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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 DAEWOOs) 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;
z Take old oil to an old oil disposal point only.
z Ensure without fail that oil will not get into the sea or rivers and canals or the
ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.
z 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
4.12. Fuel injection pump
4.13. Feed pump strainer
4.14. Separator
4.15. Air bleeding
4.16. Belts

129
129
129
130
130

5. Maintenance of Major Components


5.1. Lubrication system
5.2. Cooling system
5.3. Fuel system
5.4. Turbocharger
5.5. Air Intake System

133
137
142
172
180

6. Special Tool List

183

Appendix
WORLDWIDE NETWORK

184

Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

1. GENERAL INFORMATION
1.1. Engine specifications
Engine

DB58/S

Model Items

4 cycle in-line
Naturally
aspirated

Engine type
Combustion chamber type
Cylinder liner type
Timing gear system
No. of piston ring
No. of cylinder-bore x stroke
Total piston displacement
Compression ratio
Engine dimension

DB58TI

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
6 102 118
5,785
17.5 : 1

(mm)
(cc)

(mm)
Engine weight
(kg)
Rotating direction (from fly wheel)
Fuel injection order
Fuel injection timing (B.T.D.C static)
Injection pump type
Governor type
Injection nozzle type
Fuel injection pressure
(kg/cm2)
Compression pressure
(kg/cm2)
Intake & exhaust valve clearance
(at cold)
(mm)
Open at
Intake valve
Close at
Open at
Exhaust valve
Close at
Lubrication method
Oil pump type
Oil filter type
Lubricating oil capacity (oil pan) (lit)
Oil cooler type
Water pump
Cooling Method
Cooling water capacity(engine only) (lit)
Thermostat type
Cooling fan
Alternator voltage capacity (V - A)
Starting Motor
(voltage output)
(V - kW)
Battery (capacity)
(V - AH)
(length X width X height)

DB58T

1,173x666x793

450

1,172x724x912

1,184x657x934

480
505
counter clockwise
15-36-24

18.5
1,184x690x970

480

15 or 18

13
11
Bosch in-line A type
Mechanical governor RSV type
Multi-hole type (5 hole)
Multi-hole type (6 or 7 hole)
220
185
190
28 (at 200 rpm)
0.4
28 B.T.D.C (DB58S : 17)
62 A.B.D.C (DB58S : 51)
70 B.B.D.C (DB58S : 60)
28 A.T.D.C (DB58S : 18)
Pressurized circulation
Gear type
Full-flow, cartridge type
14.5(13) or 20.5(19)
Water cooled
Belt driven impeller type
Pressurized circulation
12
Wax pallet type (71 85C or 82 95C)
7-457 blower, 595, 625 or 8-685 sucker
24 60 or 24 - 50
24 4.5
24 - 120

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
18
20
18
16
18
16

Power
(PS/rpm)
88.5/1,800
113/2,200

35.5/1,600
38/1,600

92/2,200

32/1,600

102/2,200

35.5/1,600

108/2,200

37.5/1,600
38.0/1,600
37/1,600

98~102/2,200
102/2,200

15

90/2,200
94/2,400

18
13
18
13
18

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

33/1,600
44/1,600

132/2,200

111/1,850
114/1,950
120/2,050

45/1,600

45/1,700

18
13

139/2,300
132/2,200

45/1,600
39.0/1,700
45.5/1,600
45.0/1,600

13

150/2,000

57/1,600

13
13
13
13
11
11
11
11
11
11
11
13

160/2,200
155/2,100
145/2,000
160/2,000
173/2,000
157/1,950
162/2,200
158/2,100
135/2,200
154/2,000
124/1,950
165/2,200

11

145/2,200

13

100+2/1,850

High idle
(rpm)

950-1,000 2,000~2,030
850-900 2,370~2,470
775-825 2,370~2,470
86025
2,42025
80025

2,42050

85025

2,42025

80025

2,42050

97525
97525

2,42050
2,42050

80025

2,42050

925~975
1,10025
950-980
825~875
1,05010
1,15025
1,15025
1,05010
875~925
97525

2,64050
2,370~2,470
2,24050
2,370~2,470
2,03550
2,03550
2,14050
2,25550
2,03550
2,48050
2,42050

1,15025

2,20050

59/1,600
68/1,400
62/1,400

1,250~1,275

60/1,500

1,200~1,225

50/1,400
60,1,500
48/1,400
73/1,400

1,100~1,125

1,075~1,125

2,42050
2,31050
2,370~2,470
2,20050
2,200~2,250
2,150~2,200
2,370~2,470
2,260~2,360
2,420~2,470
2,20050
2,095~2,195
2,370~2,470

63/1,500

1,10025

2,42050

58/1,600

Remark

1,20025
975~1,025
1,15025
1,200~1,225

1,20025
1,150~1,175

TIER-II

TIER-I

TIER-II

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

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

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

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

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

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)

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.

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)

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.

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

14

15
1

10
11
12
13
16

17

18

24

25

26

19
20
21

22

1
2
3
4
5
6
7
8
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

14
15

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

6
13

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
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DB58/T/TI/TIS
Operation and Maintenance Manual

(4) DB58TIS

17

18

16

2
1

19

15

9
20

10

21

11

12 13 14

22

23

24

1
2
3
4
5
6

Flywheel housing
Lifting hook
Fuel filter
Intake manifold
Air pipe

7
8
9

Breather
Cooling fan
Oil filter

Oil filler cap

(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.
z 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.
z The engine must be started and operated only by authorized personnel. Ensure that
the engine cannot be started by unauthorized persons.
z When the engine is running, do not get too close to the rotating parts. Wear closefitting clothing.
z Do not touch the engine with bare hands when it is warm from operation risk of
burns.
z 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.
z 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
z 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.
z 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.
z Take into account the amount of oil in the sump. Use a vessel of sufficient size to
ensure that the oil will not overflow.
z 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".
z 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.
z 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.
z Keep service products (anti-freeze) only in containers which can not be confused
with drinks containers.
z 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
z Checking, setting and repair work must be carried out by authorized personnel only.
z Use only tools which are in satisfactory condition. Slip caused by the worn openend wrench could lead to Injury.
z 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.
z When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
z 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.
z 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
z
z
z
z
z

z
z
z

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
z 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.
z The drinking water supply may be contaminated.
z Oil and fuel filter elements are classed as dangerous waste and must be treated as
such.
b) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z 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>
z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
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Safety regulations
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DB58/T/TI/TIS
Operation and Maintenance Manual

z
z
z

- 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.

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Operation and Maintenance Manual

2. TECHNICAL INFORMATION
2.1. Engine model and serial number
The engine model and serial number is
located on the engine as illustrated.
These numbers are required when
requesting warranty and ordering parts.
They are also referred to as engine
model and serial number because of
their location.

z Engine serial No. (example 1 : DB58)

Engine number

DB58 3 00001 FA
Engine suffix(EARFA)
Serial no.
Production year(2003)
Engine model

z Engine serial No. (example 2 : DB58)


DB58S 3 00001 FA
Engine suffix(ECRFA)
Serial no.
Production year(2003)
Engine model

z Engine serial No. (example 3 : DB58T)


<Name plate : EPA & CARB>

DB58T 3 00001 EA
Engine suffix(EATEA)
Serial no.
Production year(2003)
Engine model

z Engine serial No. (example 4 : DB58TI)


DB58TI 3 00001 BA
Engine suffix(EAOEB)
Serial no.
Production year(2003)
Engine model

z Engine serial No. (example 5 : DB58TIS)


DB58TIS 3 00001 EC
Engine suffix(ECOEC)
Serial no.
Production year(2003)
Engine model

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DB58/T/TI/TIS
Operation and Maintenance Manual
2.2. Engine type
The Engines DB58, DB58S, DB58T, DB58TI, DB58TIS are in-line vertical, water-cooled,
6-cylinder four stroke diesel engines with direct injection. DB58 is natural aspiration,
DB58T is turbo-charged, DB58TI, DB58TIS are turbo-charged and inter-cooled engine.
2.2.1. Cylinder block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is
extended to a level below the crankshaft center line. The engine has replaceable dry
cylinder liners and common cylinder heads with struck-in valve seat rings and
replaceable valve guides,
2.2.2. Piston con-rod / crankshaft
The forged crankshaft is a integrate type (Counterweight is integrated with crank shaft
body). Radial oil seal on crankshaft and flywheel are provided to seal the flywheel
housing inside penetrations.
The con-rods (connecting rods) are die-forged and can be removed through the top of
the cylinders together with the pistons. Crankshaft and connecting rods run in steelbacked lead bronze ready-to fit type bearings.

2.3. Engine timing


Camshaft, oil pump, PTO(power take off) pump and injection pump are driven by a gear
train arranged at the front end.
Injection pump gear
(Z = 50)

Idle gear
(Z = 51)

Camshaft gear
(Z = 50)

Oil pump drive gear


(Z = 12)
P.T.O drive gear(Z=24)
Allowable torque :12kg.m

Crankshaft gear
(Z = 25)

18

Oil pump gear


(Z = 9)

P.T.O gear (Option)


(Z = 25)

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DB58/T/TI/TIS
Operation and Maintenance Manual
2.4. Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker
arms from the camshaft.

2.5. Lubrication system


The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with the
camshaft gear at the middle of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil
filter to the main distributor gallery and from there to the main bearings, big-end
bearings and camshaft bearings as well as to the small-end bearings and the rocker
arms.
The injection pump and turbo charger are also connected to the engine lubricating
system.
The cylinder block walls and timing gears are splash-lubricated.
The lube oil is cleaned in a full-flow oil filter.

2.5.1. Recommend of lubricating oil


Initial factory fill is high quality break-in oil for API Service. During the break-in period
(50 hours), frequently check the oil level. Somewhat higher oil consumption is normal
until piston rings are seated. The oil level should be maintained in the safe range
between the Min. and Max. marks on the dipstick. The safe range between the marks
represents approximately 3 liters. To obtain the best engine performance and engine
life, grade of engine oil is recommended. Engine oils are specified by API Service,
letter designations and SAE viscosity numbers. If the specified motor oil is not
available, use a reputable brand of engine oil labeled for API Service CH-4 and SAE
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DB58/T/TI/TIS
Operation and Maintenance Manual
viscosity 30 or 15W40. Refer to oil identification symbol on the container.
z Engine oil should be changed at the specified intervals.
Oil filter cartridge should be changed simultaneously.
-

First oil change : 50 hr operating


First oil change

After 50hr operation

Construction equipments

DB58
DB58T
DB58TI

every 200 Hour

DB58S
DB58TIS

every 250 Hour

z The following oils are also recommended


Engine oil capacity
Engine model

DB58
DB58T
DB58TI
DB58S
DB58TIS

Recommend oil

Oil pan
Total
(liter)

Max.
(liter)

Min.
(liter)

Fork lift

13

11

14.5

Excavator

19

16

20.5

Fork lift

19

14

20.5

Excavator

19

16

20.5

SAE No.

API No.

SAE 15W40

above CD or CE

SAE10W40
SAE15W40

ACEA-E2 or ACEA-E3
(API CH-4)

* If long oil change intervals are to be used, ACEA-E3 oil must be used.

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DB58/T/TI/TIS
Operation and Maintenance Manual
2.5.2. Oil cooler
An oil cooler is provided between the oil filter and the cylinder block. This cooler is a
flat tube type with turbulence inserts and operated by the coolant.

2.5.3. Oil filter


z Check for oil pressure and oil leaks,
and repair or replace the oil filter if
necessary.
z Change the oil filter cartridge
simultaneously at every replacement
of engine oil.

Head, oil filter

Cartridge,
Oil filter

2.6. Air cleaner


In case that elements are deformed,
damaged or if the air cleaner has a crack,
replace it.
By the definite interval, the elements must
be cleaned and replaced.

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Operation and Maintenance Manual
2.7. Fuel system
The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and
from there to the injection nozzles.

Supply

The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle
holders in the cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe
back to the tank.
A strainer is arranged ahead of the fuel feed pump.
2.7.1. Injection pump
The in-line injection pump is driven via
gears from the crankshaft. It is
connected to the force feed lubricating
system of the engine and consequently
maintenance-free. The governor flangemounted on the pump casing is a
variable range governor designed to
keep the speed set of varying load.

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DB58/T/TI/TIS
Operation and Maintenance Manual
2.7.2. Fuel filter
z This fuel filter has two functions not
only oil filtering but also water
separating
z Before entering the suction chamber
of the injection pump, the fuel is
cleaned in a strainer of fuel feed
pump and a fuel filter.
z Drain water in filter with loosening
the drain plug under filter manually
from time to time.
z The fuel filter element should be
replaced at every 200 hours.

Air bleeding plug


Seal ring

Head,
fuel filter

Cartridge,
fuel filter

Water drain plug

2.7.3. Fuel requirements


DAEWOO diesel engines was designed to use Number 2-D diesel fuel or equivalent
that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel
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.
2.7.4. How to select fuel oil
Fuel quality is an important factor in obtaining satisfactory engine performance, long
engine life, and acceptable exhaust emission levels. DAEWOO 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.
The ASTM 975 specification, however, does not in itself adequately define the fuel
characteristics needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum
engine performance. Grade 2-D fuel is normally available for generator service. Grade
1-D fuel should not be used in pleasure craft engines, except in an emergency.

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Operation and Maintenance Manual
Fuel Oil Selection Chart
General Fuel
Classification

ASTM
Test

No. 1
ASTM 1-D

No. 2
ASTM 2-D

DIN 51601

D 287

40 ~ 44

33 ~ 37

0.815 ~ 0.855

Flash Point
Min. F (C)

D 93

100 (38)

125 (52)

131 (55)

Viscosity, Kinematic
CST 100 F (40 C )

D 445

1.3 ~ 2.4

1.9 ~ 4.1

1.8 ~ 10

Cloud Point F #)

D 2500

See Note 1)

See Note 1)

See Note 1)

Sulfur Content
wt%, Max.

D 129

0.5

0.5

0.15

Carbon Residue
on 10%, wt%, Max.

D 524

0.15

0.35

0.1

Accelerated Stability
Total Insolubles
mg/100 ml, Max. #)

D 2274

1.5

1.5

Ash, wt%, Max.

D 482

0.01

0.01

Cetane Number, Min. +)

D 613

45

45

Distillation
Temperature, ()
IMP, Typican #)
10% Typical #)
50% Typical #)
90% +)
End Point #)

D 86

Gravity, API

#)

Water & Sediment


%, Max.

350(177)
375(191)
385(196)
430(221)
45(218)
510(256)
500 (260) Max. 625(329) Max.
550(288) Max. 675(357) Max.

D 1796

0.05

0.05

> 45

680(360)

0.05

#) Not specified In ASTM D 975


+) Differs from ASTM D 975
NOTE
1) The cloud point should be 6 C (10 F) below the lowest expected fuel temperature
to prevent clogging of fuel fitters by crystals.

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Operation and Maintenance Manual
2.8. Cooling system
The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by
V-belt from the crankshaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the coolant
circuit can be equipped with temperature monitors which, in the event of loss of coolant,
shut the engine down.
z Check the coolant level of the expansion tank by removing the expansion tank filler
cap, and add coolant if necessary.
z When injecting antifreeze solution, first drain out the old coolant from the cylinder
block and radiator, and then clean them with cleaning solution.
z Be sure to mix soft water with antifreeze solution.
2.8.1 Cooling system (Type -1)

2.8.2 Cooling system (Type -2)

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Operation and Maintenance Manual
2.8.3. Coolant pressure cap
Check the pressure valve opening
pressure using a expansion tank cap
tester. Replace the filler cap assembly if
the measured valve does not reach the
specified limit. (pressure valve opening
pressure : 0.9 kg/cm2)

NOTE
Because it is dangerous to open the
pressure cap quickly when coolant
is hot, after lowering the inside
pressure of the tank by slowopening at first open it fully.

2.8.4. Anti-freeze
The anti-freeze, 50% of the whole coolant, is always to be used to prevent the cooling
system from the corrosion. And in winter the amount of anti-freeze shown in the
following table should be used in accordance with the ambient temperature.
As the individual freezing points corresponding to the proportions of antifreeze in the
table are subject to change slightly according to the kind of antifreeze, you must follow
the specifications provided by the antifreeze manufacturer.
Ambient
Temperature (C)
Over -10
-10
-15
-20
-25
-30
-40

Cooling water (%)

Anti-freeze (%)

85
80
73
67
60
56
50

15
20
27
33
40
44
50

As the ratio of antifreeze in the mixture decrease each time new coolant is added to
make up for the loss coolant resulting from engine operation, Check the mix ratio with
every replenishment of coolant, and top up as necessary.

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Operation and Maintenance Manual
2.8.5. Cooling water
z Regarding the engine cooling water, the hard water must be used (Do not use the
soft water).
z The engine cooling water can be used diluting it with antifreezing solution 40% and
the additive for rust prevention (DCA4) 3 5 %.
z The density of above solution and additive must be inspected every 500 hours to
maintain it properly.
NOTE
The proper density control of antifreezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the
stable quality of engine.
For the improper control might give the fatal damage to the cooling water
pump and cylinder liners, detail care is needed.
z
z
z

Since DB58 cylinder liner is dry type, particularly the cooling water control should
be applied thoroughly.
The density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit. (Fleetguard CC2602M)
How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 55 C,
loosen the plug for cooling water discharge and fill the plastic cup about a half.
NOTE:
In taking the cooling water sample, if the water in auxiliary tank were taken,
it is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper
out through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE:
However, it should not elapse longer than 75 sec, and if it did, the hue
would change.
(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.

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(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.

2.9. V-belt tension check and adjust


z V-Belt
By the finger-pressure the belt is
pressed by 10mm 15mm between
the fan pulley and the alternator
pulley in normal condition. For the
adjustment of the tension, loosen the
adjusting bolts which support the
alternator, adjust the tension and
tighten the bolts again.
z

Poly belt
Poly belt will be properly tensioned if
the deflection force F is applied
midway between the belt`s tangent
points with the pulley.
T = 0.015 x S (about 1.5mm per 100mm)

2.10. Intercooler(Air to air)


The intercooler is air to air type and has a large cooling fan capacity. The intercooler
life and performance depends on the intake air condition greatly. Fouled air pollutes
and clogs the air fins of intercooler. As a result of this, the engine output is
decreased and engine malfunction is occurred. So you always check whether the
intake air systems like air filter element are worn or polluted.
Air/air intercooler
with radiator
(combined radiator)

Air flow by cooling fan


Hot air by turbo charger
compressor
Cooled air to intake
manifold (max. 50C)

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2.11. Valve clearance and adjustment
NOTE:
The cylinder head bolts were
previously tightened with the
torque wrench. Therefore it is not
necessary to retighten the cylinder
head bolts before adjusting the
valve clearance.
Rocker arm screw
lock nut torque

2.6 0.5kg.m

z After letting the #1 cylinder's piston


come at the compression top dead
center by turning the crankshaft,
adjust the valve clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the
feeler gauge of specified value
between a rocker arm and a valve
stem and adjust the clearance with adjusting screw respectively and then tighten
with the lock nut.
z As for the valve clearance, adjust it when in cold, as follows.

Model
DB58
DB58S
DB58T
DB58TI
DB58TIS

Intake Valve

Exhaust Valve

0.4 mm

0.4 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then
#1 cylinder become the compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to

of lower

figure. At this time there are no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression
state of top dead center.
4) Thereafter adjust the valve clearances corresponding to

of lower

figure.
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5) After reinsuring the valve clearances, retighten if necessary.
z

No. 1 cylinder is located at the side where flywheel was installed.


Cooling fan

Cylinder no.

Exhaust valve

Intake valve

Fly wheel

2.12. Cylinder compression pressure


z Stop the engine after warming up,
and take out preheating plug and
injection pipe.
z Install
the
special
tool
(compression gauge adapter) at
the preheating plug hole, and
connect the compression pressure
gauge there.
z Check the compression pressure
at gauge several times until highest
compression reading is reached.

Standard value
Limit value
Difference
between each cylinder

28kg/cm2 over
24kg/cm2
Within 10 %

z Condition : Water temperature 75C.


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2.13. Injection nozzle

z Install a nozzle on the nozzle tester.


z If the inspected injection pressure is less than the specified value, adjust using
the adjusting shims.
Injection nozzle
pressure

Engine model

220 kg/cm2

DB58, DB58S, DB58T


EAOEA/B/C/D, EAOLA/B
EAOEF
ECOLA
DB58TIS
ECOEA/B/C/D/E/F/G, ECOLB
z Check the atomizing state and replace it if abnormal.
DB58TI

185 kg/cm2
200 kg/cm2
185 kg/cm2
190 kg/cm2

2.14. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12
1.28), replenish.

2.15. Starting motor


z In case of engine maintenance, clean pinion and ring gear thoroughly putting in
the fuel, and coat them with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being
careful for water not to get in.

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2.16. Diagnosis and remedy
z The following description summarizes the probable cause of and remedy for
general failure by item.
z Immediate countermeasures should be taken before a failure is inflamed if any
symptom is detected.

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Condition

Causes

Remedies

1) Starting difficult
(1) Compression pressure

2) Idle operation abnormal

z Valve's poor shut, stem distortion

Repair or replace

Valve spring damage

Replace valve spring

Cylinder head gasket's leak

Replace gasket

Wear of piston, piston ring or liner

Adjust

Injection timing incorrect

Adjust

Air mixing at injection pump

Remove air

Valve clearance incorrect

Adjust

Valve tightness poor

Repair

Cylinder head gasket's leak

Replace gasket

Wear, stick, damage of piston ring

Replace piston ring

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Nozzle injection pressure improper or stuck

Adjust or replace

Supply pump's function lowered

Repair or replace

Fuel pipe system clogged

Repair

Air suction amount insufficient

Clean or replace air cleaner

3) Engine output insufficient


(1) Continuous output Insufficient

z
(2)

Output insufficient

Turbocharger poor

Repair or replace

Compression pressure insufficient

Disassemble engine

Injection timing incorrect

Adjust

Fuel injection amount insufficient

Adjust injection pump

Injection pump timer's function insufficient

Repair or replace

Nozzle injection pressure, injection angle

Repair, replace

when in acceleration

improper
z

Supply pump's function lowered

Repair or replace

Air intake amount insufficient

Clean or
replace air cleaner

4) Overheating

Engine oil insufficient or poor

Replenish or replace

Cooling water insufficient

Replenish or replace

Fan belt loosened, worn, damaged

Adjust or replace

Cooling water pump's function lowered

Repair or replace

Water temperature regulator's operation

Replace

poor

39

Valve clearance incorrect

Adjust

Exhaust system's resistance increased

Clean or replace

Technical information
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DB58/T/TI/TIS
Operation and Maintenance Manual
Condition
5) Engine noisy

Causes

Remedies

For noises arise compositely such as rotating


parts, lapping parts etc., there is necessity to
search the cause of noises accurately.

(1) Crankshaft

z
z

As the wear of bearing or crankshaft

Replace

bearing

progress, the oil clearances increase.

crankshaft

Lopsided wear of crankshaft

Grind or replace

Oil supply insufficient due to oil passage

Clean oil passage

&

grind

clogging

(2) Connecting rod and

Stuck bearing

Replace bearing & grind

Lopsided wear of connecting rod bearing

Replace bearing

Lopsided wear of crank pin

Grind crankshaft

Connecting rod distortion

Repair or replace

Stuck bearing

Replace & grind crankshaft

Oil supply insufficiency as clogging at oil

Clean oil passage

Connecting rod bearing

passage progresses
(3) Piston, piston pin &

Piston clearance increase as the wear of

Replace piston &

piston and piston ring progresses

piston ring

Wear of piston or piston pin

Replace

Piston stuck

Replace piston

Piston insertion poor

Replace piston

Piston ring damaged

Replace piston

Wear of crankshaft, thrust bearing

Replace thrust bearing

Camshaft end play increased

Replace thrust plate

Idle gear end play increased

Replace thrust washer

Timing gear backlash excessive

Repair or replace

Valve clearance excessive

Adjust valve clearance

Abnormal wear of tappet, cam

Replace tappet, cam

Injection timing incorrect

Adjust

Fuel injection amount excessive

Adjust injection pump

Clearance between cylinder liner & piston

Replace

Wear of piston ring, ring groove

Replace piston, piston ring

Piston ring's damage, stick, wear

Replace piston ring

Piston ring opening's disposition improper

Correct position

Piston skirt part damaged or abnormal wear

Replace piston

Oil ring's oil return hole clogged

Replace piston ring

piston ring

(4) Others

6) Fuel Consumption excessive

7) Oil consumption excessive


excessive
(1) Oil level elevated

(2) Oil level lowered

(3) Oil leak

40

Oil ring's contact poor

Replace piston ring

Looseness of valve stem & guide

Replace in set

Wear of valve stem seal

Replace seal

Cylinder head gaskets leak

Replace gasket

Looseness of connection parts

Replace gasket, repair

Various parts' packing poor

Replace packing

Oil seal poor

Replace oil seal

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

DB58/T/TI/TIS
Operation and Maintenance Manual
2.17. Engine inspection
2.17.1. Stopping engine
After checking the engine for any unusual condition at the idling speed, then turn the
key switch to the stop the engine.
2.17.2. General engine inspection cycle
In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
z Daily inspections in below figure should be checked every day.
z The following maintenance details should be executed thoroughly at regular
internals.
Inspection

Cooling
System

Daily

Check for leakage(hoses, clamp)


Check the water level
Change the coolant water

Adjust the V-belt tension

Clean the radiator


Check for leakage
Check the oil level gauge

1st

1st

Replace the oil filter cartridge

Fuel
System

Engine
Adjust

Check the leakage for intercooler


(hoses, clamp)
Clean and change
the air cleaner element
Check the leakage fuel line
Clean the fuel strainer
of fuel feed pump
Remove sediment from fuel tank
Drain the water in separator
Replace the fuel filter element

Every
2,000hrs

Lubrication
Change the lubricating oil
System

Intake &
Exhaust
System

: Check & adjust


: Replace
Every Every
Every Every Every
Remark
50hrs 200hrs 400hrs 600hrs 1200hrs

clean

Check fuel injection timing

Check the injection nozzles

Check the state of exhaust gas

Check the battery charging

When
necessary
When
necessary

Check the compression pressure


Adjust Intake/Exhaust
valve clearance

1st

When
necessary
When
necessary

2.18. Use of original parts for repair and replacement


For engine is being mechanically harmonized with many parts, only when the original
parts that the manufacture recommends to use is used, the engine trouble would be
preventively maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill
performance, it may rather bring early engine failure.
41

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

DB58/T/TI/TIS
Operation and Maintenance Manual

3. Maintenance
3.1. Engine Disassembly
3.1.1. Major part fixing nuts and bolts
1) Cylinder head cover
(Unit : kg.m)

42

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

2) Cylinder block
(Unit : kg.m)

43

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

3) Oil pan and level gauge


(Unit : kg.m)

44

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

4) Camshaft and rocker arm

(Unit : kg.m)

45

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

5) Crankshaft, piston and flywheel


(Unit : kg.m)

46

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

6) Thermostat and housing


(Unit : kg.m)

47

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

7) Intake and exhaust manifold


(Unit : kg.m)

48

Engine disassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual

8) Intake and exhaust manifold

(Unit : kg.m)

49

Engine disassembly
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Operation and Maintenance Manual

9) Intake and exhaust manifold

(Unit : kg.m)

2.60.5

3.10.5

3.80.7

3.80.7

2.9

50

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

9) Timing gear case and flywheel housing


(Unit : kg.m)

51

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

10) Oil cooler, oil filter and oil pump


(Unit : kg.m)

52

Engine disassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual

11) Fuel system


(Unit : kg.m)

53

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

12) Engine repair parts

16

14

13

12

17

18

15

20

21

22

19

Cover to timing gear case gasket

12

Oil filter cover gasket

Gear case to cylinder block gasket

13

Oil cooler gasket

Timing gear case oil seal

14

Intake manifold gasket

Flywheel housing gasket

15

Oil pan gasket

Crank shaft rear oil seal

16

Turbocharger gasket

17

Turbocharger outlet gasket

18

Water pump gasket

6
7

54

10

11

Cylinder head gasket


Cylinder head cover gasket

Valve guide oil seal

19

Water pump housing gasket

Tappet chamber cover gasket

20

Exhaust manifold gasket

10

Air heater gasket

21

Thermostat gasket

11

Thermostat housing gasket

22

Oil pump hole cover gasket

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

3.1.2. Main structure parts (1)

1. Rubber hose (Coolant by-pass)


2. Rocker arm shaft assembly
3. Push rod
4. Cylinder head bolt
5. Cylinder head assembly
6. Cylinder head gasket
7. Coolant pump assembly
8. Tappet chamber cover

9. Oil pump driving pinion


10. Nut
11. Crankshaft pulley and dust cover
12. Taper bushing
13. Timing gear cover
14. Oil thrower
15. Fly wheel

2) Rocker arm shaft


Loosen the rocker arm shaft fixing
bolts a little in numerical sequence
as specified.

55

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5) Cylinder head
Loosen the cylinder head bolts a
little in the numerical order shown in
the figure.

11) Crankshaft pulley


Use an appropriate wrench (54 mm)
to remove the crankshaft pulley nut.

12) Taper bushing


Use the taper bushing remover to
remove the crankshaft end taper
bushing.

15) Flywheel
Loosen the flywheel bolts a little in
the numerical order as specified.

56

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3.1.3. Main structure parts (2)

1. Oil cooler
2. Oil pan
3. Oil pump and coupling
4. Flywheel housing
5. Piston and connecting rod
6. Idler gear
7. Cam shaft
8. Tappet

57

9. Timing gear case


10. Idler gear shaft
11. Crank shaft bearing cap
12. Crank shaft bearing (lower part)
13. Thrust bearing
14. Crank shaft
15. Crank shaft bearing (upper part)

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Idler gear
Measure the following points before
disassembly.
<Idler gear end play>
Standard

Limit

0.058 0.115 mm

0.2 mm

<Timing gear back lash>


Standard
0.10 0.17 mm

Limit
0.3 mm

Includes the crankshaft gear, the


camshaft gear and the idler gear

7) Camshaft
Measure the following points before
disassembly.
<Cam Gear End Play>
Standard

Limit

0.050 0.114 mm

0.2 mm

11) Crankshaft bearing cap


Measure the crankshaft endplay at
the thrust bearing (center main
bearing) before disassembly.
<Crankshaft End Play>

58

Standard

Limit

0.15 0.33 mm

0.4 mm

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

3.1.4. Rocker arm disassembly

1. Bracket
2. Rocker arm

59

3. Spring
4. Rocker arm shaft

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3.1.5. Cylinder head disassembly

1. Exhaust manifold and gasket


2. Intake manifold and gasket
3. Coolant outlet pipe
4.Thmostat
5. Thermostat housing and gasket
6. Valve cotter

7. Spring seat (upper)


8. Valve spring
9. Spring seat (lower)
10.Valve
11. Valve stem oil seal

Importance
6) Valve cotter
Use the valve spring compressor to
remove the valve cotter.

60

Engine disassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
3.1.6. Piston and connecting rod disassembly

1. Piston rings
2. Snap ring
3. Piston pin and connecting rod

4. Piston
5. Connecting rod bearing

IMPORTANT:
Remove any carbon deposits from
the upper part of the cylinder bore.
This will prevent damage to the
piston and the piston rings when
they are removed from the
cylinder bore.

61

Engine disassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual

1) Piston rings
Use a piston ring remover to remove
the piston rings.
Do not attempt to use other tools.
Stretching piston ring will result in
reduced piston ring tension.

2) Snap ring
Use a pair of snap ring pliers to
remove the snap ring.

3) Piston pin
Tap the piston pin out with a hammer
and brass bar.

62

Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3.2. Engine Inspection
3.2.1. Cylinder block
z Clean the cylinder block thoroughly and make a visual inspection for cracks or
damage.
z Replace if cracked or severely damaged, and correct if slightly damaged.
z Check oil and water flow lines for restriction or corrosion.
z Make a hydraulic test to check for any cracks or air leaks.
(Hydraulic test) :
Stop up each outlet port of water/oil passages in the cylinder block, apply air
pressure of about 5kg/cm2 against the inlet ports, then immerse the cylinder block
in water for about 3 minute to check any leaks. (Water temperature : 70 C)
3.2.2. Cylinder head
1) Inspection
z Carefully remove carbon from the lower lace of the cylinder head using
nonmetallic material to prevent scratching of the valve seat faces.
z Check the entire cylinder head for very fine cracks or damage invisible to
ordinary sight using a hydraulic tester or a magnetic flaw detector.
2) Distortion at the lower face
z Measure the amount of distortion
using a straight edge and a feeler
gauge at six positions (A F) as
shown in the right figure.
z If the measured value exceeds
the standard value, retrace the
head with grinding paper of fine
grain size to correct such defect.
z If the measured value exceeds
the maximum allowable limit,
replace the cylinder head.
<Lower face warpage and height>

63

Standard

Limit

Warpage

0.2 mm or less

0.3 mm

Thickness : t

89.95 90.05 mm

89.65 mm

Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Flatness
Measure
flatness
of
the
intake/exhaust
manifolds
fitting
surfaces on the cylinder head using a
straight edge and a feeler gauge.
Standard

Limit

0.05 mm

0.2 mm

4) Hydraulic test
Hydraulic test method for the cylinder
head is same as that for cylinder
block.

3.2.3. Valve stem and valve guide clearance


1) Measuring method -
z After install dial gauge needle on
the inserted valve stem, set up
calibrator to 0. (as shown in
figure)
z Move valve head from side to side.
Record total dial indicator reading.
This valve is the clearance
between the valve stem and valve
guide.
z Valve and guide set must be
replaced if measured value
exceed the specified limit
<Valve stem clearance (T.I.R)>

64

Standard

Limit

Intake side

0.039 0.071mm

0.20mm

Exhaust side

0.064 0.096mm

0.25mm

Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) Measuring method II
z Measure valve stem outside
diameter.
z Measure valve guide inside
diameter by using of caliper
calibrator of telescoping gauge.
z The difference between the valve
stem outside diameter and the
valve guide inside diameter is the
valve stem clearance.
3) Valve guide replacement
z Removal of valve guide
z Pull out the valve guide, by using
hammer and valve guide remover,
from bottom of cylinder head.

z Install of valve guide


z The height from the bottom of the
cylinder head to the edge of valve
guide top should be 14.1mm.

4) Valve depression
z Install the valve to the cylinder
head.
z Measure valve depression by
using the depth gauge or
calibrator from the bottom of
cylinder head.
z Seat insert and valve must be
replaced if the measured value
exceed the specified limit.
z If the valve is replaced, the valve
guide must be also replaced.
65

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Operation and Maintenance Manual

Intake and exhaust


valve depression

Standard

Limit

1.0 mm

2.5mm

5) Valve contact width


z Inspect the valve contact faces
for
the
roughness
and
unevenness.
Make valve contact surfaces
smooth.
z Measure the width of valve
contact.
Standard
Valve contact width, Intake

2.4mm

Valve contact width,


Exhaust

1.6mm

6) Valve seat replacement


z Arc
weld
entire
inside
circumference of the valve
seat. (see figure)
z Cool valve seat for a few minutes.
This will make removal of the
valve seat easier.
z Pull out the valve seat by using
the inner extractor.
z Carefully remove the carbon and
other foreign material from the
cylinder head insert bore.
7) Valve seat installation
z Carefully place Jig.
Caution:
The smooth face of
contact the valve seat.
z

66

jig

must

Assemble valve insert by slowly


pressing it against the jig with the
bench press.
(The amount of needed pressure
is more than 2,500kg.)

Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
IMPORTANT:
Do not press the valve seat
excessively with the bench press.
It may damage the valve seat.
8) Valve seat correction
z Remove the carbon deposits
from the valve seat surface.
z Remove the rough areas by
using valve cutter. (30, 90 or
150)
Do not cut the valve seat too
much.
Angle Location

Standard

Intake valve seat

90

Exhaust valve seat

90

IMPORTANT:
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to
wobble inside the valve guide.

z
z
z
z

67

Spread compound on the surface


of valve seat.
Insert valve into valve guide.
Lap the valve and valve seat with
the lapping tool.
Check that valve contact width is
correct.

Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
z

Check that the entire surface of


valve seat is in contact with the
valve.

3.2.4. Valve spring


1) Valve spring free length
z Measure the valve spring with the
vernier caliper.
z Replace the spring if the
measured value is less than the
specified limit.

Standard

Limit

53.65 mm

52 mm

Exhaust and intake


valve spring free
length

2) Valve spring inclination


z Measure
the
valve
spring
inclination by the using of square.
z Replace the valve spring if the
measured value exceed the
specified limit.

Valve spring
Inclination

Standard

Limit

2.5 mm

3.5 mm

3) Valve spring tension


z Measure the valve tension by
using spring tester.
z Replace the valve spring if the
measured value exceed the
specified limit.

68

Engine inspection
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Operation and Maintenance Manual

Valve spring tension


at 44mm set length

Standard

Limit

22.5 kg

20.0 kg

3.2.5. Tappet
z Check the valve tappets for excessive
wear, damage or abnormalities.

z Measure the outside diameter of


tappet with the micrometer.

Tappet outside
diameter

Standard

Limit

27.96 27.98mm

27.92mm

z Measure the clearance between


tappets and cylinder motion parts by
the using dial indicator.

Tappet and tappet


bore clearance

Standard

Limit

0.020 0.054mm

0.1mm

3.2.6. Push rod


z Measure the run out of push rod
with the feeler gauge.
z Roll the push rod along a smooth
flat surface as shown in the figure.
Limit
Push rod of run-out

69

0.2mm

Engine inspection
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DB58/T/TI/TIS
Operation and Maintenance Manual
3.2.7. Rocker arm correction
z Check the valve stem contact part
of rocker arm.
z Grind contact surface with an oil
stone if it is irregularly contacted.
z Replace the rocker arm if it is
extremely damaged.

1) Rocker arm and shaft


z Check the disassembled parts for
wear, damage and abnormalities.

2) Rocker arm shaft outside diameter


z Measure the outside diameter of
rocker arm with the micrometer.
z Replace shaft if measured value
exceed the specified limit.

diameter of

Standard

Limit

18.98-19.00 mm

18.85 mm

rocker arm shaft

3) Rocker arm and shaft clearance


z Measure the inside diameter of
rocker arm bushing with the
vernier caliper.
z Measure the out side diameter of
rocker arm shaft.
Replace the rocker arm or rocker
arm shaft if measured value
exceed the specified limit.

70

Engine inspection
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Operation and Maintenance Manual
Standard
Diameter of rocker
Arm bushing

19.02

19.07

19.05mm

mm

Standard
Rocker arm
bushing and
rocker arm shaft
clearance

Limit

0.02 0.07
mm

Limit

0.2 mm

Check the rocker arm oil port


whether alien substance is in it or
not.
Clean the rocker arm oil port
with compressed air if necessary.

3.2.8. Idler gear and shaft


z Replace the idler gear shaft if the
measured value exceeds the
specified limit.
Standard
Diameter of
idler gear shaft

44.945 44.975

Limit
44.9 mm

mm

Measure the inside diameter of


idler gear with the dial indicator,
Standard

Clearance of
idle gear and
shaft

Limit

0.045 0.105
0.2 mm
mm

3.2.9. Camshaft
z Use the jig to install or overhaul
camshaft bearing in cylinder block.
z
Measure the clearance between
the cam journal and the camshaft
bearing.

71

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DB58/T/TI/TIS
Operation and Maintenance Manual

Standard

Limit

Clearance of
cam journal and

0.03 0.09 mm

0.15 mm

cam bearing

z Align the camshaft bearing oil port


with the mating oil port (machined on
the cylinder block).

z Measure the cam lobe with the


micrometer.
Replace the camshaft if the
measured
values
exceed
the
specified limit.

Standard

Limit

Cam lobe height (C-D), In

7.44 mm

6.94 mm

Cam lobe height (C-D), Ex

7.71 mm

7.21 mm

Cam journal diameter

56.0 mm

55.6 mm

z Set up the camshaft on a measuring


stand.
z Measure the run out of camshaft with
the dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the
measured value exceeds the
specified limit.
Limit
Camshaft run-out
72

0.12 mm

Engine inspection
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DB58/T/TI/TIS
Operation and Maintenance Manual
3.2.10. Cylinder liner
1) Cylinder liner bore measurement
z Measure the bore at measuring
position in line with the
crankshaft and across the
crankshaft.

Measured position: 20 mm from


the top of liner. (max. wear
portion)
Replace the cylinder liner if the
measured
value
exceeds
specified limit.
Standard

Diameter of

Limit

102.017102.046 mm 102.20 mm

cylinder liner bore

CAUTION:
The casting liner is specially honed without the chrome plating inside, so that
chrome plated ring (top ring and oil ring) must be used.
2) Cylinder liner inspection
z Set up the straight square along
the top edge of cylinder liner.
z Measure liner projection with the
feeler gauge.

Standard
Cylinder liner

Cast liner

0.02 0.07 mm

projection

Steel liner

0.015 0.115mm

73

The difference in the liner


projection height between any two
adjacent cylinders must NOT
exceed 0.3mm

Engine inspection
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DB58/T/TI/TIS
Operation and Maintenance Manual
3) Cylinder liner replacement
z Set the cylinder liner remover to
the cylinder liner.
z Check that cylinder liner remover
shaft ankle is firmly gripping the
cylinder liner bottom edge.
z Slowly turn the remover shaft
handle counter-clockwise to pull
the cylinder liner free.
IMPORTANT:
Take care not to damage the
cylinder body upper face when
remove the cylinder liner.
3.2.11. Cylinder block
1) Grade selection of cylinder liner
z Select a grade from the outside
diameter of the cylinder liner and
inside
diameter
of
block
combination.
z Determine a grade of the cylinder
liner after measuring the inside
diameter of the cylinder block.
z Loose fitting cylinder liners (the
liner is too small for the cylinder
bore) will adversely affect engine
cooling efficiency and may lead to
serious engine damage. Cylinder
liners which are too large for the
cylinder bore will be difficult to
install.
2) Cylinder block bore measurement
z Measure at measuring point
across the positions W- W, X-X,
Y-Y and Z-Z.
Measuring point diameter :
115 mm
z

74

Calculate average value of four


measurements to determine the
correct cylinder liner grade.

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Operation and Maintenance Manual

Grade marking

Cylinder block bore diameter

105.090 106.000 mm

106.000 106.010 mm

3) Cylinder liner outside diameter


z Measure
the
liner
outside
diameter at , and
measuring point across X-X, Y-Y.
Measuring Points :
20.0 mm
105.0 mm
185.0 mm
z
z

Calculate the average value of 6 measurements to determine the correct


cylinder liner grade.
Combination of the cylinder bore and the cylinder liner outside diameter.

Cylinder liner fitting clearance

Steel liner

Cast iron liner

(tightness)

(clearance)

0.001 0.019mm

0.005 0.026mm

<Cylinder bore and liner outside diameter>


(A) Steel cylinder liner
Grade

Cylinder bore

Cylinder liner outside diameter

105.001 105.010mm

105.011 105.020mm

105.011 105.020mm

105.021 105.030mm

105.021 105.030mm

105.031 105.040mm

(B) Cast iron cylinder liner


Cylinder liner diameter
position

75

Grade marking

, position

102.020 102.031mm

102.017 102.035mm

(Inner diameter)

102.031 102.042mm

102.028 102.046mm

105.973 105.984mm

105.970 105.988mm

(Outer diameter)

105.984 105.995mm

105.981 105.999mm

Engine inspection
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Operation and Maintenance Manual

Part no of cylinder

Cylinder liner diameter


Marking

liner grade

Outer

Inner

65.01201-0068

1A

65.01201-0069

1B

65.01201-0070

2A

65.01201-0071

2B

4) Cylinder liner assembly


z Carefully wipe away any foreign
material from the cylinder liner
inside and outside surfaces and
the cylinder bore.
z Cleanly wash cylinder liner and
bore surfaces with new kerosene
or diesel oil.
z Use a clean rag to remove all
traces of kerosene or diesel oil
from cylinder liner and bore
surfaces.
z Insert the cylinder liner into
cylinder block from the top of the
cylinder block.
z Set the cylinder liner installer to
the top of the cylinder liner.
z Position the cylinder body so that
the installer center is directly
beneath the bench press shaft
center.
z Check that the cylinder liner is
set perpendicular to the cylinder.
z Use the bench press to apply an
initial seating force of 500kg to
the cylinder liner.
z Use the bench press to apply a
final seating force of 2,500kg to
fully seat the cylinder liner.
z After installing the cylinder liner,
measure the cylinder liner
projection.
76

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Operation and Maintenance Manual
5) Piston grade selection
z Piston grade refers to the piston diameter and the cylinder liner bore
combination.
z Selection of the proper piston grade will ensure efficient engine operation,
free from cylinder liner and piston problems.
z Measure the cylinder liner bore after installing the cylinder liner.
z Determine the appropriate piston grade after measuring cylinder liner bore.
6) Cylinder liner bore measurement
z Loacte the two measuring points.
Cylinder liner measuring point
- : 20mm
- : 105mm

Measure cylinder liner bore at


measuring points and in
four different directions (X-X, Y-Y,
W-W and Z-Z).
Calculate the average value of
the 8 measurements.
Standard

Cylinder liner bore

102.020 102.042 mm

CAUTION:
It is most important to use correct piston-liner combination. Incorrect
combination will result in piston seizure.
Always measure the cylinder bore and select the appropriate piston grade.
3.2.12. Piston
1) Piston outside diameter
z Piston outside diameter vary
depending on the piston type to
be used.
z Measure the piston outside
diameter (see figure).
<Piston grade>

77

Grade

Limit

101.953 101.967 mm

101.963 101.977 mm

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Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
<Cylinder liner bore and piston>
Clearance

0.053 ~ 0.077 mm

CAUTION:
The cylinder liner-piston kit clearances are preset. However, the cylinder liner
installation procedure may result in slight decreases in the cylinder liner
bore clearances.
Always measure the cylinder liner bore clearance after installation to be sure
that it is correct.
2) Piston ring and piston groove clearance
z Measure the piston ring and the
piston ring groove clearance with
a feeler gauge.
z Measure it at several points
around the piston.
z Replace the piston ring If the
measured value exceeds the
specified limit.

<Piston ring and piston groove clearance>


Standard

Limit

Top ring

0.070 0.120 mm

0.20

2nd ring

0.050 0.085 mm

0.15

Oil ring

0.030 0.070 mm

0.15

3) Piston ring gap


z Insert the piston ring horizontally
(in the position it will assume if it
were installed to the piston) into
the cylinder liner.
z Push the piston ring with an
inverted piston into the cylinder
liner until it reaches measuring
point or .
78

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DB58/T/TI/TIS
Operation and Maintenance Manual
The cylinder liner diameter is the smallest at these two points.
Do not allow the piston ring to slant to one side or the other. It must be
perfectly horizontal.
Cylinder liner measuring point
- : 10mm
- : 130mm

z
z

Measure piston ring gap with a feeler gauge.


The piston ring must be replaced if the measured value exceeds the specified
limit.

Top ring gap


2nd ring gap
Oil ring gap

Standard

Limit

0.25-0.45 mm
0.40-0.60 mm
0.20-0.40 mm

1.50 mm
1.50 mm
1.50 mm

4) Piston pin
z Measure piston pin outside
diameter with micrometer at
several points.
z Replace the piston pin if the
measured value exceeds the
specified limit.
Standard
Piston pin
outside diameter

Limit

35.000 35.005mm 34.95 mm

5) Piston pin hole


z Measure diameter of the piston
pin hole with inside dial gauge.
Standard
Piston pin and piston clearance

35.010 35.018 mm

6) Piston pin and piston pin hole clearance


z Determine the clearance between
the piston pin and the piston pin
hole by calculating the difference
between the piston pin hole
diameter and the piston pin
outside diameter.

79

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Operation and Maintenance Manual
Limit
Piston pin and piston pin

0.005 0.018 mm

hole clearance

z If an inside dial indicator is not


available, use the following
procedure to check the piston pin
fit.
(1) Heat piston to approximately
60C with the piston heater.
(2) Push strongly against the
piston pin with your thumb.
The piston pin fitting should
feel tight.
3.2.13. Maintenance of cylinder block, cylinder liner and piston
To maintain the engine in optimum condition and retain maximum performance for a
long time, the cylinder block, cylinder liner and piston which have the same grade
marking number (the same size tolerance) should be assembled. The marking
number (the parts grade) and marking position is as follows.
z Cylinder block
a) Marking number ; 1 or 2
(Size grade for of cylinder bore
diameter)
b) Marking position ; Top of the
cylinder block side surface

Marking

z Cylinder liner
a) Marking number; 1A, 1B, 2A or 2B
1A
Can used the piston A grade
Can used the cylinder block 1 grade

b) Marking position ; Cylinder liner


lower surface

80

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DB58/T/TI/TIS
Operation and Maintenance Manual
z Piston
a) Marking number ; A or B
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper surface

z Assembly process of cylinder block, cylinder liner and piston


(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just
the same with it on the cylinder block.
(3) Assemble the piston whose marking is just same with the second digit (A or B)
of the assembled cylinder liners marking.
3.2.14. Connecting rod
1) Connecting rod alignment
z Measure the parallelism between
the connecting rod big end hole
and small end hole with a
connecting rod aligner.
z Replace the connecting rod if the
measured value exceeds the
specified limit.
Standard

Limit

Connecting rod
0.05mm or less

0.20 mm

parallelism

2) Piston pin and bush clearance


z Measure an inside of connecting
rod bushing and outside of piston
pin with the caliper gauge and
micrometer.
z Replace a connecting rod bush or
piston pin if the measured value
exceeds the specified.
Standard
Piston pin and

0.012 0.030mm

Limit
0.05 mm

bushing clearance

3) Connecting rod bush replacement


z Connecting rod bush removal
1) Clamp the connecting rod in a vise.
2) Pull out connecting rod bush by using a brass bar with a bench press or a
hammer.
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Operation and Maintenance Manual
z

Connecting rod bush assembly


(1) Use special jig to assemble
the connecting rod bush.

IMPORTANT:
Align the connecting rod bush oil hole with the connecting rod oil hole.
(2) Use a piston pin hole grinder
fitted with a reamer or
an adjustable pilot reamer to
ream the piston pin hole.
Standard
Connecting rod bush
35.017 35.030 mm
inside diameter

4) Connecting rod bearing Inspection


z Fit the connecting bearing lower
half into the connecting rod
bearing cap.
z Check the tension of the
connecting rod bearing lower half.
If the tension is insufficient, the
bearing must be replaced.
z Tighten the connecting rod and
the bearing cap to the specified
torque.
A type

B type

Connecting rod
12 00.25kg.m

9.750.25kg.m

bolt torque

A type :

B type :

82

TY
11

or

TY
12

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DB58/T/TI/TIS
Operation and Maintenance Manual
z

Measure the inside diameter of


the connecting rod bearing with
an inside dial gauge.
Standard
Connecting rod
bearing diameter

63.974 64.005
mm

3.2.15. Crankshaft
1) Crankshaft and bearing inspection
z Check the crankshaft journal surfaces and pin surfaces for excessive wear and
damage.
z Check oil seal fitting surfaces of the crankshaft front and rear ends for
excessive wear and damage.
z Replace or repair the crankshaft if any excessive wear or damage is
discovered.
z Check the crankshaft oil ports for obstructions.
z Clean oil port with high pressure air if necessary.

2) Crankshaft journal and pin diameter


z Measure the crankshaft journal
outside
diameter
with
the
micrometer across - and
-.
z Measure
crankshaft
journal
outside diameter at two points
and by using the micrometer.
z Repeat step 1 and 2 to measure
the crankshaft outside diameter.
The crankshaft must be reground
if the measured value of the
crank pin outside diameter and/or
crankshaft
journal
diameter
exceeds the specified limit.
Standard
Crankshaft journal
outside diameter

79.905 79.925mm

Standard
Crankshaft
pin
outside diameter
83

63.924 63.944 mm

Engine inspection
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DB58/T/TI/TIS
Operation and Maintenance Manual
z

Measure the crankshaft journal outside diameter (and/or crankshaft pin outside
diameter) and bearing inside diameter to determine the bearing clearance.

3) Crankshaft journal and bearing clearance


z If the bearing clearance exceeds the specified limit, the crankshaft must be
reground and/or the bearing must be replaced.
Standard
Main bearing

Limit

0.025 0.090 mm

0.11 mm

clearance

Standard
Rod bearing

Limit

0.03 0.073 mm

0.10 mm

clearance

4) Crankshaft bearing diameter


z Install the main bearing cap with
bearings to the cylinder block
with the specified torque and
facing the arrow mark on the
bearing cap toward front. Place
them in order of punched
cylinder numbers.
z Measure the main bearing
diameter with an inside dial
gauge.
Main bearing cap
torque

Main bearing diameter

24.11kg.m

80 mm

5) Crankshaft run-out
z Mount the crankshaft on a set of
V-blocks.
z Set the dial gauge to the center
of the crankshaft journal.
z Gently rotate the crankshaft in
the normal direction of engine
rotation.
z Read the dial indicator (TIR) as
you turn the crankshaft.
z The crankshaft must be replaced
if the measured value exceeds
84

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DB58/T/TI/TIS
Operation and Maintenance Manual
the specified limit.
Standard
Crankshaft run-out

0.05 mm

Limit
0.40 mm

If
the
repaired
crankshaft
generated a crack, replace it.

6) Main bearing and con-rod bearing tension


z Check to see if the bearing has
enough tension, and set bearing
into its regular position with the
finger pressure.

7) Crankshaft regrinding
z Pay close attention to the
following steps in order to ensure
the reground-crankshaft reliability.
Undersize bearing
Availability

0.25 mm

0.50 mm

<Crankshaft regrinding procedure>


(1) Grind the crankshaft journal part
and pin part.
(2) Fillet the crankshaft journal and
crank pin radius to a minimum of
R3.50.2.
There must be no stepping
around the fillet area.
(3) Finish the crankshaft journal,
crank pin and oil hole corners to a
smooth surface having a chamfer
radius of 1mm.
Crankshaft Journal and
crank pin roughness

0.4 or less

(4) Measure the clearance between


crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.
85

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Operation and Maintenance Manual
8) Crankshaft grinding limit
Classification

Limit

Crank journal outside


Diameter

79.419 mm

Crank pin outside


Diameter

63.424mm

Undersize bearings (0.25 and 0.5 mm) are available to compensate for
excessive clearance between the crankshaft journal bearing and the crankshaft.
Regrinding of the crankshaft to fit the undersize bearings is required.
Standard

Main bearing
clearance

0.039 0.098 mm

Standard
Connecting
rod bearing

0.03 0.073 mm

Limit
0.11 mm

Limit
0.10 mm

9) Crankshaft gear replacement


z Visually inspect the crankshaft gear.
z

Replace the crankshaft gear as


following steps if excessive wear
or damage is discovered.
(1) Disassemble the crankshaft
gear by using the crankshaft
remover.

(2) Replace new part.


(3) Heat the crankshaft gear for at
least 10 minutes to 120oC
(4) Use
the
crankshaft
gear
installer to install the crankshaft
gear.

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Operation and Maintenance Manual
3.2.16. Flywheel and flywheel housing
1) Ring gear inspection
z Inspect the ring gear.
z If the ring gear teeth are broken
or excessively worn the ring gear
must be replaced.

2) Ring gear replacement


z Strike around the edges of the
ring gear with a hammer and
chisel to remove it.
3) Ring gear installation
z Heat the ring gear evenly with a
gas burner to invite thermal
expansion.
Pay attention that temperature of
ring gear is not exceeded 200C.
z Use a hammer to install the ring
gear when it is sufficiently heated.
4) Oil seal replacement (rear)
z Use a pry bar to remove the
flywheel housing oil seal.
z Assemble the oil seal to flywheel
housing by using the oil seal
assemble jig.

5) Oil seal replacement (front)


z Use an adapter and a hammer to
remove the crankshaft front end
oil seal.
z Assemble the oil seal to flywheel
housing by using the oil seal
assemble jig.

87

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Operation and Maintenance Manual
3.3. Engine Reassembly
3.3.1. Piston and connecting rod assembly

1. Piston
2. Piston Pin and connecting rod
3. Snap ring

4. Piston ring
5. Connecting rod bearing
6. Connecting rod bolt

1) Piston
z Use a piston heater to heat piston
to approximately 60C.

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Operation and Maintenance Manual
2A) Connecting rod
z Install the piston and connecting
rod with setting the marks as
illustrated.
z Assemble the piston pin into the
piston and connecting rod
bushing.

3) Snap ring
z Assemble the snap rings by
using snap ring flyer.
z Check that the piston moves
smoothly on the piston pin.

4) Piston ring
z Assemble the piston ring by
using piston ring assembly jig.
z Systematically assemble piston
rings as follows:
(1) Oil ring
(2) 2nd compression ring
(3) 1st compression ring
Rightly assemble the 1st and
2nd compression rings that the
marked side must be facing up.
Oil ring may be assembled any
because it is not indicated.
z Lubricate the surface of piston ring
engine oil.
z Check it whether piston rings
smoothly rotating in the piston
grooves.

way
with
are
ring

5) Connecting rod bearing


z Assemble the connecting rod bearing to the big end and the cap.
z Lubricate the bearing with engine oil.
z Assemble the connecting rod and connecting rod bearing, and tighten cap bolt
as the specified torque.
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Operation and Maintenance Manual
3.3.2. Cylinder head assembly parts

1. Valve stem oil seal


2. Intake and exhaust valve
3. Spring seat (lower)
4. Intake and exhaust valve spring
5. Spring seat (upper)
6. Valve cotter

7. Thermostat housing and gasket


8. Thermostat
9. Cooling water outlet
10. Intake manifold and gasket
11. Exhaust manifold and gasket

1) Valve stem oil seal


z Lubricate the oil seals and valve
stem sealing area with engine oil.
z Assemble the valve stem oil seal
by using oil seal installer.

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2) Intake and exhaust valves
z Place the cylinder head on a flat
wooden surface.
z Lubricate valve stem with the
engine oil.
z Assemble the valves to the
intake or exhaust valve guides.

4) Intake and exhaust valve springs


z Assemble the valve spring with
their painted end facing top.

5) Spring seat
6) Valve cotter
z Use a spring compressor to push
the valve spring into position.
z Install the spring seat split collar.

91

Set the spring seat split collar by


tapping lightly around the head
of the collar with a rubber
hammer.

Engine reassembly
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Operation and Maintenance Manual
10) Intake manifold and gasket
z Assembly the intake manifold
gasket.
The intake manifold gasket must
be installed with its unchamfered
corner facing up and to the
front of the engine.

z
z

Assemble the intake manifold.


Tighten the intake manifold bolts
to the specified torque a little at a
time in the numerical order. (see
figure)
Intake manifold
bolt torque

2.2 kg.m

11) Exhaust manifold and gasket


z Install the exhaust manifold
gasket.
z The TOP mark must be facing
up.

z
z

Install the exhaust manifold


Tighten the exhaust manifold
bolts to the specified torque a
little at a time in the numerical
order. (see figure)

Exhaust manifold
bolt torque

92

2.2 kg.m

Engine reassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
3.3.3. Rocker arm and shaft assembly

1. Rocker arm shaft


2. Spring

3. Rocker arm
4. Bracket

1) Rocker arm shaft


z The rocker arm shaft must be
installed with the oil holes facing up.

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3.3.4. Main components

2.
3.
4.
5.
6.
7.

Crankshaft bearing (lower)


Crank shaft
Thrust washer
Crank shaft bearing (upper) and cap
Timing gear case
Tappet

8. Camshaft

9.
10.
11.
12.
13.
14.
15.

Idler gear shaft


Idler gear
Piston and connection rod
Oil pump and coupling
Flywheel housing
Oil pan
Oil cooler

* The tappet must be installed before the camshaft installation.

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Operation and Maintenance Manual
2) Crankshaft bearing (lower)
z There is no oil hole and oil
groove on the lower bearing. But
opposite upper bearing has oil
hole and oil groove.

3) Crankshaft
z Assemble the crankshaft gear in
front side.
CAUTION:
Make sure the part number of
crankshaft
because
its
counterweight
size
may
be
different depending upon engines.

4) Thrust washer
z Assemble thrust washer with the
oil groove side facing the
crankshaft sliding face.

5) Crankshaft bearing cap


z Lubricate the bearing cap bolts
with engine oil.
z Assemble the bearing caps to
the crankshaft.
The arrow mark must be pointing
to the front of the engine.

95

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z

Tighten the bearing cap bolts to


the specified torque a little at a
time in the numerical order. (see
figure)

Crankshaft bearing
cap bolt torque

24.01kg.m

Check that the crankshaft turns


smoothly by manually rotating it.

6) Timing gear case


z Tighten timing gear case bolt to
the specified torque.
Timing gear case
bolt torque

2.2 kg.m

Apply silicon to the indicated


area. (see figure)

8) Camshaft
z Tighten thrust plate bolt through
the camshaft gear hole.
Thrust plate bolt
torque

2.2 kg.m

Camshaft gear bolt


torque

13 kg.m

9) Idler gear shaft


z Assemble an idler gear shaft by
using the thrust collar fixing bolt
as a guide.
z The oil hole must be facing the
camshaft.
z Lubricate the idle gear shaft with
engine oil.

96

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10) Idler gear
z Assemble the idle gear.
Set the timing marks A, B,
and C as shown in the figure.
z Tighten the idle gear bolts
seating the thrust collar to the
specified torque.
z The thrust collar must be
installed with the chamfered side
facing the front of the engine.
Idle gear bolt torque

4.4 kg m

11) Piston and connecting rod


z Set the piston ring gaps as
shown in the figure.
z Lubricate the piston, the piston
ring and the connecting rod
bearings with engine oil.

z
z
z

Position the piston front mark


towards the front of the engine.
Use the piston ring compressor
to compress the piston rings.
Push the piston in until it makes
contact with the crank pin by
using a hammer grip.
At the same time, rotate the
crankshaft until the crank pin
reaches its highest point.
Set the bearing cap cylinder
number
marks
and
the
connecting rod cylinder number
marks.
Lubricate the connecting rod cap
bolt threads and setting face with
MoS2 grease.

z Tighten the connecting rod cap bolts to


the specified torque.
Refer to the following table.

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Operation and Maintenance Manual

Torque

120.25kg.m

9.750.25kg.m

Bolt
head

TY
11

TY
12

12) Oil pump assembled


z Lubricate the oil pump with the
specified engine oil.
z Install the oil pump with the
coupling.
z Tighten the oil pump bolts to the
specified torque.
Oil pump bolt torque

5.0 kg.m

13) Flywheel housing


z Apply silicon to the shaded area.
(see figure)
z Install the flywheel housing.
Tighten the flywheel housing bolts
to the specified torque.
M14 x 1.5

13 kg.m

M14 x 1.5

18 kg.m

14) Oil pan


z Apply liquid gasket to the area
indicated by the arrows in the
figure.
z Install the gasket and oil pan.
z Tighten the oil pan bolts to the
specified torque.
Oil pan bolt torque

98

2.2 kg m

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Operation and Maintenance Manual
15) Oil cooler
z Assemble the oil cooler with
gasket after applying sealant to
the oil cooler gasket.
z Tighten the oil cooler bolts to the
specified torque. in the numerical
order (see figure)
Oil Cooler Torque

99

2.2 kg m

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Operation and Maintenance Manual
3.3.5. Major component assembly

100

1.

Flywheel

2.

Crankshaft pulley nut

10.

Push rod

3.

Tappet chamber cover

11.

Taper bushing

4.

Water pump

12.

Crankshaft pulley and dust cover

5.

Cylinder head gasket

13.

Timing gear cover

6.

Cylinder head bolt

14.

Oil thrower

7.

Cylinder head

15.

Rubber hose

8.

Rocker arm shaft Assembly

9.

Oil pump driving pinion

Engine reassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
1) Flywheel
z Lubricate the flywheel bolt with
engine oil.
z

Install the flywheel.


Tighten the flywheel bolts to the
specified torque in the numerical
order. (see figure)
Flywheel Bolt torque

18 kg.m

2) Injection pump
z Align the injection pump gear "C"
timing mark with the idler gear
C timing mark.

Tighten the injection pump bolts


to the specified torque.

Injection Pump Bolt Torque

2.2 kg.m

3) Crankshaft pulley nut


z Tighten the crankshaft pulley nut
to the specified torque by using a
wrench.
Crankshaft pulley nut torque

101

60 kg.m

Engine reassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
3) Tappet chamber cover
z Apply silicon to the tappet
chamber cover gasket.
z Assemble the tappet chamber
cover and tighten the bolts to the
specified torque.
Tappet chamber cover
bolt torque

2.2 kg.m

4) Water pump
z Apply silicon to the pump gasket
before installing the water pump.

5) Cylinder head gasket


z The gasket TOP" mark should
be faced up and "FRONT" mark
is towards the front of the engine.

6) Cylinder head bolts


7) Cylinder head
z Carefully place the cylinder head
on the cylinder block.
z Tighten the cylinder head bolts to
the specified steps and torque in
the numerical order as figure and
following table.

102

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Bolt type

Torque
1st step : 7.0kg.m

hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step : 4.4 kg.m
Dodecagonal bolt

2nd step : 90
3rd step : 90

<12-gonal bolt limited value>

Standard(mm)

Limit(mm)

115

116.2

102

103.2

Apply engine oil to the cylinder


head bolts threads and setting
faces.

8) Rocker arm shaft assembly


z Tighten the rocker arm bolts to
the specified torque a little at a
time in the numerical order. (see
figure)
Rocker arm shaft bracket bolt
3.1 kg m
torque

103

Lubricate the rocker arm and the


rocker arm shaft with engine oil.

Adjust valve clearance.

Engine reassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
3.3.6. External parts

17

18

16

2
1

19

15

9
20

10

21

11

12 13 14

22

23

24

1
2
3
4
5
6

Flywheel housing
Lifting hook
Oil filler cap

Fuel filter
Intake manifold
Air pipe
(intercooler to manifold)

7
8
9

104

Breather
Cooling fan
Oil filter

25

10
11
12
13
14
15
16
17
18
19

27

28

20
21

Water outlet
Air pipe

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)

22
23
24
25
26
27
28

Turbo charger
Exhaust manifold
Crank shaft pulley
Starter
Push rod chamber cover

Oil level gauge


Fuel injection nozzle

Engine reassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
1) Cylinder head cover
z Tighten the cylinder head cover
bolts to the specified torque a
little at a time in the sequence.
(see figure)
Cylinder head cover bolt torque

2.2 kg m

Fan belt
z Adjust the fan belt tension.

2) Starter
z Tighten the starter bolts to the
specified torque after install the
starter to the flywheel housing.
Starter fixing nuts torque

2.2 kg m

3) Injection nozzle
z Install the injection nozzle with
the injection nozzle gaskets.
Injection nozzle nuts torque

Hex nut
Spring washer

2.2 kg.m

O-ring

Be careful not to damage the


nozzle tips.

Injection nozzle
Seal ring

4) Fuel injection pipe


z Install the fuel injection pipes
and tighten the bolts to the
specified torque.
Injection pipe torque

z
105

3.0 kg.m

Carefully position and set the


1
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Operation and Maintenance Manual

clips.
It is very important that each clip be positioned correctly.
An improperly positioned clip will result in objectionable fuel pulsing noise and
injection pipe breakage.
Install the fuel return pipes.

5) Oil filter
z Install the oil filter assembly with
tightening the bolts securely.
Oil filter assembly
mounting bolts torque

5.0 kg.m

Head, oil filter

Cartridge,
Oil filter

6) Fuel pipe
z Install the fuel pipe and tighten the fuel
pipe joint bolts to the specified torque.
Take care not to interchange the check
valves and joint bolts.
Fuel pipe joint bolt
torque

1.7 kg.m

7) Fuel hose
z Install the fuel filter hoses and
tighten the hollow screws to the
specified torque
Fuel filter hose bolt
torque

106

4.2 kg.m

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Operation and Maintenance Manual
8) Intake pipe
z Install the intake pipe and tighten
the intake pipe flange bolts to the
specified torque.
Intake pipe flange bolt
torque

107

2.2 kg m

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Operation and Maintenance Manual
3.4. Electrical Equipments
3.4.1. Wiring circuit
a) Glow plug system (type - 1)

b) Glow plug system (type - 2)

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c) Air heater system (type - 3)

3.4.2. Starting of winter


CAUTION :
1. Preheating devices are attached to the engine for improving the
starting abilities at extremely low temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails
regardless of the preheating, start the preheating again after 30
seconds.
Operation 1 : Turn the key switch to the HEAT position, then the pilot lamp lights
up for about 20 seconds When the pilot lamp is extinguished, do
operation 2
Behavior
- When the coolant temperature is below 10 C in cold weather, youd
better operate the pre-heating system (Air heater)
- If the pre-heating is not necessary, the pre-heating system is not
operated with the pilot lamp.
Operation 2 : After checking the pilot lamp, turn the key switch to the START
position to crank the engine, at once.
Behavior
- When the key switch is placed in the START position, air heater is
continuously heated to facilitate starting operation and to reduce
white smoke during 30 seconds automatically.
- If the coolant temperature is above 15 C, air eater needs not be
heated.
Operation 3 : After the engine is cranked, convert the key switch to the ON position.
Behavior
- As the engine is cranked, air heater is heated for 30 seconds (afterheating) to reduce and to element quickly white smoke.
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3.4.3. Alternator
The alternator is fitted with integral silicon rectifiers. A transistorized regulator
mounted on the alternator body interior limits the alternator voltage. The alternator
should not be operated except with the regulator and battery connected in circuit to
avoid damage to the rectifier and regulator.
a) 24V x 45A Alternator
24V 45A

The alternator is maintenance-free, nevertheless, it must be protected against dust


and, above all, against moisture and water.

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NOTE:
Operate the alternator according to the instructions given in the chapter.

110

1
2
3
4

Hex nut
Pulley
Fan
Collar

13
14
15
16

Frame
Bushing
Needle bearing
Rectipier

Bearing ass`y

17

Screw

Rotor ass`y

18

Regulator

Stator ass`y

19

Brush set ass`y

Cover

20

Brush holder

Pin

21

Spring

10

Stud bolt

22

Brush

11

Insulator

23

Brush

12

Bolt

24

Baffle

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b) 24V x 60A Alternator
24V 60A

Wiring Diagram

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3.4.4. Starting motor
The sliding-gear starter motor is flanged to the rear of the flywheel housing on the lefthand side. As parts of every engine overhaul, the starter pinion and ring gear should
be cleaned with a brush dipped in fuel and then a coat of grease should be applied
again.
24Vx4.5kW

30 Terminal
(M10x1.5)

50 Terminal
(M5x0.8)

Wiring Diagram

50
30

Always protect starter motor against moisture.


WARNING:
Always disconnect the battery earth cable before starting work on the electrical
system. Connect up the earth cable last, as there is otherwise a risk of shortcircuits.
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113

1.

Yoke assembly

14.

Coil spring

2.

Bush holder assembly

15.

Pinion starter

3.

End frame

16.

Pinion stop nut

4.

Through bolt

17.

Snap ring

5.

Armature assembly

18.

Snap ring

6.

snap retainer

19.

Snap retainer

7.

Idle gear

20.

Coil spring

8.

Clutch roller

21.

Housing

9.

Retainer

22.

Terminal cap

10.

Coil spring

23.

Screw

11.

Steel ball

24.

Cover

12.

Clutch assembly

25.

Through bolt

13.

Clutch shaft

26.

Magnet switch assembly

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4. Commissioning and Operation


4.1. Preparation
At the time of initial commissioning of a new or overhauled engine make sure to have
observed the "Technical Information for the installation DAEWOO generator engines".
z Oil filler neck on cylinder head cover
Before daily starting of the engine, check the fuel, coolant and oil level, replenish if
necessary.
The notches in the dipstick indicate the highest and lowest permissible oil levels.
The oil required in the sump is specified in the "Engine Specification.
NOTE
The oil required to fill the oil fillers and pipes depends upon the engine and
use and must be determined individually at the time of initial commissioning.
(Make the Max and Min. marks of the determined quantity on the oil level
gauge.)
z Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants
4.1.1. Starting
For engine starting, please confer the instruction.
NOTE:
1. Preheating devices are attached to the engine for improving the starting
abilities at extremely low temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails
regardless of the preheating, start the preheating again after 30 seconds.
a) Pre-heating system
Operation 1: Turn the key switch to the HEAT position, then the pilot lamp lights up
for about 20 seconds When the pilot lamp is extinguished, do
operation 2
Behavior - When the coolant temperature is below 10 C in cold weather, youd
better operate the pre-heating system (Glow plug)
- If the pre-heating is not necessary, the pre-heating system is not
operated with the pilot lamp.
Operation 2: After checking the pilot lamp, turn the key switch to the START
position to crank the engine, at once.
Behavior - When the key switch is placed in the START position, glow plug is
continuously heated to facilitate starting operation
- If the coolant temperature is above 10 C, glow plug needs not be heated.
Operation 3: After the engine is cranked, convert the key switch to the ON position.

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b) Audible Alarm
The generator gauge panel for DB58 series engine is equipped with an audible
alarm to alert the operator to the following:
* Low engine oil pressure
* Engine coolant overheat
The alarm horn will sound when the ignition is turned on and continue to sound until
the engine is started and minimum oil pressure is obtained. This provides a
functional test of warning system.
Should engine coolant overheat occur, the alarm horn will sound and the engine is
stopped by stop solenoid at the same time automatically. Proceed as follows:
First, quickly observe the coolant temperature gauge for engine coolant overheat
and/or needle oscillation indicating low coolant. If the temperature gauge indicates
engine coolant overheat, throttle back to idle speed IMMEDIATELY and cut off the
main circuit breaker of the generator control panel. Do not restart engine until cause
for the alarm has been found and corrected. Refer to "Diagnosis and remedy" in
Trouble Shooting Chart. If the coolant temperature gauge indicates low coolant, add
some amount of required coolant to fill radiator. If cause for the alarm cannot be
found, contact your DAEWOO dealer.

4.2. Starting and operation


4.2.1. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened.
Therefore the following things must be obeyed by all means.
Up to the first 150 hours (2,000km)
z Engine should be run at fast idling until the temperature of the engine
becomes normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
4.2.2. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly observant
as follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between the
"min." and max." marks on dipstick.
Note:
If you have a problem getting a good oil level reading on dipstick, rotate
dipstick 180 and re-insert for check.
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When adding engine oil, refer to Lubrication Section.
b)Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil dipstick. Add oil to the oil pan, if required.
Do not overfill. If level is correct and the status still exists, see your DEALER for
possible switch or oil pump and line malfunction.
Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM
than hot oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter
element. Fill oil pan with recommended engine oil. Refer to Lubricating System.
z Engine oil should be changed at the specified intervals.
Oil filter cartridge should be changed simultaneously.
-

First oil change : 50 hr operating


First oil change

After 50hr operation

Construction equipments

DB58
DB58T
DB58TI

every 200 Hour

DB58S
DB58TIS

every 250 Hour

The following oils are also recommended


Recommend oil
Engine model
SAE No.

API No.

DB58
DB58T
DB58TI

SAE 15W40

above CD or CE

DB58S
DB58TIS

SAE15W40
SAE10W40

ACEA-E2 or ACEA-E3
(API CH-4)

* If long oil change intervals are to be used, ACEA-E3 oil must be used.

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4.3. Inspections after starting
z It is advisable to operate an engine at idling until the engine reaches up to normal
operating temperature.
z Engine should be stopped if the color, the noise or the odor of exhaust gas is not
normal.
z Confirm the following things through warning lamps and gauge panel.
- Pressure of lubricating oil
The normal pressure comes up to 100 kPa (1.0 bar) at idling and 300 ~ 480 kPa
(3.0 ~ 4.8 bar) at maximum speed. If the pressure fluctuates at idling or does not
reach up to the expected level at high speed, shut down the engine immediately
and check the oil level and the leakage.
- Temperature of cooling water
The cooling water temperature should be 80 ~ 95 C in normal operating
conditions. Abnormally high cooling water temperature could cause the
overheating of engine and the sticking of cylinder components. And excessively
low cooling water temperature increases the fuel consumption, accelerates the
wears of cylinder liners and shortens the engine life-time.
NOTE:
When engine is overheated, do not stop the engine immediately. Lower the
engine load and run the engine and its cooling systems continuously.

4.4. Operation in winter time


Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
4.4.1. Prevention against the freeze of cooling water
When not using anti-freeze, completely
Cooling water
discharge the whole cooling water after
drain valve
engine running. The freeze of cooling
water causes the fatal damages of the
engine. Because the anti-freeze is used
to prevent cooling water from freeze,
consult "The amount of anti-freeze".

4.4.2. Prevention against excessive cooling


Drop of thermal efficiency caused by excessive cooling increases fuel consumption,
therefore prevent the engine from excessive cooling. If the temperature of coolant does
not reach to normal condition (80 ~ 95 C) after continuous operation, examine the
thermostat or the other cooling lines.
4.4.3. Lubricating oil
As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after
starting. Therefore the lubricating oil for winter should be used to prevent this
unstability. Refer to Lubrication System section.
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4.4.4. Starting of engine in winter
It is necessary to preheat engine satisfactorily under 10 C (50 F) in winter. Refer to
Starting.
4.4.5. Tuning the engine
The purpose of an engine tune-up is to restore power and performance that's been
lost through wear, corrosion or deterioration of one or more parts or components. In
the normal operation of an engine, these changes can take place gradually at a
number of points, so that it's seldom advisable to attempt an improvement in
performance by correction of one or two items only. Time will be saved and more
lasting results will be obtained by following a definite and thorough procedure of
analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is
performed once every years, preferably in the spring. Components that affect power
and performance to be checked are:
z Components affecting fuel injection ;
Nozzle, delivery valve, fuel filter, water separator, etc.
z
Components affecting Intake & exhaust ;
Air filter, inter-cooler, turbo, silencer, etc.
z Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, etc.

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4.5. Maintenance and care
4.5.1. Periodical inspection and maintenance
In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
z Daily inspections in below figure should be checked every day.
z The maintenance should be executed thoroughly at regular internals.
(refer to appendix General Engine Inspection Cycle.)
4.5.1. Exchanging of lubrication oil
Engine oil and the oil filter are important factors affecting engine life. They affect ease
of starting, fuel economy, combustion chamber deposits and engine wear. Refill and
drain oil pan every 200 hours of operation or 6 months whichever occurs first. At the
end of the break-in period (50 hours), change the oil sump oil and replace the oil filter.
4.5.2. Oil level
Check the oil level in the engine sump
daily with a dipstick.
z The notches in dipstick must indicate
the oil level between the max. and
the min. permissible.
z The oil level should be checked with
the engine horizontal and only after it
has been shut down for about 5
minutes.
z Examining the viscosity and the contamination of the oil smeared at the dipstick
replace the engine oil if necessary.
IMPORTANT:
Do not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Over lifting will result in damage to the engine.
4.5.3. Oil exchange procedure
While the oil is still hot, exchange oil as follows:
z Take out the oil dip dipstick.
z Remove the drain valve from oil
pan, then drain out the engine oil
into a container.

Oil drain
valve

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z Refill with new engine oil at the oil
filler neck on the head cover and the
lubricating oil in accordance with the
oil capacity of the engine through oil
filler. Be careful about the mixing of
dust or contaminator during the
supplement of oil. Then confirm that
oil level gauge indicates the vicinity
of its maximum level.
z For a few minutes, operate the
engine at idling in order to circulate
oil through lubrication system.
z Thereafter shut down the engine.
After waiting for about 10 minutes
measure the quantity of oil and refill
the additional oil if necessary.

Oil filler cap

Cylinder head cover

4.5.4. Replacement of oil filter cartridge


At the same times of oil exchanges,
replace the oil filter cartridge.
IMPORTANT:
Don't forget tightening the drain
valve after having drained engine
oil.
z Loosen the oil filter by turning it
counter-clockwise with a filter
wrench.
z With a rag wipe clean the fitting face
of the filter body and the oil filter
body so that new oil filter cartridge
can be seated properly.
z Lightly oil the O-ring and turn the oil
filter until sealing face is fitted
against the O-ring. Turn 1-1/4 turns
further with the filter wrench.

Head, oil filter

Cartridge,
Oil filter

IMPORTANT:
It is strongly advisable to use DAEWOO genuine oil filter cartridge for
replacement.
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4.6. Cooling system
The coolant must be changed at intervals of 1,200 hours operation or six months
whichever comes first. If the coolant is being fouled greatly, it will lead an engine
overheat or coolant blow off from the expansion tank.
4.6.1. Coolant draining
z Remove the pressure cap.
z Open the drain valve at the
radiator lower part to drain the
coolant as the right figure.

z Loosen the coolant drain plug of the


cylinder block and oil cooler.

CAUTION:
When removing the pressure filler
cap while the engine is still hot,
cover the cap with a rag, then turn it
slowly to release the internal steam
pressure This will prevent a person
from scalding with hot steam
spouted out from the filler port.

Cooling water
drain valve

4.6.2. Cleaning of the cooling inside system circuit


(by authorized specialist personnel)
When the cooling system circuit are fouled with water scales or sludge particles, the
cooling efficiency will be lowered.
Investigations have shown that in many cases the poor condition of the coolant and /or
the cooling system accounts for damage to the water pump mechanical seal, The poor
condition of the cooling system is normally due to use of unsuitable or no anti-freezing
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agents and corrosion inhibitor or defect, not early enough replaced covers for filler
neck and working valves.
If twice in a short time the water pump of an engine develops leases or the coolant is
heavily contaminated (dull, brown, mechanically contaminated, grey or black sings of a
leakage on the water pump casing) clean the cooling system prior to removing that
water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown
through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of
cleaner. (Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60C is reached, run engine
for a further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Flush cooling system.
h) Replace drain plug by drain plug with a bore of 8mm diameter.
i) Fill cooling system with hot water.
j) Run engine at idle for 30 minutes. At the same time continuously replenish the
water leaking from the bore in drain plug by adding fresh water.
CAUTION:
Periodically clean the circuit interior with a cleaner.

4.7. Valve clearance and adjustment


NOTE:
The cylinder head bolts were
previously tightened with the
torque wrench. Therefore it is not
necessary to retighten the cylinder
head bolts before adjusting the
valve clearance.
Rocker arm screw
lock nut torque

2.6 kg.m

z After letting the #1 cylinder's piston


come at the compression top dead
center by turning the crankshaft,
adjust the valve clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the
feeler gauge of specified value
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between a rocker arm and a valve stem and adjust the clearance with adjusting
screw respectively and then tighten with the lock nut.
z As for the valve clearance, adjust it when in cold, as follows.

Model
DB58
DB58S
DB58T
DB58TI
DB58TIS

Intake Valve

Exhaust Valve

0.4 mm

0.4 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then
#1 cylinder become the compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to

of lower

figure. At this time there are no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression
state of top dead center.
4) Thereafter adjust the valve clearances corresponding to

of lower

figure.
5) After reinsuring the valve clearances, retighten if necessary.
z

No. 1 cylinder is located at the side where flywheel was installed.

Cooling fan

123

Cylinder no.

Exhaust valve

Intake valve

Fly wheel

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4.8. Injection timing
CAUTION:
Take care to avoid entry of dust or foreign particles into the pump interior
when the timing adjustment is made.

<Check procedure>
z Align the crankshaft pulley TDC
mark with the pointer.
z Remove the inspection hole cover
at the front of the injection pump on
the timing gear case cover.

z Check the alignment between the


pointer on the injection pump
gear nut lock plate and the
projection area mark on the
injection pump gear case.
z If it is in misalignment, recheck with
turning the crankshaft pulley one
more turn to repeat the foregoing
procedure to mark sure that it is in
alignment.
z Check the alignment of the
notched lines and . (These
notched lines were aligned at the
factory to set the injection pump
body and the mounting flange.)
Next, inspect the crank angle
position of the injection timing.

<Check procedure>
z Turn
the
crankshaft
pulley
counterclockwise about 30 crank
angle.

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z Disconnect the injection pipe from
the No.1 plunger.
This will allow you to visually check
the full injection starting flow at No.
1 plunger.

z Remove the delivery valve holder,


the valve seat, valve spring,
and the delivery valve from the
No.1 plunger.
z Assemble the delivery holder
and tighten it to the specified torque.
Do not reassemble the delivery
valve, the delivery valve spring and
the valve seat.
These parts will be reassembled later.
z Hold the fuel control lever at the
fully open position.
z Slowly turn the crankshaft pulley
clockwise, at the same time,
continue to feed the fuel with
pumping the priming pump.
When the fuel stop to flow out from
the No.1 delivery valve holder, stop
the pump instantaneously.
This crank angle position is the
injection starting of the engine.
z Observe and make sure that mark
(injection starting angle line o) on
the crankshaft pulley is aligning
with the pointer.
Blow out the remaining fuel from
the delivery valve holder.
Make sure that there is no fuel
being delivered from the priming
pump.

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z Fuel injection timing angle

Fuel injection timing (BTDC)

DB58/S

DB58T

DB58TI

DB58TIS

- Refer to the 1. 2. Engine power

z Remove the delivery valve holder


from the No.1 plunger
z Reassemble the delivery valve
internal parts to the delivery valve
holder.
z Reassemble the delivery valve
holder assembly to the No.1
plunger and tighten it to the
specified toque.
Delivery valve holder torque

4.25 kg m

z Assemble the No.1 cylinder injection pipe and tighten it to the specified torque.
Injection pipe nut torque

3.1 kg m

INPORTANT:
1) Do not overtighten the injection pump body. The injection pump body is
made of aluminum.
2) Overtighten will distort the injection pump body shape and adversely affect
control rack operation.
<Adjusting procedure>
z Align the pointer and the specified timing mark on the crank pulley.
z Perform the steps of checking procedure of Injection Timing.
z Loosen the 4 injection pump fixing nuts.
z Timing adjustment
To advance the timing
Pivot the injection pump at the
pump drive shaft toward out.
To retard the timing
Pivot the injection pump at the
pump drive shaft toward in. (toward
the cylinder block)

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IMPORTANT:
The 1 mm misalignment between the two setting mark lines corresponds to
about 2o in crank angle.
z Do a fine injection pump position adjustment, while continue the pumping
operation to feed the fuel, and stop to pivot the injection pump when the fuel stop
to flow out from the No. 1 delivery valve holder.
z Tighten the four injection pump fixing nuts.
z Once remove the No. 1 delivery valve holder, and reassemble the delivery valve,
spring and the valve holder with the specified torque.
z Install the No.1 injection pipe and tighten it to the specified torque.

4.9. Tightening the cylinder head bolts


z The cylinders head bolts are to be
tightened in the sequence shown
in the illustrations. First tighten the
bolts slightly, then slightly more
again and finally tighten with a
torque wrench as follows.
z The tightening by excessive torque
may cause the damages of the
cylinder head gaskets, the flanges
of cylinder liners and the cylinder
head bolts, therefore obey the
regular torque.
Bolt type

Torque

hexagonal bolt

1st step : 7.0kg.m


2nd step: 11.5+0.5kg.m

dodecagonal
bolt

1st step : 4.4kg.m


2nd step : 90
3rd step : 90

<Dodecagonal bolt limited value>


Standard(mm)
115
102

127

Limit(mm)
116.2
103.2

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4.10. Fuel injection pump
z Check the housing crack, damage
etc. and replace it if abnormal.
z Check if the idle operation and
speed regulating lever's sealing is
removed.
z The adjustment and testing of fuel
injection pump should necessarily
be done at the test bench.

4.11. Feed pump strainer


z Release joint bolt A.
z Remove the strainer with a
screwdriver and wash the strainer
with clean diesel fuel.

4.12. Separator (Add if necessary)


z Check water level of the separator.
z Release the plug at the bottom to
eliminate water when water level
(floating) reaches the warning point.
Elimination plug torque

128

1.2 kg.m

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4.13. Air bleeding
z Loosen the priming pump cap(1)
on the Injection pump.
z Loosen the hollow screw for air
bleed(2).
z Operate the priming pump until
there are no more bubbles visible
in the fuel being discharged from
the fuel filter fuel return eye bolt.
z Retighten the hollow screw.
z Operate the priming pump several
times and check for fuel leakage
around the injection pump and the
fuel filter.

4.14. Belts
The tension of the belts should be checked after every 2,000 hours of operation.
1) Change the belts if necessary
If in the case of a multiple belt drive, wear or differing tensions are found, always
replace the complete set of belts.
2) Checking condition
Check belts for cracks, oil, overheating and wear.
3) Testing by hand
z V-belt
By the finger-pressure the belt is
pressed by 10-15mm between the
pulleys
in
normal
condition.(Pressed
mid-way
between the belt pulleys)
A more precise check of the V-belt
tension is possible only by using a
V-belt tension tester.

z Poly belt
Poly belt will be properly tensioned
if the deflection force F is applied
mid-way between the belts tangent
points with the pulley.
T = 0.015 x S(about 1.5mm per 100mm)

T = 0.015 x *S (mm)
(T : Deflection , S : Span)
129

Commissioning & operation


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
*

(D d )2
S= C
2
2

(mm)

C : Distance of pulleys (mm),


D : Large pulley diameter (mm),
d : Small pulley diameter (mm)

4) Measuring tension
Lower indicator arm (1) into the
scale.
z Apply tester to belt at a point
midway between two pulleys so
that edge of contact surface (2) is
flush with the V- belt.
z Slowly depress pad (3) until the
spring can be heard to disengage.
This will cause the indicator to
move upwards.
If pressure is maintained after the
spring has disengaged a false
reading will be obtained!
Reading of tension
z Read of the tensioning force of the
belt at the point where the top
surface of the indicator arm (1)
intersects with the scale.
z Before taking readings make
ensure that the indicator arm
remains in its position.

z V-belt tension
Tensioning forces on the tester

Type

M
A
B
C

130

Drive belt width

9.5 mm
11.8 mm
15.5 mm
20.2 mm

new installation
Installation

After 10 min.
running time

50 kg
55 kg
75 kg
75 kg

45 kg
50 kg
70 kg
70 kg

When servicing after


long running time

40 kg
45 kg
60 kg
60 kg

Commissioning & operation


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
z Poly belt tension

No of rib
(PK type)

Force(kgf)

20 - 27

27 - 36

34 45

41 57

48 66

59 - 73

5) Tensioning and changing belts


z Loosen fixing bolts and nuts.
z Adjust the alternator until belts
have correct tensions.
z Retighten fixing bolts and nuts.
z

131

To change the belts loosen fixing


bolts and nuts. Then push the
alternator toward water pump
pulley by hand.

Commissioning & operation


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

5. Maintenance of Major Components


5.1. Lubrication system
5.1.1. Oil pump
1) Disassembly

3
4
2

1. Oil suction pipe


2. Cover and dowel
3. Drive shaft and gear

133

4. Pinion Gear
5. Pinion gear shaft

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) Inspection
z Visually inspect the disassembled
parts for the excessive wear and
damage.
z Correct or replace the parts if the
wear or damage is discovered
during inspection.

3) Oil Pump Drive Gear


z
Use a feeler gauge to
measure
the
clearance
between the oil pump cover
(oil pump case) inside surface
and the drive gear.
z
If the clearance exceeds the
specified limit, the drive gear
and/or the oil pump cover must
be replaced.
Limit
0il pump cover and
drive gear clearance

0.18 mm

4) Oil pump pinion gear


z Use a feeler gauge to measure
the clearance between the oil
pump case cover inside
surface and the pinion gear.
z

If the clearance exceeds the


specified limit, the pinion gear
and/or the oil pump cover must
be replaced.
Limit
0il pump cover and
pinion gear clearance

0.12 mm

5) Oil pump reassembly


z To
assemble,
follow
disassembly
procedures
reverse order.
134

the
in

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.1.2. Oil cooler
1) Disassembly

1. Oil cooler element


2. Gasket
3. By-pass plug

4. O-ring
5. By-pass valve spring
6. By-pass valve

2) Inspection
z Correct or replace the part if the wear or damage is discovered during
inspection.
3) Oil cooler element
z Install the oil cooler element to
the oil cooler, then tighten the
oil cooler element fixing bolts
to the specified torque.
Oil cooler element
fixing bolts torque

2.2 kg.m

4) Oil cooler reassembly


z To assemble, follow the disassembly procedures in reverse order.
135

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.2. Cooling system
5.2.2. Water pump

5
4
3

1
7

1) Disassembly
1. Pulley flange
2. Snap ring
3. Unit bearing
4. Mechanical seal

5. Impeller
6. Pump housing
7. Cover
8. Gasket

(1) Impeller
z Remove the impeller by using
the jig.

(2) Unit bearing


z Remove the unit bearing by
using a bench press and a
suitable remover.

136

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
(3) Mechanical seal
z Remove the mechanical seal
by using a suitable remover.

(4) Hub
z Remove the hub by using a
bench press and a suitable rod.

(5) Snap ring


z Remove the snap ring by using
a pair of the snap ring plier.

2) Inspection
(1) Unit bearing
z Correct or replace the part if
the wear, defect or other
damage is discovered during
inspection.

137

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Water pump reassembly
(1) Unit bearing
z Lubricate the bearing with
multipurpose grease.
z Use a bench press to
assemble the unit bearing at
the pump.

(2) Snap Ring


z Use a pair of snap ring plier to
install the snap ring.

(3) Hub
z Use a bench press and a bar
to install the hub.

(4) Mechanical seal


z Apply sealant to the seal unit
outer
periphery
before
installation.

138

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
z

Use a bench press and a bar


to install the seal unit into the
pump body.

(5) Impeller
z Use a bench press to install
the impeller to the shaft.
z Use a feeler gauge to measure
the clearance between the
impeller and the pump body.
Clearance
between impeller and

0.3 ~ 0.8mm

pump body

(6) Pulley
z Install the pulley and tighten
the pulley bolts to the specified
torque.
Pulley fixing bolts

Fan flange

2.2 kg.m

torque

Pulley
Cooling fan

5.2.2. Thermostat
z Correct or replace thermostat if
the wear, defect or other damage
is discovered during inspection.
Valve

Temperature

Close

71C

82C

Standard

85C

95C

Maximum

110C

110C

Lift
10mm
less
16mm

139

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.3. Fuel system
5.3.1. Fuel filter
1) Cartridge type

Air vent plug

Fuel filter head

Cartridge,
fuel filter

Water drain plug

2) Paper element type


1. Drain plug
2. Center bolt
3. Fuel filter body
4. Body cover gasket
140

5.Fuel filter element


6.Spring seat
7.spring

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Inspection
z Make the necessary adjustments,
repairs and part replacements if
excessive wear or damage is
discovered during inspection.
4) Fuel filter reassembly
z To reassemble the fuel filter, follow
the disassembly procedure in the
reverse order.

5.3.2. Injection nozzle


1) Disassembly

1. Nozzle holder body


2. Seal ring
3. Injection pipe connector
4. Injection nozzle
5. Retaining nut
6. Nozzle holder push rod

141

7. Push rod spring


8. Spring seat
9. Nozzle adjusting screw
10.Cap nut gasket
11. Nozzle holder cap nut

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) Injection nozzle
Remove the nozzle assembly from the nozzle body. Keep the parts separately to
maintain the proper needle valve to body combination.

3) Inspection
Make the necessary adjustments, repairs and parts replacements if excessive
wear or damage is discovered during inspection.

(1) Push rod spring


z Check the push rod spring for
wear, weakness and corrosion.

(2) Nozzle holder push rod


z
Check the nozzle holder push
rod curvature.
z
Check the nozzle holder push
rod and needle valve contact
surface for excessive wear and
poor contact.

(3) Injection nozzle


z Check the injection nozzle
needle valve, the valve seat,
and the injection nozzle hole for
carbon deposits.
If carbon deposits are present,
the injection nozzle and the
needle valve must be replaced.
z Hold the nozzle body vertically.
Pull the needle valve about onethird of the way out of the nozzle body. Release the needle valve.
142

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
Check that the needle valve falls back into the nozzle body as far as the valve
seat.
If the needle does not fall back into the nozzle body as far as the valve seat,
the injection nozzle and the needle valve must be replaced.
3) Reassembly
(1) Injection pipe connector
Injection pipe
connector torque

5.5 kg.m

(2) Injection nozzle


z There must be no oil on the
contact surface of the injection
nozzle and the injection nozzle
holder.
Clean these contact surface
with
diesel
fuel
before
installation.
z The nozzle dowel pin must be
aligned with the dowel hole in
the nozzle holder body.
(3) Retaining nut
z Clamp the injection nozzle in a
vise.
z Tighten the retaining nut to the
specified torque by using a
wrench.
Nozzle retaining nut
Torque

7 kg.m

(4) Nozzle holder cap nut


z Clamp the injection nozzle in a
vise.
z Tighten the nozzle holder cap
nut to the specified torque by
using a wrench.

143

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
Nozzle holder cap nut
torque

4.5 kg.m

(5) Nozzle adjusting screw (injection starting pressure check)


z Attach the injection nozzle
holder to the injection nozzle
tester.

Loosen the adjustment screw


.

Check the injection nozzle starting pressure and the spray condition by
operating the injection tester.
<spray condition check>
Operate the injection nozzle
tester hand lever 4 to 6 times
while looking for abnormal
injection
nozzle
spray
conditions. (See figure)
(1) Correct (Good)
(2) Incorrect (Bad - orifice)
(3) Incorrect (Bad - dripping)

Adjust the injection nozzle starting pressure.


Turn the adjusting screw clockwise while operating the injection nozzle tester
handle.

CAUTION:
Keep away your skin from the tester because pressure of nozzle tester is very
high when inject.

144

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.3.3. Parts no of injection system
1) Injection pump assembly
Engine model

Part no.

Suffix

DB58

65.11101-7380

EARDA/EAREA/B/EARFA/B/C/D/E/F/H/I/J
EARLA/B/C

DB58S

65.11101-7399

ECRFA/B/C/ECRLA

65.11101-7655

EATEA/B/C/D/EATLA

65.11101-7375

EATEE/F/G/H/I/J/EATLB

65.11101-7327

EAOEA/D/E/F

65.11101-7374

EAOEB/C/G

65.11101-7353

EAOLA/B

65.11101-7391

ECOEA/B

65.11101-7389A

ECOEC/D/E/F/G

65.11101-7392

ECOLA

65.11101-7390

ECOLB

DB58T

DB58TI

DB58TIS

2) Injection nozzle assembly


Engine model

Part no.

Suffix

DB58
DB58T

65.10101-7295

EARDA/EAREA/B
EARFA/B/C/D/F/G/K/EARLA/B/C
EATEA/B/C/D/E/F/G/H/I/J/EATLA/B

DB58
DB58S

65.10101-7086

EARFE/H/I/J
ECRFA/B/C/ECRLA

DB58TI
DB58TIS

65.10101-7058

EAOEA/B/C/D/E/G/EAOLA/B

65.10101-7092

EAOEF/ECOEA/B

DB58TIS

65.10101-7091

ECOEC/D/E/F/G/ECOLB

3) Injection pipe assembly


Engine model

145

Part no.

Suffix

DB58
DB58S

65.10301-6144

EARDA/EAREA/B
EARFA/B/C/D/E/F/G/H/I/J/K
EARLA/B/C/ECRFA/B/C/ECRLA

DB58T

65.10301-6289

EATEA/B/C/D/E/F/G/H/I/J/EATLA/B

DB58TI

65.10301-6072

EAOEA/B/C/D/E/F/G/EAOLA/B

DB58TIS

65.10301-6088
65.10301-6089

ECOEA/B/C/D/E/F/G/ECOLA/B

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.3.4. Injection pump calibration
1) DB58 engine
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe
(5) Injection order

: 65.11101-7380 (101605-996F DOOWON)


: KP-PES6A95C410RS2000 (101062-8300)
: KP-EP/RSV200-1450AQ43A311 (105419-1340)
: 131151-3200, 131100-7900
: 131160-1120
: KP-FP/KS-A (105220-6290)
: 3.60.05mm
: 156639-9820
: 65.10101-7295 (105160-4650 DOOWON)
: 65.10102-6044 (105025-138A DOOWON)
: 65.10301-6144
:153624

105780-8140
Opening pressure :175kg/cm2
2.0 x 6.0 600 mm
ISO4113
Temperature : 40 5C
65.10102-6044
Nozzle (5 x 0.27)
Nozzle & holder assy
(B) Engine standard parts
65.10101-7295
220 kg/cm2
Injection pipe(IDxODxL)
65.10301-6144
1.6x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7380)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D

Rack

Injection Q`ty on RIG

Pump

position speed
(mm)

(rpm)

8.8
9.1
6.7
-

1,100
800
415
100

(mm3 / 1,000st)
(A) Test condition
for inj. pump

55.0 1
(56.0) 2
8.0 1.3
100 10

Press.
(mmHg)

(B) Engine
standard parts

59.4 2
62.7

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

9.5 Left hand 20 lead


2,290 rpm

retraction pressure
Delivery valve

opening pressure
Spring

43mm3/st(6x1.5mm)
t=0.99
25.9 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Governor spring

k=12 kgf/mm

Start spring

k=0.005 kgf/mm

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Idling sub spring

k=2.1 kgf/mm

Adapter spring

k=11 kgf/mm

Feed pump
Max. operating pressure

146

3.4 kgf/cm2

Piston spring

k=0.735 kgf/mm

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58 : EARDA
Check Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

Pressure
(mmHg)

A
B
C
D

8.8
9.1
6.7
-

1,100
800
415
100

58.0 1
(56.0) 2
8.0 1.3
100 10

b) DB58 : EAREA
Check Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

Pressure
(mmHg)

A
B
C
D

8.8
9.1
6.7
-

1,100
800
415
100

61.0 1
(59.0) 2
8.0 1.3
100 10

Injection Q`ty on RIG


3
(mm / 1,000st)
50.0 1
(50.0) 2
8.0 1.3
100 10

Pressure
(mmHg)
-

Pump speed
(rpm)
1,100
800
415
100

Injection Q`ty on RIG


(mm3 / 1,000st)
55.0 1
(56.0) 2
8.0 1.3
100 10

Pressure
(mmHg)
-

Pump speed
(rpm)
1,100
800
415
100

Injection Q`ty on RIG


3
(mm / 1,000st)
58.0 1
(58.0) 2
8.0 1.3
100 10

Pressure
(mmHg)
-

Injection Q`ty on RIG


(mm3 / 1,000st)
55.0 1
(59.0) 2
8.0 1.3
100 10

Pressure
(mmHg)
-

c) DB58 : EAREB/RFE/RFI/RFJ/RFH
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

Pump speed
(rpm)
1,100
800
415
100

d) DB58 : EARFF
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

e) DB58 : EARLA/B
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

f) DB58 : EARLC
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

Pump speed
(rpm)
1,100
800
415
100

g) Rack curve of standard injection pump (65.11101-7380)

147

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) DB58 engine (EARFG/EARFK)
1. Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
2. Nozzle holder assembly
3. Nozzle
4. Injection pipe
5. Injection order

: 65.11101-7398 (101605-996G DOOWON)


: KP-PES6A95C410RS2000 (101062-8300)
: KP-EP/RSV200-1450AQ43A311 (105419-134A)
: 131151-3200, 131100-7900
: 131160-1120
: KP-FP/KS-A (105220-6290)
: 3.60.05mm
: 156639-9820
: 65.10101-7295 (105160-4650 DOOWON)
: 65.10102-6044 (105025-138A DOOWON)
: 65.10301-6144
:153624

105780-8140
Opening pressure :175kg/cm2
2.0 x 6.0 600 mm
ISO4113
Temperature : 40 5C
65.10102-6044
Nozzle (5 x 0.27)
Nozzle & holder assy
(B) Engine standard parts
65.10101-7295
220 kg/cm2
Injection pipe(IDxODxL)
65.10301-6144
1.6x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7380)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D

Rack

Injection Q`ty on RIG

Pump

position speed
(mm)

(rpm)

8.9
9.2
6.6
-

1,100
800
400
100

(mm3 / 1,000st)
(A) Test condition
for inj. pump

Press.
(mmHg)

(B) Engine
standard parts

58.0 1
(59.0) 2
8.0 1.3
100 10

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

9.5 Left hand 20 lead


2,290 rpm

retraction pressure
Delivery valve

opening pressure
Spring

43mm3/st(6x1.5mm)
t=0.99
25.9 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=12 kgf/mm

Idling sub spring

k=3.0 kgf/mm

Idle spring

k=1.9 kgf/mm

Start spring

k=0.005 kgf/mm

Adapter spring

k=11 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

148

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack curve of standard injection pump (65.11101-7380)

149

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) DB58S engine (ECRFA/B/C)
1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
2) Nozzle holder assembly
3) Nozzle
4) Injection pipe
5) Injection order

: 65.11101-7399 (101605-996X DOOWON)


: KP-PES6A95C410RS2000 (101062-830A)
: KP-EP/RSV200-1450AQ43A311 (105419-1340)
: 131151-3200, 131100-7900
: 131160-1120
: KP-FP/KS-A (105220-6290)
: 3.60.05mm
: 156639-9820
: 65.10101-7086 (105160-465B DOOWON)
: 65.10102-6056 (105025-138B DOOWON)
: 65.10301-6144
:153624

105780-8140
Opening pressure :175kg/cm2
2.0 x 6.0 600 mm
ISO4113
Temperature : 40 5C
65.10102-6056
Nozzle (5 x 0.22)
Nozzle & holder assy
(B) Engine standard parts
65.10101-7086
220 kg/cm2
Injection pipe(IDxODxL)
65.10301-6144
1.6x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7380)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D

Rack

Injection Q`ty on RIG

Pump

position speed
(mm)

(rpm)

10.1
6.8
10.7
-

1,100
400
700
100

(mm3 / 1,000st)
(A) Test condition
for inj. pump

Press.
(mmHg)

(B) Engine
standard parts

58.0 1
8.0 1.3
(68.0)
100 10

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

9.5 Left hand 20 lead


2,290 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x1.5mm)
t=0.09
25.9 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=12 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idle spring

k=1.9 kgf/mm

Start spring

k=0.005 kgf/mm

Adapter spring

k=11 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

150

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack curve of standard injection pump (65.11101-7399)
a) DB58S : ECRFA
Check

Rack position

Pump speed

Injection Q`ty on RIG


3

Pressure

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

A
B
C
D

10.1
6.8
10.7
-

1,100
400
700
100

58.0 1
8.0 1.3
(68.0)
100 10

Pump speed

Injection Q`ty on RIG

Pressure

b) DB58S : ECRFB
Check

Rack position

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

8.8

1,100

73.5 1.5

9.1

800

9.4 1.3

6.7

415

(63)

100

(43.6) 10

c) DB58S : ECRFC

151

Check

Rack position

Pump speed

Injection Q`ty on RIG

Pressure

Point

(mm)

(rpm)

(mm3 / 1,000st)

(mmHg)

8.8

1,100

73.5 1.5

9.1

800

9.4 1.3

6.7

415

(63)

100

(43.6) 10

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
4) DB58T engine (EATEA/B//D/TLA)
(1) Injection pump assembly
: 65.11101-7655 (101605-9760 DOOWON)
- Injection pump
: KP-PES6A95C410RS2000 (101062-9040)
- Governor
: KP-EP/RSV200-1350AQ49A311(105411-1820)
- Plunger and barrel
: 131151-3200, 131100-7900
- Delivery valve
: 131110-4320
- Feed pump
: KP-FP/KS-A (105220-6410)
- Prestroke
: 3.40.05mm
- Coupling
: 156639-4220
(2) Nozzle holder assembly
: 65.10101-7295 (105160-4650 DOOWON)
(3) Nozzle
: 65.10102-6044 (105025-138A DOOWON)
(4) Injection pipe
: 65.10301-6289
(5) Injection order
:153624

(A) Test condition


for injection pump

(B) Engine standard parts

Nozzle & holder assy

105780-8140

Opening pressure :175kg/cm2

2.0 x 6.0 600 mm

ISO4113

Temperature : 40 5C

65.10102-6044

Nozzle (5 x 0.27)

65.10101-7295

220 kg/cm2

65.10301-6289

1.8x6.0x580mm

Injection pipe(IDxODxL)
Test oil
Nozzle & holder assy
Injection pipe(IDxODxL)

Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7655)
Check
Point

Rack

Injection Q`ty on RIG

Pump

position speed

(mm3 / 1,000st)
(A) Test condition

(mm)

(rpm)

9.1

1,100

73.5 2.5

5.7

550

9.4 1.3

for inj. pump

Press.

(B) Engine

(mmHg)

standard parts

67.1 2

Above 300

9.1

800

(63)

68.1

Above 300

9.1-0.25

500

(43.6) 2

58.1

100

65

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

9.5 Left hand 20 lead


2,290 rpm

retraction pressure
Delivery valve

opening pressure
Spring

51mm3/st(6x1.8mm)
17.0 kgf/cm2
k=1.78 kgf/mm

Governor
Governor weight

740 g

Governor spring

k=10 kgf/mm

Start spring

k=0.005 kgf/mm

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Idling sub spring

k=2.1 kgf/mm

Boost compensator spring

k=0.6 kgf/mm

Feed pump
Max. operating pressure

152

3.4 kgf/cm2

Piston spring

k=0.735 kgf/mm

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58T : EATEA
Check

Rack position

Pump speed

Injection Q`ty on RIG


3

Pressure

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

8.8

1,100

73.5 1.5

9.1

800

9.4 1.3

6.7

415

(63)

100

(43.6) 2

b) DB58T : EATEB
Check

Rack position

Pump speed

Injection Q`ty on RIG

Pressure

Point

(mm)

(rpm)

3
(mm / 1,000st)

(mmHg)

8.8

1,100

73.5 1.5

9.1

800

9.4 1.3

6.7

415

(63)

100

(43.6) 10

c) DB58T : EATED
Check

Rack position

Pump speed

Injection Q`ty on RIG

Pressure

Point

(mm)

(rpm)

(mm3 / 1,000st)

(mmHg)

8.8

1,100

72.0 1.5

9.1

800

9.4 1.3

6.7

415

(62)

100

(42) 10

Pump speed

Injection Q`ty on RIG

Pressure

c) DB58T : EATLA
Check

Rack position

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

8.8

1,100

73.5 1.5

9.1

800

9.4 1.3

6.7

415

(63)

100

(43.6) 10

e) Rack curve and boost pressure of standard injection pump(65.11101-7655)

153

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5) DB58T engine (EATEE/F/G/H/I/EATLB)
(1) Injection pump assembly
: 65.11101-7375 (101605-9720 DOOWON)
- Injection pump
: KP-PES6A95C410RS2000 (101062-8250)
- Governor
: KP-EP/RSV200-1350AQ49A311(105411-1940)
- Plunger and barrel
: 131151-3200, 131100-7900
- Delivery valve
: 131110-4320
- Feed pump
: KP-FP/KS-A (105220-6410)
- Prestroke
: 3.40.05mm
- Coupling
: 156639-7620
(2) Nozzle holder assembly
: 65.10101-7295 (105160-4650 DOOWON)
(3) Nozzle
: 65.10102-6044 (105025-138A DOOWON)
(4) Injection pipe
: 65.10301-6289
(5) Injection order
:153624

(A) Test condition


for injection pump

(B) Engine standard parts

Nozzle & holder assy

Opening pressure :175kg/cm2

105780-8140
-

2.0 x 6.0 600 mm

ISO4113

Temperature : 40 5C

65.10102-6044

Nozzle (5 x 0.27)

65.10101-7295

220 kg/cm2

65.10301-6289

1.8x6.0x580mm

Injection pipe(IDxODxL)
Test oil
Nozzle & holder assy
Injection pipe(IDxODxL)

Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7375)
Check
Point

Rack

Injection Q`ty on RIG

Pump

position speed

(mm3 / 1,000st)
(A) Test condition

Press.
(mmHg)

(B) Engine

(mm)

(rpm)

9.1

1,100

73.5 1.5

5.7

550

9.4 1.3

9.1

800

(63)

68.1

Above 300

9.1-0.25

500

(43.6) 2

58.1

100

65

for inj. pump

standard parts

67.1 2

Above 300

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

9.5 Left hand 20 lead


2,290 rpm

retraction pressure
Delivery valve

opening pressure
Spring

51mm3/st(6x1.8mm)
17.0 kgf/cm2
k=1.78 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

Boost compensator spring

k=0.6 kgf/mm

k=0.005 kgf/mm
-

Feed pump
Max. operating pressure

154

3.4 kgf/cm2

Piston spring

k=0.735 kgf/mm

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58 : EATEE/TEH/TLB
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

A
B
C
D

8.8
9.1
6.7
-

1,100
800
415
100

73.5 1.5
9.4 1.3
(63)
(43.6) 2

Pressure
(mmHg)
Above 300

Above 300

b) DB58 : EATEF
Pressure
(mmHg)

Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

A
B
C
D

8.8
9.1
6.7
-

1,100
800
415
100

73.5 1.5
9.4 1.3
(63)
46.6 10

Pump speed
(rpm)
1,100
800
415
100

Injection Q`ty on RIG


(mm3 / 1,000st)
72.0 1.5
9.4 1.3
(60)
53 10

Pressure
(mmHg)

Pump speed
(rpm)
1,100
800
415
100

Injection Q`ty on RIG


(mm3 / 1,000st)
67.0 1.5
9.4 1.3
(57)
50 10

Pressure
(mmHg)

Above 300

Above 300

c) DB58 : EATEG
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

Above 300

Above 300

d) DB58 : EATEI
Check
Point
A
B
C
D

Rack position
(mm)
8.8
9.1
6.7
-

Above 300

Above 300

e) Rack curve and boost pressure of standard injection pump(65.11101-7374)

155

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) DB58TI engine (EAOEA/D/E/F)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly

: 65.11101-7327 (101605-9880 DOOWON)


: KP-PES6AD100B410R (101062-8260)
: KP-EP/RSV200-1350AQ49A311(105411-2240)
: 131150-2600, 131100-8600
: 131110-5520
: KP-FP/KS-AD (105220-6490)
: 3.80.05mm
: 156639-8820
: 65.10101-7058 (105160-466A DOOWON) : EAOEA/D/E
65.10101-7092 (105160-5420 DOOWON) : EAOEF

(3) Nozzle

: 65.10102-6054 (105025-139A DOOWON) : EAOEA/D/E


65.10102-6064 (105025-4200 DOOWON) : EAOEF

(4) Injection pipe


(5) Injection order

: 65.10301-6072
:153624

Nozzle & holder assy


105780-8140
Opening pressure :175kg/cm2
Injection pipe(IDxODxL)
2.0 x 6.0 600 mm
Test oil
ISO4113
Temperature : 40 5C
Nozzle & holder assy
65.10102-6054
Nozzle (6 x 0.235)
(EAOEA/D/E)
65.10101-7058
185 kg/cm2
(B) Engine standard parts
Nozzle & holder assy
65.10102-6064
Nozzle (7 x 0.22)
(EAOEF)
65.10101-7092
200 kg/cm2
Injection pipe(IDxODxL)
65.10301-6072
1.8x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7327)
(A) Test condition
for injection pump

Rack
Pump
Check
position speed
Point
(mm)
(rpm)

A
B
C
E

R1(9.8)

6.9
(R1)
-

Injection Q`ty on RIG


(mm3 / 1,000st)
(A) Test condition
for inj. pump

97.5 1.5
22.0 1.5
(63)
70 0+10

1,000
550
750
100

(B) Engine
standard parts

Press.
(mmHg)

80.7 2
86.4

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight
Governor spring
Idling spring
Boost compensator spring

740 g
k=10 kgf/mm
k=2.6 kgf/mm
k=0.6 kgf/mm

Lever ratio (min. speed / max. speed)


Idling sub spring
Start spring
-

1 : 1.2 / 1 : 1.2
k=2.1 kgf/mm
k=0.005 kgf/mm
-

3.4 kgf/cm2

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

156

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58TI : EAOEA/OED
Check

Rack position

Pump speed

Injection Q`ty on RIG


3

Pressure

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

8.8

1,100

97.5 1.5

9.1

800

22.0 1.5

6.7

415

(93.5)

100

75 5.0

b) DB58TI : EAOEE
Check

Rack position

Pump speed

Injection Q`ty on RIG

Pressure

Point

(mm)

(rpm)

3
(mm / 1,000st)

(mmHg)

8.8

1,100

104.5 1.5

9.1

800

22.0 1.5

6.7

415

(100)

100

75 5.0

c) Rack curve of standard injection pump(65.11101-7374)


Rack curve

157

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
7) DB58TI engine (EAOEB/OEC)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe
(5) Injection order

: 65.11101-7374 (101605-983X DOOWON)


: KP-PES6AD100B410R (101062-8260)
: KP-EP/RSV200-1350AQ49A311(105411-2240)
: 131150-2600, 131100-8600
: 131110-5520
: KP-FP/KS-AD (105220-6490)
: 3.80.05mm
: 156639-8820
: 65.10101-7058 (105160-466A DOOWON)
: 65.10102-6054 (105025-139A DOOWON)
: 65.10301-6072
:153624

105780-8140
Opening pressure :175kg/cm2
2.0 x 6.0 600 mm
ISO4113
Temperature : 40 5C
65.10102-6054
Nozzle (5 x 0.28)
Nozzle & holder assy
(B) Engine standard parts
65.10101-7058
185 kg/cm2
Injection pipe(IDxODxL)
65.10301-6289
1.8x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7374)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
E

Rack

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

95.0 1.5
22.0 1.5
(85.0)
77 +10
5

9.6
6.9

1,100
550
R1(9.6)
500
100

Press.
(mmHg)

(B) Engine
standard parts

80.8 2

Above 350

76.7

Above 350

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

Boost compensator spring

k=0.6 kgf/mm

k=0.005 kgf/mm
-

Feed pump
Max. operating pressure

158

3.4 kgf/cm2

Piston spring

k=0.735 kgf/mm

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58TI : EAOEB
Check

Rack position

Pump speed

Injection Q`ty on RIG


3

Pressure

Point

(mm)

(rpm)

(mm / 1,000st)

(mmHg)

9.6

1,100

95.0 1.5

Above 350

6.9

550

22.0 1.5

R1(9.6)

500

(85.0)

Above 350

100

77

b) DB58TI : EAOEC
Check

Rack position

Pump speed

Injection Q`ty on RIG

Pressure

Point

(mm)

(rpm)

3
(mm / 1,000st)

(mmHg)

9.6

1,100

97.0 1.5

Above 350

6.9

550

22.0 1.5

R1(9.6)

500

(87.0)

Above 350

100

77

c) Rack curve and boost pressure of standard injection pump (65.11101-7374)


Rack curve

Boost pressure

159

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
8) DB58TI engine (EAOLA/OLB)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe:
(5) Injection order:

: 65.11101-7353 (101609-9130 DOOWON)


: KP-PES6AD100B410R (101062-8260)
: KP-EP/RSV200-1350AQ49A311(105411-2350)
: 131150-2600, 131100-8600
: 131110-5520
: KP-FP/KS-AD (105220-6490)
: 3.80.05mm
: 156639-8820
: 65.10101-7058 (105160-466A DOOWON)
: 65.10102-6054 (105025-139A DOOWON)
: 65.10301-6072
:153624

105780-8140
Opening pressure :175kg/cm2
2.0 x 6.0 600 mm
ISO4113
Temperature : 40 5C
65.10102-6054
Nozzle (5 x 0.28)
Nozzle & holder assy
(B) Engine standard parts
65.10101-7058
185 kg/cm2
Injection pipe(IDxODxL)
65.10301-6072
1.8x6.0x580mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7353)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D
E

Rack

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

88 1.5
22.0 2.0
(92.0)
(72.0) 2.0
80.010

9.2
7.0

1,100
488
R1(9.8)
750
R1-0.6
550
100

Press.

(B) Engine

(mmHg)

standard parts

71.5 2

Above 500

83.4

Above 500

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

Angleich spring

k=5.4 kgf/mm

Boost compensator spring

3.4 kgf/cm2

Piston spring

k=0.005 kgf/mm
k=0.6 kgf/mm

Feed pump
Max. operating pressure

160

k=0.735 kgf/mm

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58TIS : EAOLA/OLB
Check
Point

A
B
C
D
E

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

9.2

1,100
488
750
550
100

88 1.5
22 2.0
(92)
(72) 2.0
8010

7.0

R1(9.8)
R1-0.6
-

Pressure
(mmHg)
Above 500

Above 500

b) Rack curve and boost pressure of standard injection pump (65.11101-7353)


Rack curve

Boost pressure

161

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
9) DB58TIS engine (ECOEA/OEB)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe:
(5) Injection order:

: 65.11101-7391 (101605-830A DOOWON)


: KP-PES6AD100B410R (101062-826A)
: KP-EP/RSV200-1350AQ49A311(105411-2340)
: 131150-2600 131100-8600
: 131160-3620
: KP-FP/KS-AD (105220-6490)
: 3.80.05mm
: 156639-882C
: 65.10101-7092 (105160-5420 DOOWON)
: 65.10102-6064 (105025-4200 DOOWON)
: 65.10301-6088, 65.10301-6089
:153624

Opening pressure :175kg/cm2


2.0 x 6.0 600 mm
Temperature : 40 5C
Nozzle (7 x 0.22)
Nozzle & holder assy
(B) Engine standard parts
190 kg/cm2
Injection pipe(IDxODxL) 65.10301-6088,6089
1.8x6.0x912mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7391)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D
E

Rack

105780-8140
ISO4113
65.10102-6064
65.10101-7092

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

112 1.5
22 2.0
(103)
(84)
9510

R1(10.6) 1,000

6.7
6.7
(R1-0.9)

550
550
550
100

Press.

(B) Engine

(mmHg)

standard parts

92
Above 400

82

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

k=0.005 kgf/mm

Boost compensator spring

k=0.6 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

162

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58TIS : ECOEA
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

Pressure
(mmHg)

A
B
C
D
E

R1(10.6)

1,000
550
550
550
100

112 1.5
22 2.0
(103)
(84)
9510

Above 400

6.7
6.7

(R1-0.9)

b) DB58TIS : ECOEB
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

Pressure
(mmHg)

A
B
C
D
E

R1(10.6)

1,000
550
550
550
100

105 1.5
22 2.0
(96)
(81)
9510

6.7
6.7

(R1-0.9)

Above 400

c) Rack curve and boost pressure of standard injection pump (65.11101-7391)


Rack curve

Boost pressure

163

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
10) DB58TIS engine (ECOEC/D/E/F/G)
(1) Injection pump assembly
: 65.11101-7389A (101605-810A DOOWON)
- Injection pump
: KP-PES6AD100B410R (101062-826A)
- Governor
: KP-EP/RSV200-1350AQ49A311(105411-2240)
- Plunger and barrel
: 131150-2600, 131100-8600
- Delivery valve
: 131110-5520
- Feed pump
: KP-FP/KS-AD (105220-6490)
- Prestroke
: 3.80.05mm
- Coupling
: 156639-882C
(2) Nozzle holder assembly
: 65.10101-7091 (105160-5330 DOOWON)
(3) Nozzle
: 65.10102-6061 (105025-4000 DOOWON)
(4) Injection pipe:
: 65.10301-6088, 65.10301-6089
(5) Injection order:
:153624

(A) Test condition


for injection pump

(B) Engine standard parts

Nozzle & holder assy

Opening pressure :175kg/cm2

105780-8140
-

2.0 x 6.0 600 mm

ISO4113

Temperature : 40 5C

65.10102-6061

Nozzle (6 x 0.235)

65.10101-7091

190 kg/cm2

Injection pipe(IDxODxL)
Test oil
Nozzle & holder assy

Injection pipe(IDxODxL) 65.10301-6088,6089

1.8x6.0x912mm

Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7389)
Power
Check
Point

Rack

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

109 1.5

R1(10.3) 1,100

Press.

(B) Engine

(mmHg)

standard parts

85.8 2

6.6

600

22 2.0

R1

500

(97)

95.2

(R1-1.5)

500

(61)

69.9

100

9610

Above 450

Above 450

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

k=0.005 kgf/mm

Boost compensator spring

k=0.6 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

164

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack diagram and setting valve at each point
a) DB58TIS : ECOEC
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

A
B
C
D
E

R1(10.3)

1,100
600
500
500
100

109 1.5
22 2.0
(97)
(61)
9610

6.6
R1

(R1-1.5)

Pressure
(mmHg)
Above 450

Above 450

b) DB58TIS : ECOED
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

A
B
C
D
E

R1(10.3)

1,100
600
500
500
100

91 1.5
22 2.0
(81)
(53)
9610

6.6
R1

(R1-1.5)

Pressure
(mmHg)
Above 450

Above 450

c) DB58TIS : ECOEE
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

A
B
C
D
E

R1(10.3)

1,100
600
500
500
100

113 1.5
22 2.0
(101)
(61)
9610

6.6
R1

(R1-1.5)

Pressure
(mmHg)
Above 450

Above 450

d) DB58TIS : ECOEF
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


3
(mm / 1,000st)

A
B
C
D
E

R1(10.3)

1,100
600
500
500
100

95 1.5
22 2.0
(84)
9610

6.6
R1

(R1-1.5)

Pressure
(mmHg)
Above 450

Above 450

e) DB58TIS : ECOEG
Check
Point

Rack position
(mm)

Pump speed
(rpm)

Injection Q`ty on RIG


(mm3 / 1,000st)

A
B
C
D
E

R1(10.3)

1,100
600
500
500
100

111 1.5
22 2.0
(99)
(61)
9610

6.6
R1

(R1-1.5)

Pressure
(mmHg)
Above 450

Above 450

f) Rack curve and boost pressure of standard injection pump(65.11101-7389)

165

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
11) DB58TIS engine (ECOLA)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe:
(5) Injection order:

: 65.11101-7392 (101605-840A DOOWON)


: KP-PES6AD105B410RS2 (101061-882B)
: KP-EP/RSV200-1350AQ49A311(105411-224A)
: 131151-2700 131100-7800
: 131110-8820
: KP-FP/KS-ADS (105210-5280)
: 4.3 0.05mm
: 156639-8820
: 65.10101-7092 (105160-5420 DOOWON)
: 65.10102-6064 (105025-4200 DOOWON)
: 65.10301-6088, 65.10301-6089
:153624

Opening pressure :175kg/cm2


2.0 x 6.0 600 mm
Temperature : 40 5C
Nozzle (7 x 0.22)
Nozzle & holder assy
(B) Engine standard parts
185 kg/cm2
1.8x6.0x912mm
Injection pipe(IDxODxL) 65.10301-6088,6089
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7392)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D
E

Rack

105780-8140
ISO4113
65.10102-6061
65.10101-7091

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

128 1.5
20 1.5
(130)
(95)
11010

R1(10.6) 1,100

6.8
R1
(R1-1.6)

550
550
1,100
100

Press.

(B) Engine

(mmHg)

standard parts

88 2

Above 450

Above 450

86

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10.5 Left hand 20+40 lead

1970 rpm

retraction pressure
Delivery valve

opening pressure
Spring

70mm3/st(6x2.5mm)
t=0.11mm
23.1 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

k=0.005 kgf/mm

Boost compensator spring

k=0.35 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

166

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
(6) Rack curve
a) Rack curve and boost pressure of standard injection pump(65.11101-7392)
Rack curve

Boost pressure

167

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
12) DB58TIS engine (ECOLB)
(1) Injection pump assembly
- Injection pump
- Governor
- Plunger and barrel
- Delivery valve
- Feed pump
- Prestroke
- Coupling
(2) Nozzle holder assembly
(3) Nozzle
(4) Injection pipe:
(5) Injection order:

: 65.11101-7390 (101605-820A DOOWON)


: KP-PES6AD100B410R (101062-8260)
: KP-EP/RSV200-1350AQ49A311(105411-2350)
: 131150-2600, 131100-8600
: 131110-5520
: KP-FP/KS-AD (105220-6490)
: 3.80.05mm
: 156639-882C
: 65.10101-7091 (105160-5330 DOOWON)
: 65.10102-6061 (105025-4000 DOOWON)
: 65.10301-6088, 65.10301-6089
:153624

Opening pressure :175kg/cm2


2.0 x 6.0 600 mm
Temperature : 40 5C
Nozzle (6 x 0.235)
Nozzle & holder assy
(B) Engine standard parts
190 kg/cm2
Injection pipe(IDxODxL) 65.10301-6088,6089
1.8x6.0x912mm
Rack diagram and setting valve at each point : Specification of standard pump(65.11101-7390)
(A) Test condition
for injection pump

Nozzle & holder assy


Injection pipe(IDxODxL)
Test oil

Check
Point

A
B
C
D
E

Rack

105780-8140
ISO4113
65.10102-6061
65.10101-7091

position speed
(mm)

Injection Q`ty on RIG

Pump
(rpm)

(mm3 / 1,000st)
(A) Test condition
for inj. pump

97 1.5
22 2.0
(92)
(58)
7210

9.8
6.8

1,100
550
R1(10.1) 600
(R1-1.5)
600
100

Press.

(B) Engine

(mmHg)

standard parts

76.6 2

Above 500

97

Above 500

Boost pressure : zero boost


Fuel injection pump
Plunger
Max. pump speed
(limit plunger bouncing)
Holder delivery valve
with damping valve

10 Left hand 20+50 lead

2,100 rpm

Retraction pressure
Delivery valve

opening pressure
Spring

59mm3/st(6x2.1mm)
20.8 kgf/cm2
k=1.63 kgf/mm

Governor
Governor weight

740 g

Lever ratio (min. speed / max. speed)

1 : 1.2 / 1 : 1.2

Governor spring

k=10 kgf/mm

Idling sub spring

k=2.1 kgf/mm

Idling spring

k=2.6 kgf/mm

Start spring

k=0.005 kgf/mm

Boost compensator spring

k=0.6 kgf/mm

Piston spring

k=0.735 kgf/mm

Feed pump
Max. operating pressure

168

3.4 kgf/cm2

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
(6) Rack curve and boost pressure of standard injection pump(65.11101-7390)
Rack curve

Boost pressure

169

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
13) Injection pump

170

1. Pump housing
2. Cover assembly
3. Bolt, cover
4. O-ring
5. Gasket
16. Screw, plug
18. Bolt, stud
20. Spring washer
21. Nut
23. O-ring
30. Plunger
36. Delivery valve
37. Delivery valve spring
40. Delivery valve holder
45. Lock plate assembly
49. O-ring
55. Tappet

56. Shim
61. Plunger spring
62. Seat, spring(upper)
63. Seat, spring(lower)
67. Control rack
68. Stop bolt
76. Pinion
77. Sleeve
78. Bolt
90. Camshaft
91.91a. Taper roller bearing
92.92a Camshaft ring
93.93a. Shim
95. Center bearing
101a. Bearing cover
104a Bolt
112a. Woodruf key

115a. Adapter

196. Nut

117a. Connection bolt


118a. Gasket
121. Plug screw
122. Gasket
130. Connect
130a. Adapter
131a. Bolt
132a. Gasket
133a. Gasket
145. Plug screw
146 Gasket
152. Connection bolt
154. Packing
191. Bracket
192. O-ring
194. Washer
195. Spring washer

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
14) Governor

1. Governor housing
4. Plate
6. Adapter
7. Bolt
9. Spring
10. Bolt
13. Nut
19. Adapter
20. Bolt
21. Gasket
35. Governor cover
38. Tension lever bolt
39. Nut
44. Stop bolt
46. Cap
47. Plug
48. Adjusting bolt
49. Nut
50. Stop bolt
51. Bolt
52. Bolt

171

80. Cover
82. Bolt
83. Bolt
100.Fly wheel
101. Woodruf key
102. Spring washer
103. Nut
117. Sleeve
118. Shim
130. Governor spring
132. Starting spring
136. Nut
137. Gasket
138. Cap
140. Idle spring
141. Nut
150. Speed setting lever
170. Guide lever
173. Split pin
174. Floating lever link
181. Tension lever

182. Lever shaft


183. Collar
190. Control lever
192. Nut
195. Return spring
198. Spring washer
201. O-ring
202. Bush
203. Shim
205. Shaft lever
207. Support lever
211. Snap ring
220. Damper spring
236. Gasket
239. Gasket
240. Lead seal
241. Wire, lead seal
255. Bracket
331. Angleich spring
332. Connection nut

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.4. Turbocharger
5.4.1. Main data and specifications
1) Main data and specifications
Specification

DB58T

DB58TI

DB58TIS

HOLSET
3539678

HOLSET
3539678

HOLSET
3598337

Air pressure
at compressor outlet

1.3 kg/cm2

1.50 kg/cm2

1.70 kg/cm2

Air suction volume

11.5 m3/min

12.5 m3/min

13.5 m3/min

95,00 rpm

100,000 rpm

105,000 rpm

127,500 rpm

127,500 rpm

127,500 rpm

750 C

750 C

External oil supply

External oil supply

External oil supply

9.7 kg

9.7 kg

9.7 kg

Turbocharger Model

at
maximum
output

Speed of turbine revolution


Maximum allowable speed
Max. allowable temperature of exhaust
gas at turbine inlet
Lubricating system
Weight

750 C

2) Construction

1. Impeller casing
2. Turbine casing
3. Bearing casing
4. Impeller
5. Turbine
172

A. Air inlet
B. Gas outlet
C. Gas inlet
D. Oil supply
E. Oil return

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Construction

173

Bearing housing

32

O-ring

67

Hex bolt

Turbine housing

33

Oil baffle

74

Actuator ass`y

Turbine wheel ass`y

34

Inlet baffle

75

Hose clamp

Compressor wheel

36

Thrust collar

77

Actuator clip

Compressor housing

38

Heat protector cover

80

Cover plate

11

Journal bearing

43

Oil seal plate

81

Hose

12

Thrust bearing

46

Gasket

82

Elbow

13

Piston ring seal(turbine)

57

Hex bolt

83

Hex nut

16

Piston ring seal

61

Lock nut

88

Clamp plate

22

Retainer ring

64

Snap ring

91

Retaining ring

31

Oil stopper

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Operating principle
The turbocharger is a system designed to make use of the engine exhaust gas
energy to charge high-density air into the cylinders, thereby to increase the engine
output.

5.4.2. General descriptions


The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine, the
volume of air enough to burn the fuel completely should be supplied into the cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and
a greater volume of compressed air is charged into cylinders of given capacity, the
greater engine output can be obtained as a greater volume of air charged into the
cylinders burns so much more fuel.
As explained, the compressing of air to supply into the cylinders is called
"Supercharging" and the making use of the energy of exhaust gas discharged from the
combustion chamber to charge the compressed air into the cylinders is called
"Turbocharging".
5.4.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy to
the turbine blades while passing the inside of the turbine housing, with the result
that the turbine shaft can get rotating force. This is the operating principle of 'turbine',
which is mounted with seal rings and heat protector to prevent exhaust gas from
affecting the bearings adversely.

174

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) Compressor
The compressor, which is connected to the turbine over the one and same shaft to
form a rotating body, takes in and compresses ambient air with rotating force
transmitted from the turbine shaft. Then, the compressed air is delivered to the
intake stake. This is the operating principle of the compressor.
3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the shaft
is not deviated from its the original position due to this thrust.
(2) Journal bearing
This journal bearing of floating type forms a dual oil film on both the inside and
outside of the bearing so that the bearing can rotate independently. As the dual oil
film plays a role as a damper, the sliding speed of the bearing surface becomes
lower than the rotating speed of the shaft, resulting in assurance of stability in its
movement.
4) Sealing-compressor shaft
The compressor is of a dual construction type composed of seal plate and seal ring
to prevent the leak of compressed air or lubricating oil.
5.4.4. Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or stopping
the engine:
Operations
Precautions
Reasons
When starting
the engine

1) Check oil level


2) Crank the engine with starter to 2) Abrupt starting of the engine
check the increase in oil
causes the engine to rotate with
oil not being distributed not only
pressure(until the needle of
to each part but also to the
pressure gauge starts to move or
pressure indicator lamp is
turbocharger,
resulting
in
abnormal wear or seizure on the
actuated) before starting the
bearing due to insufficient supply
engine.
of oil.
3) When having replaced oil, oil 3) In the case of the engine stopped
filter element, or lubricating
for extended time or in a cold
parts, or when having stopped
place, oil fluidity within the
the engine for extended period of
pipes can be deteriorated
time, or in a cold place, loosen
the oil pipe connections and
operate the starter motor until oil
is discharged. After completing

175

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
the operation, be sure to retighten
the oil pipe connections portion
before starting the engine.
Immediately
after starting

1) Run the engine at idle for 5 1) Applying load abruptly If load is


minutes after starting off.
abruptly applied with the engine
and
turbocharger
rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of 2) Leakage of oil, gas, and air
oil, gas, and air, and take proper
(especially, oil leak) causes drop
measure.
in oil pressure and loss of oil
results in seizure of the bearing.

During operation

Check the followings:


1) Oil pressure At idle: 0.8 kg/cm2 1) Excessively low oil pressure
or more At full load: 3.04.8
causes unusual wear or seizure of
kg/cm2
the bearing. Too high pressure
causes oil leakage.
2) If unusual sound or vibration is 2) The engine Is operated
heard or felt, reduce engine
continuously with unusual sound
or vibration not corrected, it can
revolutions slowly and locate the
cause.
be damaged beyond repair.

When stopping
the engine

1) Run the engine at idle for 5 1) If the engine is put to a stop after
minutes before stopping.
being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.

5.4.5. Walk-around check and servicing


As the condition of turbocharger depends greatly on how well the engine is serviced, it
is very important to maintain the engine in accordance with the specified maintenance
procedure.
1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified,
cleaning effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to
create vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake
resistance as much as possible.

176

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the exhaust
system because leakage of exhaust gas from discharge pipes, turbocharger fixing
portions, etc. lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use
heat resisting steel nuts, do not interchange these nuts with ordinary steel nuts. In
addition, apply anti-seizure coating to fixing nuts on the portions as designated.
3) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing
the lubricating system. Deteriorated engine oil affects adversely not only the engine
but torso the turbocharger. Suggested engine oils for the turbocharger-mounted
engine are as follows:
Engine
model

Recommend oil
SAE No.

API No.

DB58
DB58T
DB58TI

SAE 15W40

above CD or CE

DB58S
DB58TIS

SAE15W40
SAE10W40

ACEA-E2 or ACEA-E3
(API CH-4)

5.4.6. Periodical checking and servicing


Make it a rule to check the turbocharger assembly for condition and contamination
periodically.
1) Guide for checking the rotor for rotating condition
The inspection of the rotor assembly for rotating condition should be performed by
the degree of unusual sound. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch
sound is heard continuously, it means that the rotor assembly is not normal. In this
case, as the metal bearing and rotor are likely to be in abnormal conditions, the
turbocharger should be replaced or repaired.
2) Guide for checking rotor end play
Disassemble the turbocharger from the engine, then check the rotor axial play and
radial play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
with taps, etc.

177

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
(1) Rotor axial play

(2) Rotor radial play

(3) If the measured axial and radial plays are beyond the limit of wear, replace or
repair the turbocharger.
3) Guide for disassembling/cleaning and checking the turbocharger
First, disassemble the turbocharger from the engine and clean/check it with the oil
inlet and outlet plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto the engine
For reassembly of the turbocharger or handling it after reassembly operation, be
sure to observe the following precautions:
Especially, exercise extreme care to prevent foreign matters from entering the
inside of the turbocharger.
(1) Lubricating system
z Before reassembling the turbocharger onto the engine, inject new oil in the
oil inlet port and lubricate the journal and thrust bearings by rotating them
with hand .
z Clean not only the pipes installed between the engine and oil inlet port but
also the oil outlet pipe and check them for damage or foreign matters.
z Assemble each joint on oil pipes securely to prevent oil leaks.
178

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
(2) Intake system
z Check the inside of the intake system for foreign matters.
z Assemble each joint on the intake duct and air cleaner securely to prevent
air leaks.
(3) Exhaust system
z Check the inside of the exhaust system for foreign matters.
z Be sure to use heat resisting steel bolts and nuts. Do not interchange them
with ordinary steel bolts and nuts when performing reassembly operation.
Apply anti-seizure coating to the bolts and nuts.
z Assemble each joint on the exhaust pipes securely to prevent gas leaks.
5.4.7. Diagnostics and troubleshooting
Complaints
1. Excessive black smoke

Possible causes

Corrections

1) Air cleaner element clogged

Replace or clean

2) Restrictions in air duct

Check and correct

3) Leakage at intake manifold

Check and correct

4) Turbocharger seized up and not rotating


5) Turbine blades and compressor blades coming in
contact with each other or damaged

Disassemble/repair

1) Oil leak into turbine and compressor

or replace

of bearing
1) Gas leak at each part of exhaust system

Check and correct

2) Air cleaner element restricted

Replace or clean
Disassemble/repair
or replace

4) Leakage at discharge port on compressor side


1) Rotor assembly coming in contact
2) Unbalanced rotation of rotor
3) Seized up
4) Each joint loosened

179

Disassemble/repair
or replace

3) Turbocharger fouled or damaged

4. Unusual sound or
vibration

Disassemble/repair

Check and correct

2) Worn or damaged seal ring due to excessive wear

3. Low engine output

or replace
or replace

6) Exhaust piping deformed or clogged

2. Excessive white smoke

Disassemble/repair

Check and correct


Disassemble/repair
or replace
Disassemble/repair
or replace
Disassemble/repair
or replace
Check and correct

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.5. Air Intake System
5.5.1. Maintenance
(only when engine is switched off)
Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway
with dust.
On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover
(6) of the dust bowl and empty.
Be careful to assemble cover and bowl correctly.
There is a recess in the cover rim and a lug on the collector which should register.
Where the filter is installed horizontally, watch for top mark on cleaner bowl.

1. Connection port,
fouling indicator
2. Cleaner housing
3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl

5.5.2. Changing filter element


z On removing the hexagon nut, take
out the dirty cartridge and renew or
clean.
z Wipe the cleaner housing with a
damp cloth, in particular the sealing
surface for the element.

NOTE:
Do not allow dirt to get into the
clean air end.

180

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
5.5.3. Cleaning filter elements
z By compressed air
(wear goggles)
- For the purpose, the air gun should
be fitted with a nozzle extension
which is bent 90 at the discharge
end and which is long enough to
reach down inside to the bottom of
the element.
- Moving the air gun up and down,
blow out the element from the
inside (maximum 500kPa - 5 bar)
until no more dust comes out of the filter pleats.
z By washing
- Before washing, the element should
be precleaned by means of
compressed air, as described
above.
- Then allow the element to soak in
lukewarm washing solvent for 10
minutes, and then move it to and
for in the solvent for about 5
minutes.
- Rinse thoroughly in clean water, shake out and allow drying at room temperature.
The cartridge must be dry before it is reinstalled.
- Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean
the filter elements.
z Knocking out dirt by hand
- In emergencies, when no compressed air or cleaning agent is available, it is
possible to clean the filter cartridge provisionally by hitting the end disk of the
cartridge with the ball of one's thumb.
- Under no circumstances should the element be hit with a hard object or knocked
against a hard surface to loosen dirt deposits.
z Checking the filter cartridge
- Before reinstalling the cartridge, it
must be checked for damage e.g.
to the paper pleats and rubber
gaskets, or for bulges and dents
etc. in the metal jacket.
- Cracks and holes in the paper
pleating can be established by
inspecting the cartridge with a
flashlight.
- Damaged cartridges should not be reused under any circumstances. In cases of
doubt, discard the cartridge and install a new one.
181

Maintenance of major components


Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

6. Special Tool List


No.

182

Part No.

Figure

Tool Name

EU.2-0529

Compression gauge adapter

EF122-249

Valve spring compressor

EF.122-265

Crankshaft gear punch

EF.122-253

Crankshaft pilot bearing remover

EF.122-251

Pilot bearing punch

EF.122-262A

Crankshaft rear oil seal installer

EF.122-255

Crankshaft front oil seal installer

EF.122-289

Valve stem oil seal installer

Remark

Special tools
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
No.

183

Part No.

Figure

Tool Name

Remark

E1.03901-0124

Piston insert sleeve

10

EF.122-281

Cylinder liner remover

11

EF122-261

Cylinder liner installer

12

EU.1-0022

Pulley bush puncher

13

EU.2-0328

Pulley bush puller

14

60.99901-0027

Feeler gauge

15

T7610001E

Snap ring plier

16

T7621010E

Piston ring plier

Special tools
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual

Appendix
1) Tightening torque for major parts
Major Parts

Screw

Strength

(Diameter x pitch)

(grade)

Tightening
Torque

Remarks

DB58/S/T/TI
1st : 4.4 kg.m
2nd : 150
(Angle method)
Cylinder head bolt

M12 x 1.5

10.9T

DB58TIS
1st : 4.4 kg.m
2nd : 90
3rd 90
(Angle method)

Connecting rod bearing cap bolt

M12 x 1.5

12.9T

9.75 kg.m

Crankshaft main bearing cap bolt

M16 x 2

12.9T

24.0 kg.m

Flywheel housing fixing bolt

M14 x 1.5

10.9T

13 kg.m

M16 x 1.5

10.9T

16 kg.m

Flywheel fixing bolt

M16 x 1.5

10.9T

18 kg.m

Crankshaft pulley fixing nut

M36 x 1.5

8.8T

60 kg.m

M10 x 1.25

2.1 kg.m

Oil spray nozzle hollow screw


(Relief valve assembly)

2) Tightening torque for fuel injection pump system


Screw

Strength

(Diameter x pitch)

(grade)

Tightening
Torque

M28 x 1.5

7.0 kg.m

Injection pump bracket bolt

M10

8.8T

4.4 kg.m

Injection pump coupling bolt

6.0 ~ 6.5 kg.m

Injection pump driving gear nut

M24 x 1.5

8.8T

25.0 kg.m

Injection pipe nut

M14 x 1.5

8.8T

3.0 kg.m

11.0 ~ 12.0 kg.m

Major Parts
Injection nozzle nut

Injection pump delivery valve holder

Remarks

184
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
3) Standard bolt tightening torque table
Refer to the following table for bolts other then described above
Degree of strength
Diameter
x
pitch
(mm)

3.6

4.6

4.8

5.6

5.8

6.6

6.8

(4A)

(4D)

(4S)

(5D)

(5S)

(6D)

(6S)

6.9

8.8

10.9

12.9

(6G) (8G)

(10K)

(12K)

64

90

108

0.5
0.9
1.4
2.2
2.4
4.4
5
7.5
8
12
13
18
20
25
28
36
41
49
56
63
74

0.75
1.25
1.95
3.1
3.35
6.2
7
10.5
11.2
17
18.5
26
28
36
41
51
58
67
75
82
93

0.9
0.5
2.35
3.8
4.1
7.4
8.4
12.5
13.4
20
22
31
33
43
49
60
68
75
85
92
103

Limit value for elasticity (kg/mm2)


20

24

32

30

40

36

48

54

Tightening torque (kg.m)


M5
M6
M7
M8
M8x1
M10
M10x1
M12
M12x1.5
M14
M14x1.5
M16
M16x1.5
M18
M18x1.5
M20
M20x1.5
M22
M22x1.5
M24
M24x1.5

0.15
0.28
0.43
0.7
0.73
1.35
1.5
2.4
2.55
3.7
4.1
5.6
6.2
7.8
9.1
11.5
12.8
15.5
17
20.5
23

0.16
0.30
0.46
0.75
0.8
1.4
1.6
2.5
2.7
3.9
4.3
6
6.5
8.3
9.5
12
13.5
16
18.5
21.5
25

0.25
0.45
0.7
1.1
1.2
2.2
2.5
3.7
4
6
6.6
9
9.7
12.5
14.5
18
20.5
24.5
28
33
37

0.22
0.4
0.63
1
1.1
1.9
2.1
3.3
3.5
5.2
5.7
8
8.6
11
12.5
16
18
21
24
27
31

0.31
0.55
0.83
1.4
1.5
2.7
3.1
4.7
5
7.5
8.3
11.5
12.5
16
18.5
22
25
30
34
40
45

0.28
0.47
0.78
1.25
1.34
2.35
2.8
4.2
4.6
7
7.5
10.5
11.3
14.5
16.7
19
22.5
26
29
34
38

0.43
0.77
1.2
1.9
2.1
3.7
4.3
6.3
6.8
10
11.1
17.9
17
21
24.5
31.5
35
42
47
55
61

0.48
0.85
1.3
2.1
2.3
4.2
4.9
7.2
7.7
11.5
12.5
18.5
19.5
24.2
27.5
35
39.5
46
52
58
67

Others :
1. The above torque rating have been determined to 70% or so of the limit value for
bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the
standard value.

4) Tightening torque for hollow screw(4-hole)


Material

SM25C
SUM22L

STS304

M8
0.8
0.8

M10
1.6
1.8
1.8

M12
2.5
3.0
3.0

M14
3.5
4.0
4.0

M16
4.5
5.5
5.5

M18
5.5
6.5
6.5

M22
9.0
11.0
11.0

M26
13.0
16.0
16.0

M30
18.0
20.0
20.0

M38
30.0
35.0
35.0

: Adopted in DAEWOO engine


185
Printed in Jan. 2003 PS-MMA0300-E1A

5) Engine assembly DB58-Fork lift RFJ


a) DB58-Fork lift : EARFJ

186

b) DB58T- Excavator : EATEI

187

c) DB58TI Excavator : EAOLB

188

d) DB58TIS Excavator : ECOEB

189

e) DB58TIS Excavator : ECOEG

190

z Parts Center
z Applications for Daewoo Engine
z Worldwide Network

Parts center
85-1 Palgok Ei-dong, Sangnok-gu Ansan-shi Kyunggi-do, Korea
Tel. : 82-31-400-2206
Fax. : 82-31-400-2255
http://www.dhiltd.co.kr , http://cs.dhiltd.co.kr

Applications for Daewoo Engine

Automotive & Industrial Engines


Power
kW(PS)/rpm

Model

For
Vehicle

For
Industrial

Marine Propulsion Engines


Power
kW(PS)/rpm

Model

D1146
D1146TI
DE08TIS
GE08TI
DE12
DE12T

133(181)/2,500
158(215)/2,200
176(240)/2,300
191(260)/2,300
169(230)/2,200
220(300)/2,200

DE12TI
DE12TIS
GE12TI
DV15T
DV15TI
DV15TIS

250(340)/2,100
250(340)/2,100
250(340)/2,100
272(370)/2,300
309(420)/2,100
309(420)/2,100

DC23
DC24
DC24T
DB33
DB33A
DB58
DB58S
DB58T
DB58TI

37(50)/3,000
41(56)/3,000
41(55)/2,600
53(72)/3,000
46(63)/2,300
96(130)/2,800
75(102)/2,200
104(142)/2,500
112(152)/2,200

D1146
D1146T
D1146TI
DE08TIS
DE12T
DE12TI
DE12TIS
DV15T

115(156)/2,200
140(190)/2,200
162(220)/2,200
151(205)/1,900
188(255)/2,000
213(290)/2,000
238(323)/2,000
238(324)/2,300

Model

L034
L034TIH
MD136
MD136T
MD136TI
L086TIH
L086TIM
MD196T
MD196TI

Power kW(PS)/rpm

Model

51(70)/3,000
88(120)/3,000
118(160)/2,200
147(200)/2,200
169(230)/2,200
210(285)/2,100
232(315)/2,300
206(280)/2,000
235(320)/2,000

Power kW(PS)/rpm

L126TIH
L126TIM
V158TIH
V158TIM
V180TIH
V180TIM
V222TIH
V222TIM

265(360)/2,000
294(400)/2,100
353(480)/1,800
397(540)/2,100
441(600)/1,800
478(650)/2,100
530(720)/1,800
588(800)/2,100

Generator Set Engines (G-Drive & G-Pac)


Power (Output ISO 3046)
Model

@ 1,800rpm
Power (Stand-by)

DC23-2
DC23-1
DC23
DC24
DC24T
DB33
P034TI
DB58
D1146
D1146T
P086TI-1
DE12T

Power(Output ISO 3046)

@ 1,500rpm

Power (Prime) Power (Stand-by)

Model

@ 1,800rpm

@ 1,500rpm

Power (Prime)

Power (Stand-by)

Power (Prime)

Power (Stand-by)

kW(PS)

kW(PS)

kW(PS)

kW(PS)

kW(PS)

kW(PS)

kW(PS)

kW(PS)

13(17)
18(25)
24(33)
25(34)
32(43)
35(47)
60(82)
70(95)
105(143)
138(187)
191(303)
199(270)

11(15)
17(23)
22(30)
23(31)
29(39)
32(43)
55(75)
64(87)
96(130)
125(170)
174(279)
180(245)

15(11)
16(22)
19(26)
21(28)
26(36)
29(39)
48(65)
59(80)
85(116)
118(160)
164(270)
166(226)

14(10)
15(20)
18(24)
18(25)
24(32)
26(35)
42(57)
54(73)
77(105)
107(145)
149(420)
151(205)

205(237)
262(356)
278(378)
329(447)
366(498)
402(547)
454(617)
497(676)
563(765)
591(803)

199(223)
272(370)
321(437)
362(492)
414(563)
442(601)
496(674)
552(750)
574(781)

177(203)
241328)
293(399)
327(444)
363(494)
403(548)
443(602)
496(675)
532(723)

P086TI
P126TI-1
P126TI
P126TI-2
P158LE-2
P158LE-1
P158LE
P180LE-1
P180LE
P222LE-1
P222LE

223(260)
288(392)
298(405)
342(465)
361(491)
402(546)
443(602)
498(677)
540(734)
625(850)
649(883)

Power (Prime)

Marine Auxiliary Engines


Model

Power
(Output ISO 3046)

Model

kW(PS) @ 1,500rpm

AD034F
AD136F
AD136TIF
AD196TF
AD126TIF
AD180TIF

26(35)
77(105)
121(165)
155(210)
206(280)
357(485)

Power
(Output ISO 3046)

Model

kW(PS) @ 1,500rpm

AD034TIF
AD136TF
AD086TIF
AD196TIF
AD158TIF
AD222TIF

42(57)
107(145)
151(205)
173(235)
302(410)
446(606)

Power
(Output ISO 3046)

Model

kW(PS) @ 1,800rpm

AD034S
AD136S
AD136TIS
AD196TS
AD126TIS
AD180TIS

32(43)
93(126)
143(195)
181(246)
247(336)
441(600)

Power
(Output ISO 3046)
kW(PS) @ 1,800rpm

AD034TIS
AD136TS
AD086TIS
AD196TIS
AD158TIS
AD222TIS

55(75)
125(170)
186(253)
199(270)
353(480)
530(720)

Generator Sets

Marine Generator Sets

Generator Set Model


Power
(Stand-by)

Power
(Prime)

Power (kW/kVA)

Suffix

Engine
Model

1800rpm(60Hz)
Power
(Stand-by)

kW/kVA

Power
(Prime)

kW/kVA

Power (kW/kVA)

1500rpm(60Hz)
Power
(Stand-by)

kW/kVA

Power
(Prime)

Engine
Model

Generator Set

kW/kVA

1800rpm(60Hz)
Power (Prime)

1500rpm(60Hz)
Power (Prime)

kW/kVA

kW/kVA

PNM

DB33

24/30

20/25

PNB

AD034TI

50/63

36/45

PNJ

AD136

80/100

68/85

PNK

AD136T

104/130

96/120

PND

DW10E

DW10

PIG

DC23-2

10/13

9/11

9/11

8/10

DW15E

DW15

PIH

DC23-1

15/19

14/17

13/17

12/15

DW20E

DW20

PIF

DC23

20/25

18/23

16/20

14/18

PJF

DC24

20/25

18/23

16/20

14/18

AD136TI

132/165

108/135

PNE

AD086TI

172/215

136/170

DW26E

DW26

PII

DC24T

26/33

24/30

22/27

20/24

PNL

AD196TI

176/220

160/200

PJM

DB33

26/33

24/30

22/27

20/25

PNI

AD126TI

224/280

192/240

DW50E

DW50

PIA

P034TI

50/63

45/56

40/50

36/45

PNZ

AD158TI

328/410

276/345

DW60E

DW60

PJB

DB58

60/75

55/69

48/60

44/55

PNS

AD180TI

400/500

332/415

DW85E

DW85

PJJ

D1146

85/106

77/96

70/88

64/80

PNY

AD222TI

500/625

408/510

DW115E

DW115

PJK

D1146T

115/144

105/131

101/126

92/115

DW170E

DW170

PIE

P086TI-1

170/212

155/194

145/181

132/165

PJE

DE12T

170/213

155/194

145/181

132/165
160/200

DW200E

DW200

PIL

P086TI

200/250

182/228

176/220

DW260E

DW260

PIW

P126TI-1

260/325

235/294

DW275E

DW275

PIQ

P126TI

275/344

250/313

242/303

220/275

DW320E

DW320

PIZ

P158LE-2

320/400

290/362

282/353

256/320

DW360E

DW360

PIS

P158LE-1

360/450

327/409

320/400

288/360

DW400E

DW400

PIY

P158LE

400/500

364/455

370/463

320/400

DW450E

DW450

PIO

P180LE-1

450/563

409/511

396/495

360/450

DW500E

DW500

PIM

P180LE

500/625

445/556

440/550

400/500

DW600E

DW600

PIN

P222LE

600/750

541/676

528/660

480/600

Power Units
Model

PU024
PU024T
PU034
PU066

Power
kW(PS)/rpm

32(44)/2,800
40(55)/2,600
50(68)/3,000
85(116)/2,800

Model

PU086
PU086T
PU086TI

Power
kW(PS)/rpm

116(160)/2,200
151(205)/2,200
213(290)/2,200