Documente Academic
Documente Profesional
Documente Cultură
99897-8079
OPERATION and
MAINTENANCE MANUAL
DIESEL ENGINE
DB58
DB58S
DB58T
DB58TI
DB58TIS
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
Reassembly
Directional Indication
Inspection
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.
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
114
115
117
117
119
121
122
124
127
128
128
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
133
137
142
172
180
183
Appendix
WORLDWIDE NETWORK
184
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
(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
DB58/T/TI/TIS
Operation and Maintenance Manual
Performance
Output
(rated)
Torque
(min)
Fuel consumption
DIN 6270B
(min)
104 kW (142PS) /
2,500 rpm
DIN 6270A
90 kW (122PS) /
2,500 rpm
DB58/T/TI/TIS
Operation and Maintenance Manual
Performance
Output
(rated)
Torque
(min)
Fuel consumption
DIN 6270B
(min)
112 kW (152PS) /
2,200 rpm
DIN 6270A
102 kW (138PS) /
2,200 rpm
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)
Torque
(min)
Fuel consumption
DIN 6270B
(rated)
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
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2.
3.
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7.
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9.
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14.
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17.
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18.
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20.
21.
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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
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DB58/T/TI/TIS
Operation and Maintenance Manual
10 11 12
20 21 22
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
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13.
14.
15.
16.
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17.
18.
19.
20.
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22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
29
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General information
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
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1
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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
19
20
21
22
23
24
25
26
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
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2
3
4
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6
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25
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12
13
14
Vibration damper
Oil filter
Oil drain plug
Air pipe
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
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
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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
25
26
General information
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
(4) DB58TIS
17
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2
1
19
15
9
20
10
21
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12 13 14
22
23
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1
2
3
4
5
6
Flywheel housing
Lifting hook
Fuel filter
Intake manifold
Air pipe
7
8
9
Breather
Cooling fan
Oil filter
(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)
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.
<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.
15
Safety regulations
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
z
z
z
16
Safety regulations
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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.
Engine number
DB58 3 00001 FA
Engine suffix(EARFA)
Serial no.
Production year(2003)
Engine model
DB58T 3 00001 EA
Engine suffix(EATEA)
Serial no.
Production year(2003)
Engine model
17
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
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.
Idle gear
(Z = 51)
Camshaft gear
(Z = 50)
Crankshaft gear
(Z = 25)
18
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
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.
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
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.
-
Construction equipments
DB58
DB58T
DB58TI
DB58S
DB58TIS
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.
20
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
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.
Cartridge,
Oil filter
21
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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.
Head,
fuel filter
Cartridge,
fuel filter
23
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DB58/T/TI/TIS
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
D 482
0.01
0.01
D 613
45
45
Distillation
Temperature, ()
IMP, Typican #)
10% Typical #)
50% Typical #)
90% +)
End Point #)
D 86
Gravity, API
#)
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
24
Technical information
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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)
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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
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.
26
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Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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.
27
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Operation and Maintenance Manual
(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.
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)
28
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Operation and Maintenance Manual
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
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.
29
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Operation and Maintenance Manual
5) After reinsuring the valve clearances, retighten if necessary.
z
Cylinder no.
Exhaust valve
Intake valve
Fly wheel
Standard value
Limit value
Difference
between each cylinder
28kg/cm2 over
24kg/cm2
Within 10 %
Technical information
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DB58/T/TI/TIS
Operation and Maintenance Manual
2.13. Injection nozzle
Engine model
220 kg/cm2
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.
31
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Operation and Maintenance Manual
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.
32
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Operation and Maintenance Manual
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Operation and Maintenance Manual
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Operation and Maintenance Manual
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Operation and Maintenance Manual
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Operation and Maintenance Manual
38
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Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
Condition
Causes
Remedies
1) Starting difficult
(1) Compression pressure
Repair or replace
Replace gasket
Adjust
Adjust
Remove air
Adjust
Repair
Replace gasket
Adjust
Adjust or replace
Repair or replace
Repair
z
(2)
Output insufficient
Turbocharger poor
Repair or replace
Disassemble engine
Adjust
Repair or replace
Repair, replace
when in acceleration
improper
z
Repair or replace
Clean or
replace air cleaner
4) Overheating
Replenish or replace
Replenish or replace
Adjust or replace
Repair or replace
Replace
poor
39
Adjust
Clean or replace
Technical information
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DB58/T/TI/TIS
Operation and Maintenance Manual
Condition
5) Engine noisy
Causes
Remedies
(1) Crankshaft
z
z
Replace
bearing
crankshaft
Grind or replace
&
grind
clogging
Stuck bearing
Replace bearing
Grind crankshaft
Repair or replace
Stuck bearing
passage progresses
(3) Piston, piston pin &
piston ring
Replace
Piston stuck
Replace piston
Replace piston
Replace piston
Repair or replace
Adjust
Replace
Correct position
Replace piston
piston ring
(4) Others
40
Replace in set
Replace seal
Replace gasket
Replace packing
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
1st
1st
Fuel
System
Engine
Adjust
Every
2,000hrs
Lubrication
Change the lubricating oil
System
Intake &
Exhaust
System
clean
When
necessary
When
necessary
1st
When
necessary
When
necessary
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
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Operation and Maintenance Manual
2) Cylinder block
(Unit : kg.m)
43
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44
Engine disassembly
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Operation and Maintenance Manual
(Unit : kg.m)
45
Engine disassembly
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46
Engine disassembly
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Operation and Maintenance Manual
47
Engine disassembly
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48
Engine disassembly
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Operation and Maintenance Manual
(Unit : kg.m)
49
Engine disassembly
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Operation and Maintenance Manual
(Unit : kg.m)
2.60.5
3.10.5
3.80.7
3.80.7
2.9
50
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51
Engine disassembly
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52
Engine disassembly
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53
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Operation and Maintenance Manual
16
14
13
12
17
18
15
20
21
22
19
12
13
14
15
16
Turbocharger gasket
17
18
6
7
54
10
11
19
20
10
21
Thermostat gasket
11
22
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Operation and Maintenance Manual
55
Engine disassembly
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Operation and Maintenance Manual
5) Cylinder head
Loosen the cylinder head bolts a
little in the numerical order shown in
the figure.
15) Flywheel
Loosen the flywheel bolts a little in
the numerical order as specified.
56
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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
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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
Limit
0.3 mm
7) Camshaft
Measure the following points before
disassembly.
<Cam Gear End Play>
Standard
Limit
0.050 0.114 mm
0.2 mm
58
Standard
Limit
0.15 0.33 mm
0.4 mm
Engine disassembly
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DB58/T/TI/TIS
Operation and Maintenance Manual
1. Bracket
2. Rocker arm
59
3. Spring
4. Rocker arm shaft
Engine disassembly
Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
3.1.5. Cylinder head disassembly
Importance
6) Valve cotter
Use the valve spring compressor to
remove the valve cotter.
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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.
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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
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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
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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.
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.
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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Standard
Limit
1.0 mm
2.5mm
2.4mm
1.6mm
66
jig
must
Engine inspection
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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
90
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
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Operation and Maintenance Manual
z
Standard
Limit
53.65 mm
52 mm
Valve spring
Inclination
Standard
Limit
2.5 mm
3.5 mm
68
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Operation and Maintenance Manual
Standard
Limit
22.5 kg
20.0 kg
3.2.5. Tappet
z Check the valve tappets for excessive
wear, damage or abnormalities.
Tappet outside
diameter
Standard
Limit
27.96 27.98mm
27.92mm
Standard
Limit
0.020 0.054mm
0.1mm
69
0.2mm
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
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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.
diameter of
Standard
Limit
18.98-19.00 mm
18.85 mm
70
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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
44.945 44.975
Limit
44.9 mm
mm
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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Standard
Limit
Clearance of
cam journal and
0.03 0.09 mm
0.15 mm
cam bearing
Standard
Limit
7.44 mm
6.94 mm
7.71 mm
7.21 mm
56.0 mm
55.6 mm
0.12 mm
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
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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.
Diameter of
Limit
102.017102.046 mm 102.20 mm
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
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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
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Grade marking
105.090 106.000 mm
106.000 106.010 mm
Steel liner
(tightness)
(clearance)
0.001 0.019mm
0.005 0.026mm
Cylinder bore
105.001 105.010mm
105.011 105.020mm
105.011 105.020mm
105.021 105.030mm
105.021 105.030mm
105.031 105.040mm
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
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
Part no of cylinder
liner grade
Outer
Inner
65.01201-0068
1A
65.01201-0069
1B
65.01201-0070
2A
65.01201-0071
2B
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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
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
Engine inspection
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.
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
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
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
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
35.010 35.018 mm
79
Engine inspection
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Operation and Maintenance Manual
Limit
Piston pin and piston pin
0.005 0.018 mm
hole clearance
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
80
Engine inspection
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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
Limit
Connecting rod
0.05mm or less
0.20 mm
parallelism
0.012 0.030mm
Limit
0.05 mm
bushing clearance
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
z
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
B type
Connecting rod
12 00.25kg.m
9.750.25kg.m
bolt torque
A type :
B type :
82
TY
11
or
TY
12
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
z
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.
79.905 79.925mm
Standard
Crankshaft
pin
outside diameter
83
63.924 63.944 mm
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
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.
Limit
0.025 0.090 mm
0.11 mm
clearance
Standard
Rod bearing
Limit
0.03 0.073 mm
0.10 mm
clearance
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
Engine inspection
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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.
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
0.4 or less
Engine inspection
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
8) Crankshaft grinding limit
Classification
Limit
79.419 mm
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
86
Engine inspection
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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.
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.
88
Engine reassembly
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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
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
3.3.2. Cylinder head assembly parts
90
Engine reassembly
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Operation and Maintenance Manual
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.
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
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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
2.2 kg.m
z
z
Exhaust manifold
bolt torque
92
2.2 kg.m
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
3.3.3. Rocker arm and shaft assembly
3. Rocker arm
4. Bracket
93
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Operation and Maintenance Manual
3.3.4. Main components
2.
3.
4.
5.
6.
7.
8. Camshaft
9.
10.
11.
12.
13.
14.
15.
94
Engine reassembly
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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.
95
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z
Crankshaft bearing
cap bolt torque
24.01kg.m
2.2 kg.m
8) Camshaft
z Tighten thrust plate bolt through
the camshaft gear hole.
Thrust plate bolt
torque
2.2 kg.m
13 kg.m
96
Engine reassembly
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Operation and Maintenance Manual
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
z
z
z
97
Engine reassembly
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Operation and Maintenance Manual
Torque
120.25kg.m
9.750.25kg.m
Bolt
head
TY
11
TY
12
5.0 kg.m
13 kg.m
M14 x 1.5
18 kg.m
98
2.2 kg m
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
3.3.5. Major component assembly
100
1.
Flywheel
2.
10.
Push rod
3.
11.
Taper bushing
4.
Water pump
12.
5.
13.
6.
14.
Oil thrower
7.
Cylinder head
15.
Rubber hose
8.
9.
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
1) Flywheel
z Lubricate the flywheel bolt with
engine oil.
z
18 kg.m
2) Injection pump
z Align the injection pump gear "C"
timing mark with the idler gear
C timing mark.
2.2 kg.m
101
60 kg.m
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
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.
102
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Operation and Maintenance Manual
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
Standard(mm)
Limit(mm)
115
116.2
102
103.2
103
Engine reassembly
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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
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
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
Injection nozzle
Seal ring
z
105
3.0 kg.m
DB58/T/TI/TIS
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
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
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
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
Engine reassembly
Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
3.4. Electrical Equipments
3.4.1. Wiring circuit
a) Glow plug system (type - 1)
107
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Operation and Maintenance Manual
c) Air heater system (type - 3)
Electrical equipments
Printed in Jan. 2003 PS-MMA0300-E1A
DB58/T/TI/TIS
Operation and Maintenance Manual
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
109
Electrical equipments
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Operation and Maintenance Manual
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
Cover
20
Brush holder
Pin
21
Spring
10
Stud bolt
22
Brush
11
Insulator
23
Brush
12
Bolt
24
Baffle
Electrical equipments
Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
b) 24V x 60A Alternator
24V 60A
Wiring Diagram
111
Electrical equipments
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Operation and Maintenance Manual
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
Electrical equipments
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Operation and Maintenance Manual
113
1.
Yoke assembly
14.
Coil spring
2.
15.
Pinion starter
3.
End frame
16.
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.
Electrical equipments
Printed in Jan. 2003 PS-MMA0300-E1A
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Operation and Maintenance Manual
114
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Operation and Maintenance Manual
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.
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
-
Construction equipments
DB58
DB58T
DB58TI
DB58S
DB58TIS
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.
116
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
118
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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
119
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
Cartridge,
Oil filter
IMPORTANT:
It is strongly advisable to use DAEWOO genuine oil filter cartridge for
replacement.
120
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Operation and Maintenance Manual
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.
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
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
2.6 kg.m
DB58/T/TI/TIS
Operation and Maintenance Manual
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
Cooling fan
123
Cylinder no.
Exhaust valve
Intake valve
Fly wheel
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
<Check procedure>
z Turn
the
crankshaft
pulley
counterclockwise about 30 crank
angle.
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Operation and Maintenance Manual
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.
125
DB58/T/TI/TIS
Operation and Maintenance Manual
z Fuel injection timing angle
DB58/S
DB58T
DB58TI
DB58TIS
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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Operation and Maintenance Manual
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.
Torque
hexagonal bolt
dodecagonal
bolt
127
Limit(mm)
116.2
103.2
DB58/T/TI/TIS
Operation and Maintenance Manual
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.
128
1.2 kg.m
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Operation and Maintenance Manual
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)
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Operation and Maintenance Manual
*
(D d )2
S= C
2
2
(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
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
40 kg
45 kg
60 kg
60 kg
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
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Operation and Maintenance Manual
3
4
2
133
4. Pinion Gear
5. Pinion gear shaft
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.
0.18 mm
0.12 mm
the
in
DB58/T/TI/TIS
Operation and Maintenance Manual
5.1.2. Oil cooler
1) Disassembly
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
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.
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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.
2) Inspection
(1) Unit bearing
z Correct or replace the part if
the wear, defect or other
damage is discovered during
inspection.
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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.
(3) Hub
z Use a bench press and a bar
to install the hub.
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DB58/T/TI/TIS
Operation and Maintenance Manual
z
(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
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Operation and Maintenance Manual
5.3. Fuel system
5.3.1. Fuel filter
1) Cartridge type
Cartridge,
fuel filter
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.
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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.
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
7 kg.m
143
DB58/T/TI/TIS
Operation and Maintenance Manual
Nozzle holder cap nut
torque
4.5 kg.m
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)
CAUTION:
Keep away your skin from the tester because pressure of nozzle tester is very
high when inject.
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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
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
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
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
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
Check
Point
A
B
C
D
Rack
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
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
1 : 1.2 / 1 : 1.2
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
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)
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)
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
Pressure
(mmHg)
-
Pump speed
(rpm)
1,100
800
415
100
Pressure
(mmHg)
-
Pump speed
(rpm)
1,100
800
415
100
Pressure
(mmHg)
-
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
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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
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
Check
Point
A
B
C
D
Rack
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=12 kgf/mm
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
DB58/T/TI/TIS
Operation and Maintenance Manual
6) Rack curve of standard injection pump (65.11101-7380)
149
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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
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
Check
Point
A
B
C
D
Rack
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=12 kgf/mm
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
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
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
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
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
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
105780-8140
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
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
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
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
1 : 1.2 / 1 : 1.2
k=2.1 kgf/mm
k=0.6 kgf/mm
Feed pump
Max. operating pressure
152
3.4 kgf/cm2
Piston spring
k=0.735 kgf/mm
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
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
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
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
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
153
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
105780-8140
-
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
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
standard parts
67.1 2
Above 300
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start 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
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)
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)
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
Pressure
(mmHg)
Pump speed
(rpm)
1,100
800
415
100
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
155
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
(3) Nozzle
: 65.10301-6072
:153624
Rack
Pump
Check
position speed
Point
(mm)
(rpm)
A
B
C
E
R1(9.8)
6.9
(R1)
-
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
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
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
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
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
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
157
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
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
Check
Point
A
B
C
E
Rack
position speed
(mm)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start 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
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
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
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
Boost pressure
159
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:
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
Check
Point
A
B
C
D
E
Rack
position speed
(mm)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start spring
Angleich spring
k=5.4 kgf/mm
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
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)
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
Boost pressure
161
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:
Check
Point
A
B
C
D
E
Rack
105780-8140
ISO4113
65.10102-6064
65.10101-7092
position speed
(mm)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start spring
k=0.005 kgf/mm
k=0.6 kgf/mm
Piston spring
k=0.735 kgf/mm
Feed pump
Max. operating pressure
162
3.4 kgf/cm2
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)
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)
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
Boost pressure
163
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
105780-8140
-
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
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)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start spring
k=0.005 kgf/mm
k=0.6 kgf/mm
Piston spring
k=0.735 kgf/mm
Feed pump
Max. operating pressure
164
3.4 kgf/cm2
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)
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)
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)
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)
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)
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
165
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:
Check
Point
A
B
C
D
E
Rack
105780-8140
ISO4113
65.10102-6061
65.10101-7091
position speed
(mm)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start spring
k=0.005 kgf/mm
k=0.35 kgf/mm
Piston spring
k=0.735 kgf/mm
Feed pump
Max. operating pressure
166
3.4 kgf/cm2
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
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:
Check
Point
A
B
C
D
E
Rack
105780-8140
ISO4113
65.10102-6061
65.10101-7091
position speed
(mm)
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
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
1 : 1.2 / 1 : 1.2
Governor spring
k=10 kgf/mm
k=2.1 kgf/mm
Idling spring
k=2.6 kgf/mm
Start spring
k=0.005 kgf/mm
k=0.6 kgf/mm
Piston spring
k=0.735 kgf/mm
Feed pump
Max. operating pressure
168
3.4 kgf/cm2
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
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
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
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
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
9.7 kg
9.7 kg
9.7 kg
Turbocharger Model
at
maximum
output
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
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
34
Inlet baffle
75
Hose clamp
Compressor wheel
36
Thrust collar
77
Actuator clip
Compressor housing
38
80
Cover plate
11
Journal bearing
43
81
Hose
12
Thrust bearing
46
Gasket
82
Elbow
13
57
Hex bolt
83
Hex nut
16
61
Lock nut
88
Clamp plate
22
Retainer ring
64
Snap ring
91
Retaining ring
31
Oil stopper
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.
174
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
175
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
During operation
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.
176
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)
177
DB58/T/TI/TIS
Operation and Maintenance Manual
(1) Rotor axial 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
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
Replace or clean
Disassemble/repair
or replace
of bearing
1) Gas leak at each part of exhaust system
Replace or clean
Disassemble/repair
or replace
179
Disassemble/repair
or replace
4. Unusual sound or
vibration
Disassemble/repair
or replace
or replace
Disassemble/repair
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
NOTE:
Do not allow dirt to get into the
clean air end.
180
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
DB58/T/TI/TIS
Operation and Maintenance Manual
182
Part No.
Figure
Tool Name
EU.2-0529
EF122-249
EF.122-265
EF.122-253
EF.122-251
EF.122-262A
EF.122-255
EF.122-289
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
10
EF.122-281
11
EF122-261
12
EU.1-0022
13
EU.2-0328
14
60.99901-0027
Feeler gauge
15
T7610001E
16
T7621010E
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)
M12 x 1.5
12.9T
9.75 kg.m
M16 x 2
12.9T
24.0 kg.m
M14 x 1.5
10.9T
13 kg.m
M16 x 1.5
10.9T
16 kg.m
M16 x 1.5
10.9T
18 kg.m
M36 x 1.5
8.8T
60 kg.m
M10 x 1.25
2.1 kg.m
Strength
(Diameter x pitch)
(grade)
Tightening
Torque
M28 x 1.5
7.0 kg.m
M10
8.8T
4.4 kg.m
M24 x 1.5
8.8T
25.0 kg.m
M14 x 1.5
8.8T
3.0 kg.m
Major Parts
Injection nozzle nut
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
24
32
30
40
36
48
54
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.
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
186
187
188
189
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
Model
For
Vehicle
For
Industrial
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
@ 1,800rpm
Power (Stand-by)
DC23-2
DC23-1
DC23
DC24
DC24T
DB33
P034TI
DB58
D1146
D1146T
P086TI-1
DE12T
@ 1,500rpm
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)
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
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