to an old oil disposal point only.

Ensure without fail that oil will not get into the sea or rivers and canals or the ground.

Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.

The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some quality improvement. Thank you.

DAEWOO Heavy Industries & Machinery LTD. Aug. 2003 Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

CONTENTS 1. GENERAL INFORMATION 1.1 Engine specifications 1.2. Engine power 1.3. Performance curve 1.4. Engine assembly 1.5. Safety regulations

1 2 3 7 13

2. TECHNICAL INFORMATION 2.1. Engine model and serial number 2.2. Engine type 2.3. Engine timing 2.4. Valves 2.5. Lubrication system 2.6. Air cleaner 2.7. Fuel system 2.8. Cooling system 2.9. V-belt tension check and adjust 2.10. Valve clearance and adjustment 2.11. Cylinder compression pressure 2.12. Injection nozzle 2.13. Battery 2.14. Starting motor 2.15. Diagnosis and remedy

17 18 18 18 18 21 22 25 28 29 30 31 31 31 32

3. MAINTENANCE 3.1. Engine Disassembly 3.2. Engine Inspection 3.3. Reassembly 3.4. Electrical Equipments

42 63 88 107

4. Commissioning and Operation 4.1. Preparation 4.2. Starting and operation 4.3. Inspections after starting 4.4. Operation in winter time 4.5. Maintenance and care 4.6. Cooling system 4.7. Valve clearance and adjustment 4.8. Injection timing 4.9. Tightening the cylinder head bolts

114 115 117 117 119 121 122 124 127

4.10. Cylinder compression pressure 4.11. Injection nozzle

128 128

Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

1. GENERAL INFORMATION 1.1. Engine specifications Engine Model Items Engine type Combustion chamber type Cylinder liner type Timing gear system No. of piston ring

1

DB58/S

DB58T

DB58TI

4 cycle in-line Naturally aspirated

4 cycle in-line, Water-cooled Turbo charged

DB58TIS

4 cycle in-line, Water-cooled type Turbo charged & intercooled

Direct injection type Dry type Gear driven type 2 Compression 1 ring, oil ring

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual 1. 2. Engine power Production tolerance : 5% Engine model Model

Suffix

EARDA EAREA EAREB EARFE EARFI/J DB58 EARFH EARFF EARFG EARFK EARLA/B EARLC ECRFA DB58S ECRFB ECRFC EATEA EATEE EATEH EATEB EATEF DB58T EATED EATEG EATEI EATLA EATLB EAOEA EAOED EAOEB DB58TI EAOEC EAOLA/B EAOEE ECOEA ECOEB ECOEC ECOEG DB58TIS ECOED ECOEE ECOEF ECOLA ECOLB

Performance Injection timing (BTDC ) 20

16

Power (PS/rpm)

Torque Low idle (kg.m/rpm) (rpm)

88.5/1,800

35.5/1,600

113/2,200

38/1,600

92/2,200

32/1,600

18 20

High idle (rpm)

950-1,000 2,000~2,030 850-900

2,370~2,470

775-825

2,370~2,470

860 25

2,420 25

800 25

2,420 50

850 25

2,420 25

800 25

2,420 50

102/2,200

35.5/1,600

18

108/2,200

37.5/1,600

975 25

2,420 50

16

98~102/2,200

38.0/1,600

975 25

2,420 50

102/2,200

37/1,600

18 16

15

90/2,200 94/2,400

18 13 18 13 18

33/1,600 44/1,600

132/2,200

111/1,850

45/1,600

45/1,700

114/1,950

800 25

2,420 50

925~975

TIER-II

2,370~2,470

1,100 25

2,240 50

950-980

2,370~2,470

825~875

2,035 50

1,050 10

2,035 50

1,150 25

2,140 50 2,255 50

120/2,050

45/1,600

1,150 25

39.0/1,700

1,050 10

2,035 50

18

139/2,300

45.5/1,600

875~925

2,480 50

13

132/2,200

45.0/1,600

975 25

2,420 50

13

150/2,000

57/1,600

1,150 25

2,200 50

13

160/2,200

13

155/2,100

13

145/2,000

13

160/2,000

59/1,600

11

173/2,000

68/1,400

1,250~1,275 2,200~2,250

11

157/1,950

62/1,400

1,200~1,225 2,150~2,200

11

162/2,200

11

158/2,100

60/1,500

1,200~1,225

11

135/2,200

50/1,400

1,100~1,125 2,420~2,470

11

154/2,000

60,1,500

58/1,600

-

2,640 50

100+2/1,850

13

Remark

1,200 25

2,420 50 2,310 50

TIER-I

-

975~1,025 2,370~2,470 1,150 25

1,200 25

2,200 50

2,370~2,470 2,260~2,360 2,200 50

11

124/1,950

48/1,400

1,150~1,175 2,095~2,195

13

165/2,200

73/1,400

1,075~1,125 2,370~2,470

11

145/2,200

63/1,500

1,100 25

TIER-II

2,420 50

* Note : All data are based on operation without cooling fan at DIN 6270B

2

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual 1. 3. Performance curve 1. 3.1. Performance curve (DB58)

Performance Output

(rated)

Torque

(min)

Fuel consumption

3

DIN 6270B

(min)

96 kW (130PS) / 2,800 rpm

DIN 6270A 85 kW (115PS) / 2,800 rpm

370 N.m (38.0 kg.m) / 1,600 rpm 218 g/kW.h (160 g / PS.h) General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

1. 3.2. Performance curve (DB58T)

Performance Output

(rated)

Torque

(min)

Fuel consumption

4

DIN 6270B

(min)

104 kW (142PS) / 2,500 rpm

DIN 6270A 90 kW (122PS) / 2,500 rpm

450 N.m (46.0 kg.m) / 1,600 rpm 211 g/kW.h (155 g / PS.h) General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

1. 3.3. Performance curve (DB58TI)

Performance Output

(rated)

Torque

(min)

Fuel consumption

5

DIN 6270B

(min)

112 kW (152PS) / 2,200 rpm

DIN 6270A 102 kW (138PS) / 2,200 rpm

539 N.m (55.0 kg.m) / 1,600 rpm 204 g/kW.h (150 g / PS.h)

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual 1. 3.4. Performance curve (DB58TIS)

Performance Output

(rated)

126.5 kW (172PS) /2,200 rpm

Torque

(min)

696 N.m (71 kg.m) / 1,400 rpm

Fuel consumption

6

DIN 6270B

(rated)

217.5 g/kW.h (160 g / PS.h)

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual 1.4. Engine assembly 1.4.1. Engine sectional view (DB58TI/TIS : air to water type)

7

8

9

10 11 12

20

21

22

23

24

25

19

26

18

27

17

28

16

6 5 4 3 2 1

13 14 15

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

7

Oil spray nozzle Connecting rod Cylinder liner Oil cooler Piston Swirl chamber Fuel injection pipe Fuel injection nozzle Valve cotter Valve spring Valve stem seal Valve guide Oil pan Oil pump strainer Oil pump Cooling water pump Cooling water pump pulley

29

18.

19.

20.

21.

22 23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

30

31 32 33

Piston pin Thermostat Intake valve Exhaust valve Breather Inter cooler Rocker arm Oil filler cap Cylinder head cover Cylinder head Push rod Vibration damper Oil drain plug Crank shaft Cam shaft tappet

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

1.4.2. Engine sectional view (DB58TIS : air to air type)

7

8

9

10 11 12

20 21 22

23

24

19 25

18

26

17

27

16 6 5 4 3 2 1 13 14 15

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

8

Oil spray nozzle Connecting rod Cylinder liner Oil cooler Piston Swirl chamber Fuel injection pipe Fuel injection nozzle Valve cotter Valve spring Valve stem seal Valve guide Oil pan Oil pump strainer Oil pump Cooling water pump

28

17.

18.

19.

20.

21 22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

29

30 31 32

Cooling water pump pulley Piston pin Thermostat Intake valve Exhaust valve Breather Rocker arm Oil filler cap Cylinder head cover Cylinder head Push rod Vibration damper Oil drain plug Crank shaft Cam shaft tappet

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

1.4.3. Engine assembly views (1) DB58

3

4

5

6

7

8

14

2

15 1

9

10 11 12 13 16

17

18

24

25

26

19 20 21

22

1 2 3 4 5 6 7 8 9

9

Oil filter Lifting hook Oil cooler Intake manifold Priming pump Fuel injection pump Fuel injection pipe Water outlet Cooling fan

10 11 12 13 14 15 16 17 18

23

Cooling fan idler Crank shaft pulley Vibration damper Oil drain plug Cooling water pump Alternator Fan drive mounting Oil level gauge Exhaust manifold

19 20 21 22 23 24 25 26

Push rod chamber cover

Flywheel housing Fly wheel Oil pan Starter Cylinder head cover Fuel injection nozzle Fuel filter

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

(2) DB58T

3

4

5

6

7

8

14 15

2

16

1 9

10 11 12 17

13 18 19

20

26

27

28

29 21 22 23

24

1 2 3 4 5 6 7 8 9 10

10

Engine pick-up sensor Lifting hook Oil cooler Intake manifold Priming pump Fuel injection pump Fuel injection pipe Water outlet Cooling fan Crank shaft pulley

25

11 12 13 14

Vibration damper Oil filter Oil drain plug Air pipe

15 16 17 18 19

Cooling water pump Alternator Breather Turbo charger Exhaust manifold

(turbo charger to intake manifold)

20 21 22 23 24 25 26 27 28 29

Oil filler cap Push rod chamber cover

Flywheel housing Fly wheel Oil pan Starter Oil level gauge Cylinder head cover Fuel injection nozzle Fuel filter

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

(3) DB58TI/TIS

2

3

4

5

6 13

1

14 7

8 9 10

11

15

12 16

17

22 23

24 25 26

18 19 20

21

1 2 3 4 5 6 7 8 9

11

Fuel filter Oil cooler Intake manifold Priming pump Fuel injection pump Fuel injection pipe Cooling fan Crank shaft pulley Vibration damper

10 11 12 13 14 15 16 17 18

Oil filter Oil pan Oil drain plug Cooling water pump Alternator Water outlet Exhaust manifold

19 20 21 22 23 24

Flywheel housing Fly wheel Starter Turbo charger Oil level gauge Air pipe

Oil filler cap Push rod chamber cover

25 26

Fuel injection nozzle Intercooler

(turbo charger to intercooler)

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual

(4) DB58TIS

3

4

5

6

7

17

18

16

2 1

8

19

15

9 20

10

21

11

12 13 14

22

23

24

1 2 3 4 5 6

Flywheel housing Lifting hook

7 8 9

Breather Cooling fan Oil filter

Oil filler cap

Fuel filter Intake manifold Air pipe (intercooler to manifold)

12

25

10 11 12 13 14 15 16 17 18 19

27

28

20 21

Water outlet Air pipe

22 23 24 25 26 27 28

Turbo charger Exhaust manifold Crank shaft pulley Starter

26

Oil pan Oil drain plug Fuel injection pump Fuel feed pump Priming pump Cooling water pump Air heater Thermostat housing Water pump pulley Alternator

(turbocharger to intercooler)

Push rod chamber cover

Oil level gauge Fuel injection pipe

General information Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual 1.5. Safety regulations 1.5.1. General notes Day-to-day use of power engines and the service products necessary for running them presents no problems if the persons occupied with their operation, maintenance and care are given suitable training and think as they work.

This summary is a compilation of the most important regulations. These are broken down into main sections which contain the information necessary for preventing injury to persons, damage to property and pollution. In addition to these regulations those dictated by the type of engine and its site are to be observed also.

IMPORTANT. If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc., consult a doctor immediately.

1.5.2. Regulations designed to prevent accidents a) During commissioning, starting and operation Before putting the engine into operation for the first time, read the operating instructions carefully and familiarize yourself with the "critical" points. If you are unsure, ask your DAEWOO representative.

For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room.

The engine must be started and operated only by authorized personnel. Ensure that the engine cannot be started by unauthorized persons.

When the engine is running, do not get too close to the rotating parts. Wear closefitting clothing.

Do not touch the engine with bare hands when it is warm from operation risk of burns.

Exhaust gases are toxic. Comply with the installation instructions for the installation of DAEWOO diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate ventilation and air extraction.

Keep vicinity of engine, ladders and stairways free of oil and grease.

Accidents caused by slipping can have serious consequences. b) During maintenance and care Always carry out maintenance work when the engine is switched off. If the engine has to be maintained while it is running, e.g. changing the elements of change-over filters, remember that there is a risk of scalding. Do not get too close to rotating parts.

Change the oil when the engine is warm from operation.

13

Safety regulations Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual CAUTION There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare hands.

Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil will not overflow.

Open the coolant circuit only when the engine has cooled down. If opening while the engine is still warm is unavoidable, comply with the instructions In the chapter entitled "Cooling".

Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.

Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only when the engine is switched off.

Keep service products (anti-freeze) only in containers which can not be confused with drinks containers.

Comply with the manufacturer's instructions when handling batteries.

CAUTION Accumulator acid is toxic and caustic. Battery gases are explosive. c) When carrying out checking, setting and repair work Checking, setting and repair work must be carried out by authorized personnel only.

Use only tools which are in satisfactory condition. Slip caused by the worn openend wrench could lead to Injury.

When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lifting gear in good condition.

When checking injectors, do not put your hands under the jet of fuel.

Do not inhale at atomized fuel.

When working on the electrical system disconnect the battery earth cable first.

Connect it up again last in prevent short circuits.

1.5.3. Regulations designed to prevent damage to engine and premature wear (1) Never demand more of the engine than it was designed to yield for its intended purpose.

Detailed information on this can be found in the sales literature. The injection pump must not be adjusted without prior written permission of DAEWOO. (2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of damage.

(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for damage resulting from the installation of other parts which are supposedly "just as good".

(4) In addition to the above, note the following points.

Never let the engine run when dry, i.e. without lube oil or coolant. Use only DAEWOO-approved service products. (engine oil, anti-freeze and anticorrosion 14

Safety regulations Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual agent) Pay attention to cleanliness. The Diesel fuel must be free of water. See "Maintenance and care".

Have the engine maintained at the specified intervals.

Do not switch off the engine immediately when it is warm, but let it run without load for about 5 minutes so that temperature equalization can take place.

Never put cold coolant into an overheated engine. See "Maintenance and care".

Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do not exceed the maximum permissible tilt of the engine.

Serious damage to the engine may result if these instructions are not adhered to.

Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and coolant temperature) function satisfactorily.

Comply with instructions for operation of the alternator. See "Commissioning and operation".

Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine switched off.

1.5.4. Regulations designed to prevent pollution a) Engine oil, filter element, fuel filter Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into the drains or into the ground.

The drinking water supply may be contaminated.

Oil and fuel filter elements are classed as dangerous waste and must be treated as such. b) Coolant Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.

When disposing of spent coolant comply with the regulations of the relevant local authorities.

1.5.5. Notes on safety in handling used engine oil Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.

Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous substances which have caused skin cancer in animal experiments.

If the basic rules of hygiene and health and safety at work are observed, health risks are not to the expected as a result of handling used engine oil.

<Health precautions> Avoid prolonged or repeated skin contact with used engine oil.

Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.

Clean skin which has been in contact with engine oil.

- Wash thoroughly with soap and water, A nailbrush is an effective aid.

15

Safety regulations Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS Operation and Maintenance Manual - Certain products make it easier to clean your hands.

- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.

After washing apply a fatty skin cream to the skin.

Change oil-soaked clothing and shoes.

Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations are punishable. Collect and dispose of used engine oil carefully.

For information on collection points please contact the seller, the supplier or the local authorities.

1.5.6. General repair instructions 1. Before performing service operation, disconnect the grounding cable from the battery for reducing the chance of cable damage and burning due to short-circuiting.

2. Use covers for preventing the components from damage or pollution.

3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.

4. The use of proper tools and special tools where specified is important to efficient and reliable service operation.

5. Use genuine DAEWOO parts necessarily.

6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused.

7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nut separately is very important as they vary in hardness and design depending on position of installation.

8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make certain they are free from restrictions.

9. Lubricate rotating and sliding faces of parts with oil or grease before installation.

10. When necessary, use sealer on gaskets to prevent leakage.

11. Carefully observe all torque specifications for bolts and nuts.

12. When service operation is completed, make a final check to be sure service has been done properly.

16

Safety regulations Printed in Jan. 2003 PS-MMA0300-E1A

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