Daewoo Doosan DB58, DB58S, DB58T, DB58TI, DB58TIS Diesel Engine Operation & Maintenance Manual

Printed in Jan. 2003 PS-MMA0300-E1A OPERATION and MAINTENANCE MANUAL DIESEL ENGINE DB58 DB58S DB58T DB58TI DB58TIS 65.99897-8079

DB58/T/TI/TIS Operation and Maintenance Manual Printed in Jan. 2003 PS-MMA0300-E1A 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 Lubricate with oil Inspection 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

DB58/T/TI/TIS Operation and Maintenance Manual Printed in Jan. 2003 PS-MMA0300-E1A CONTENTS 1. GENERAL INFORMATION 1.1 Engine specifications 1 1.2. Engine power 2 1.3. Performance curve 3 1.4. Engine assembly 7 1.5. Safety regulations 13 2. TECHNICAL INFORMATION 2.1. Engine model and serial number 17 2.2. Engine type 18 2.3. Engine timing 18 2.4. Valves 18 2.5. Lubrication system 18 2.6. Air cleaner 21 2.7. Fuel system 22 2.8. Cooling system 25 2.9. V-belt tension check and adjust 28 2.10. Valve clearance and adjustment 29 2.11. Cylinder compression pressure 30 2.12. Injection nozzle 31 2.13. Battery 31 2.14. Starting motor 31 2.15. Diagnosis and remedy 32 3. MAINTENANCE 3.1. Engine Disassembly 42 3.2. Engine Inspection 63 3.3. Reassembly 88 3.4. Electrical Equipments 107 4. Commissioning and Operation 4.1. Preparation 114 4.2. Starting and operation 115 4.3. Inspections after starting 117 4.4. Operation in winter time 117 4.5. Maintenance and care 119 4.6. Cooling system 121 4.7. Valve clearance and adjustment 122 4.8. Injection timing 124 4.9. Tightening the cylinder head bolts 127 4.10. Cylinder compression pressure 128 4.11. Injection nozzle 128

DB58/T/TI/TIS Operation and Maintenance Manual Printed in Jan. 2003 PS-MMA0300-E1A 4.12. Fuel injection pump 129 4.13. Feed pump strainer 129 4.14. Separator 129 4.15. Air bleeding 130 4.16. Belts 130 5. Maintenance of Major Components 5.1. Lubrication system 133 5.2. Cooling system 137 5.3. Fuel system 142 5.4. Turbocharger 172 5.5. Air Intake System 180 6. Special Tool List 183 ● Appendix 184 ● WORLDWIDE NETWORK

DB58/T/TI/TIS Operation and Maintenance Manual 1 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. GENERAL INFORMATION 1.1. Engine specifications Engine Model Items DB58/S DB58T DB58TI DB58TIS Engine type 4 cycle in-line Naturally aspirated 4 cycle in-line, Water-cooled Turbo charged 4 cycle in-line, Water-cooled type Turbo charged & intercooled Combustion chamber type Direct injection type Cylinder liner type Dry type Timing gear system Gear driven type No. of piston ring 2 Compression 1 ring, oil ring No. of cylinder-bore x stroke (mm) 6 – 102 × 118 Total piston displacement (cc) 5,785 Compression ratio 17.5 : 1 18.5 Engine dimension (length X width X height) (mm) 1,173x666x793 1,172x724x912 1,184x657x934 1,184x690x970 Engine weight (kg) 450 480 505 480 Rotating direction (from fly wheel) counter clockwise Fuel injection order 1 – 5 - 3 – 6 - 2 – 4 Fuel injection timing (B.T.D.C static) 15° or 18° 13° 11° Injection pump type Bosch in-line A type Governor type Mechanical governor RSV type Injection nozzle type Multi-hole type (5 hole) Multi-hole type (6 or 7 hole) Fuel injection pressure (kg/cm 2 ) 220 185 190 Compression pressure (kg/cm 2 ) 28 (at 200 rpm) Intake & exhaust valve clearance (at cold) (mm) 0.4 Open at 28° B.T.D.C (DB58S : 17°) Intake valve Close at 62° A.B.D.C (DB58S : 51°) Open at 70° B.B.D.C (DB58S : 60°) Exhaust valve Close at 28° A.T.D.C (DB58S : 18°) Lubrication method Pressurized circulation Oil pump type Gear type Oil filter type Full-flow, cartridge type Lubricating oil capacity (oil pan) (lit) 14.5(13) or 20.5(19) Oil cooler type Water cooled Water pump Belt driven impeller type Cooling Method Pressurized circulation Cooling water capacity(engine only) (lit) 12 Thermostat type Wax pallet type (71 ∼ 85°C or 82 ∼95°C) Cooling fan 7-Ø457 blower, Ø595, Ø625 or 8-Ø685 sucker Alternator voltage – capacity (V - A) 24 – 60 or 24 - 50 Starting Motor (voltage – output) (V - kW) 24 – 4.5 Battery (capacity) (V - AH) 24 - 120

DB58/T/TI/TIS Operation and Maintenance Manual 2 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. 2. Engine power Production tolerance : ±5% Engine model Performance Model Suffix Injection timing (BTDC°) Power (PS/rpm) Torque (kg.m/rpm) Low idle (rpm) High idle (rpm) Remark EARDA 88.5/1,800 35.5/1,600 950-1,000 2,000~2,030 EAREA 113/2,200 38/1,600 850-900 2,370~2,470 EAREB 775-825 2,370~2,470 EARFE 20 860±25 2,420±25 EARFI/J 16 EARFH 18 92/2,200 32/1,600 800±25 2,420±50 EARFF 20 850±25 2,420±25 EARFG 18 EARFK 16 102/2,200 35.5/1,600 800±25 2,420±50 EARLA/B 18 108/2,200 37.5/1,600 975±25 2,420±50 DB58 EARLC 16 98~102/2,200 38.0/1,600 975±25 2,420±50 - ECRFA 102/2,200 37/1,600 ECRFB 90/2,200 2,420±50 DB58S ECRFC 15 94/2,400 33/1,600 800±25 2,640±50 TIER-II EATEA 18 44/1,600 925~975 2,370~2,470 EATEE 1,100±25 2,240±50 EATEH 13 132/2,200 45/1,600 950-980 2,370~2,470 EATEB 18 825~875 2,035±50 EATEF 13 111/1,850 1,050±10 2,035±50 EATED 18 114/1,950 45/1,700 1,150±25 2,140±50 EATEG 120/2,050 45/1,600 1,150±25 2,255±50 EATEI 13 100+2/1,850 39.0/1,700 1,050±10 2,035±50 EATLA 18 139/2,300 45.5/1,600 875~925 2,480±50 DB58T EATLB 13 132/2,200 45.0/1,600 975±25 2,420±50 TIER-I EAOEA EAOED 13 150/2,000 57/1,600 1,150±25 2,200±50 EAOEB 13 160/2,200 2,420±50 EAOEC 13 155/2,100 1,200±25 2,310±50 EAOLA/B 13 145/2,000 58/1,600 975~1,025 2,370~2,470 DB58TI EAOEE 13 160/2,000 59/1,600 1,150±25 2,200±50 - ECOEA 11 173/2,000 68/1,400 1,250~1,275 2,200~2,250 ECOEB 11 157/1,950 62/1,400 1,200~1,225 2,150~2,200 ECOEC 11 162/2,200 2,370~2,470 ECOEG 11 158/2,100 60/1,500 1,200~1,225 2,260~2,360 ECOED 11 135/2,200 50/1,400 1,100~1,125 2,420~2,470 ECOEE 11 154/2,000 60,1,500 1,200±25 2,200±50 ECOEF 11 124/1,950 48/1,400 1,150~1,175 2,095~2,195 ECOLA 13 165/2,200 73/1,400 1,075~1,125 2,370~2,470 TIER-II DB58TIS ECOLB 11 145/2,200 63/1,500 1,100±25 2,420±50 * Note : All data are based on operation without cooling fan at DIN 6270B

DB58/T/TI/TIS Operation and Maintenance Manual 3 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. 3. Performance curve 1. 3.1. Performance curve (DB58) Performance DIN 6270B DIN 6270A Output (rated) 96 kW (130PS) / 2,800 rpm 85 kW (115PS) / 2,800 rpm Torque (min) 370 N.m (38.0 kg.m) / 1,600 rpm Fuel consumption (min) 218 g/kW.h (160 g / PS.h)

DB58/T/TI/TIS Operation and Maintenance Manual 4 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. 3.2. Performance curve (DB58T) Performance DIN 6270B DIN 6270A Output (rated) 104 kW (142PS) / 2,500 rpm 90 kW (122PS) / 2,500 rpm Torque (min) 450 N.m (46.0 kg.m) / 1,600 rpm Fuel consumption (min) 211 g/kW.h (155 g / PS.h)

DB58/T/TI/TIS Operation and Maintenance Manual 5 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. 3.3. Performance curve (DB58TI) Performance DIN 6270B DIN 6270A Output (rated) 112 kW (152PS) / 2,200 rpm 102 kW (138PS) / 2,200 rpm Torque (min) 539 N.m (55.0 kg.m) / 1,600 rpm Fuel consumption (min) 204 g/kW.h (150 g / PS.h)

DB58/T/TI/TIS Operation and Maintenance Manual 6 Printed in Jan. 2003 PS-MMA0300-E1A General information 1. 3.4. Performance curve (DB58TIS) Performance DIN 6270B Output (rated) 126.5 kW (172PS) /2,200 rpm Torque (min) 696 N.m (71 kg.m) / 1,400 rpm Fuel consumption (rated) 217.5 g/kW.h (160 g / PS.h)

Daewoo Doosan DB58, DB58S, DB58T, DB58TI, DB58TIS Diesel Engine Operation & Maintenance Manual

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