Daewoo doosan db58 tis diesel engine service repair manual

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

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

DB58/T/TI/TIS
1
General information
1. GENERAL INFORMATION
1.1. Engine specifications
Engine
Model Items
DB58/S DB58T DB58TI DB58TIS
Engine type
4 cycle in-line
Naturally
aspirated
4 cycle in-line,
Water-cooled
Turbo charged
4 cycle in-line,
Water-cooled type
Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Dry type
Timing gear system Gear driven type
No. of piston ring 2 Compression 1 ring, oil ring

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

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

DB58/T/TI/TIS
4
General information
1. 3.2. Performance curve (DB58T)
Output (rated)
104 kW (142PS) /
2,500 rpm
90 kW (122PS) /
2,500 rpm

DB58/T/TI/TIS
5
General information
1. 3.3. Performance curve (DB58TI)
Output (rated)
112 kW (152PS) /
2,200 rpm
102 kW (138PS) /
2,200 rpm

DB58/T/TI/TIS
6
General information
1. 3.4. Performance curve (DB58TIS)
Performance DIN 6270B
Output (rated) 126.5 kW (172PS) /2,200 rpm
Torque (min) 696 N.m (71 kg.m) / 1,400 rpm
Fuel consumption (rated) 217.5 g/kW.h (160 g / PS.h)

DB58/T/TI/TIS
7
General information
1.4. Engine assembly
1.4.1. Engine sectional view (DB58TI/TIS : air to water type)
1. Oil spray nozzle 18. Piston pin
2. Connecting rod 19. Thermostat
3. Cylinder liner 20. Intake valve
4. Oil cooler 21. Exhaust valve
5. Piston 22 Breather
6. Swirl chamber 23. Inter cooler
7. Fuel injection pipe 24. Rocker arm
8. Fuel injection nozzle 25. Oil filler cap
9. Valve cotter 26. Cylinder head cover
10. Valve spring 27. Cylinder head
11. Valve stem seal 28. Push rod
12. Valve guide 29. Vibration damper
13. Oil pan 30. Oil drain plug
14. Oil pump strainer 31. Crank shaft
15. Oil pump 32. Cam shaft
16. Cooling water pump 33. tappet
17. Cooling water pump pulley
1
2
3
4
5
6
7 8 9 10 11 12
13 14 15 29 30 31 32 33
20 21 22 23 24 25
19
18
17
16
26
27
28

DB58/T/TI/TIS
8
General information
1.4.2. Engine sectional view (DB58TIS : air to air type)
1. Oil spray nozzle 17. Cooling water pump pulley
2. Connecting rod 18. Piston pin
3. Cylinder liner 19. Thermostat
4. Oil cooler 20. Intake valve
5. Piston 21 Exhaust valve
6. Swirl chamber 22. Breather
7. Fuel injection pipe 23. Rocker arm
8. Fuel injection nozzle 24. Oil filler cap
9. Valve cotter 25. Cylinder head cover
10. Valve spring 26. Cylinder head
11. Valve stem seal 27. Push rod
12. Valve guide 28. Vibration damper
13. Oil pan 29. Oil drain plug
14. Oil pump strainer 30. Crank shaft
15. Oil pump 31. Cam shaft
16. Cooling water pump 32. tappet
1
2
3
4
5
6
13 14 15 28 29 30 31 32
7 8 9 10 11 12 20 21 22 23 24
19
18
17
16
25
26
27

DB58/T/TI/TIS
9
General information
1.4.3. Engine assembly views
(1) DB58
1 Oil filter 10 Cooling fan idler 19 Push rod chamber cover
2 Lifting hook 11 Crank shaft pulley 20 Flywheel housing
3 Oil cooler 12 Vibration damper 21 Fly wheel
4 Intake manifold 13 Oil drain plug 22 Oil pan
5 Priming pump 14 Cooling water pump 23 Starter
6 Fuel injection pump 15 Alternator 24 Cylinder head cover
7 Fuel injection pipe 16 Fan drive mounting 25 Fuel injection nozzle
8 Water outlet 17 Oil level gauge 26 Fuel filter
9 Cooling fan 18 Exhaust manifold
1
2
3 4 5 6 7 8
16 17 18 24 25 26
13
9
10
11
12
14
15
22 23
19
20
21

DB58/T/TI/TIS
10
General information
(2) DB58T
1 Engine pick-up sensor 11 Vibration damper 20 Oil filler cap
2 Lifting hook 12 Oil filter 21 Push rod chamber cover
3 Oil cooler 13 Oil drain plug 22 Flywheel housing
4 Intake manifold 14 Air pipe 23 Fly wheel
5 Priming pump (turbo charger to intake manifold) 24 Oil pan
6 Fuel injection pump 15 Cooling water pump 25 Starter
7 Fuel injection pipe 16 Alternator 26 Oil level gauge
8 Water outlet 17 Breather 27 Cylinder head cover
9 Cooling fan 18 Turbo charger 28 Fuel injection nozzle
10 Crank shaft pulley 19 Exhaust manifold 29 Fuel filter
1
2
3 4 5 6 7 8
9
10
11
15
16
14
12 13
17 18 19 20 26 27 28
24 25
21
22
23
29

DB58/T/TI/TIS
11
General information
(3) DB58TI/TIS
1 Fuel filter 10 Oil filter 19 Flywheel housing
2 Oil cooler 11 Oil pan 20 Fly wheel
3 Intake manifold 12 Oil drain plug 21 Starter
4 Priming pump 13 Cooling water pump 22 Turbo charger
5 Fuel injection pump 14 Alternator 23 Oil level gauge
6 Fuel injection pipe 15 Water outlet 24 Air pipe
7 Cooling fan 16 Exhaust manifold (turbo charger to intercooler)
8 Crank shaft pulley 17 Oil filler cap 25 Fuel injection nozzle
9 Vibration damper 18 Push rod chamber cover 26 Intercooler
1
2 3 4 5 6
7
8
9
13
14
10 11 12
15 16 17 22 23 24 25 26
18
19
20
21

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DB58/T/TI/TIS
12
General information
(4) DB58TIS
1 Flywheel housing 10 Oil pan 20 Water outlet
2 Lifting hook 11 Oil drain plug 21 Air pipe
3 Oil filler cap 12 Fuel injection pump (turbocharger to intercooler)
4 Fuel filter 13 Fuel feed pump 22 Turbo charger
5 Intake manifold 14 Priming pump 23 Exhaust manifold
6 Air pipe 15 Cooling water pump 24 Crank shaft pulley
(intercooler to manifold) 16 Air heater 25 Starter
7 Breather 17 Thermostat housing 26 Push rod chamber cover
8 Cooling fan 18 Water pump pulley 27 Oil level gauge
9 Oil filter 19 Alternator 28 Fuel injection pipe
1
22
2
1
3 4 5 6 7 17 18
8
19
15
9 10 11 12 13 14
27 28
23
21
20
24 25 26
16
22

DB58/T/TI/TIS
13
Safety regulations
1.5. Safety regulations
1.5.1. General notes
Day-to-day use of power engines and the service products necessary for running them
presents no problems if the persons occupied with their operation, maintenance and
care are given suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken
down into main sections which contain the information necessary for preventing injury
to persons, damage to property and pollution. In addition to these regulations those
dictated by the type of engine and its site are to be observed also.
IMPORTANT.
If, despite all precautions, an accident occurs, in particular through contact with
caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc., consult a doctor immediately.
1.5.2. Regulations designed to prevent accidents
a) During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating
instructions carefully and familiarize yourself with the "critical" points. If you are unsure,
ask your DAEWOO representative.
For reasons of safety we recommend you attach a notice to the door of the engine
room prohibiting the access of unauthorized persons and that you draw the
attention of the operating personal to the fact that they are responsible for the safety
of persons who enter the engine room.
The engine must be started and operated only by authorized personnel. Ensure that
the engine cannot be started by unauthorized persons.
When the engine is running, do not get too close to the rotating parts. Wear close-
fitting clothing.
Do not touch the engine with bare hands when it is warm from operation risk of
burns.
Exhaust gases are toxic. Comply with the installation instructions for the installation
of DAEWOO diesel engines which are to be operated in enclosed spaces. Ensure
that there is adequate ventilation and air extraction.
Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.
b) During maintenance and care
Always carry out maintenance work when the engine is switched off. If the engine
has to be maintained while it is running, e.g. changing the elements of change-over
filters, remember that there is a risk of scalding. Do not get too close to rotating
parts.
Change the oil when the engine is warm from operation.

DB58/T/TI/TIS
14
Safety regulations
CAUTION
There is a risk of burns and scalding. Do not touch oil drain valve or oil filters
with bare hands.
Take into account the amount of oil in the sump. Use a vessel of sufficient size to
ensure that the oil will not overflow.
Open the coolant circuit only when the engine has cooled down. If opening while
the engine is still warm is unavoidable, comply with the instructions In the chapter
entitled "Cooling".
Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any
additional hydraulic oil circuit) during the operation. The fluid which flow out can
cause injury.
Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must
be filled only when the engine is switched off.
Keep service products (anti-freeze) only in containers which can not be confused
with drinks containers.
Comply with the manufacturer's instructions when handling batteries.
CAUTION
Accumulator acid is toxic and caustic. Battery gases are explosive.
c) When carrying out checking, setting and repair work
Checking, setting and repair work must be carried out by authorized personnel only.
Use only tools which are in satisfactory condition. Slip caused by the worn open-
end wrench could lead to Injury.
When the engine is hanging on a crane, no-one must be allowed to stand or pass
under it. Keep lifting gear in good condition.
When checking injectors, do not put your hands under the jet of fuel.
Do not inhale at atomized fuel.
When working on the electrical system disconnect the battery earth cable first.
Connect it up again last in prevent short circuits.
1.5.3. Regulations designed to prevent damage to engine and premature wear
(1) Never demand more of the engine than it was designed to yield for its intended
purpose.
Detailed information on this can be found in the sales literature. The injection pump
must not be adjusted without prior written permission of DAEWOO.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent
more serious of damage.
(3) Use only genuine DAEWOO spare parts. DAEWOO will accept no responsibility for
damage resulting from the installation of other parts which are supposedly "just as
good".
(4) In addition to the above, note the following points.
Never let the engine run when dry, i.e. without lube oil or coolant. Use only
DAEWOO-approved service products. (engine oil, anti-freeze and anticorrosion

DB58/T/TI/TIS
15
Safety regulations
agent)
Pay attention to cleanliness. The Diesel fuel must be free of water. See
"Maintenance and care".
Have the engine maintained at the specified intervals.
Do not switch off the engine immediately when it is warm, but let it run without
load for about 5 minutes so that temperature equalization can take place.
Never put cold coolant into an overheated engine. See "Maintenance and care".
Do not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered
to.
Always ensure that the testing and monitoring equipment (for battery charge, oil
pressure, and coolant temperature) function satisfactorily.
Comply with instructions for operation of the alternator. See "Commissioning
and operation".
Do not let the water pump run dry. If there is a risk of frost, drain the water when
the engine switched off.
1.5.4. Regulations designed to prevent pollution
a) Engine oil, filter element, fuel filter
Take old oil only to an oil collection point. Take strict precautions to ensure that oil
does not get into the drains or into the ground.
The drinking water supply may be contaminated.
Oil and fuel filter elements are classed as dangerous waste and must be treated as
such.
b) Coolant
Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
When disposing of spent coolant comply with the regulations of the relevant local
authorities.
1.5.5. Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and any kind of engine oil decreases
the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also
contains dangerous substances which have caused skin cancer in animal experiments.
If the basic rules of hygiene and health and safety at work are observed, health risks
are not to the expected as a result of handling used engine oil.
<Health precautions>
Avoid prolonged or repeated skin contact with used engine oil.
Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.

DB58/T/TI/TIS
16
Safety regulations
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
After washing apply a fatty skin cream to the skin.
Change oil-soaked clothing and shoes.
Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or the
sewers. Violations are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local
authorities.
1.5.6. General repair instructions
1. Before performing service operation, disconnect the grounding cable from the battery
for reducing the chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient and
reliable service operation.
5. Use genuine DAEWOO parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should
be discarded and new ones should be prepared for installation as normal function of
the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separately is very important as they
vary in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use sealer on gaskets to prevent leakage.
11. Carefully observe all torque specifications for bolts and nuts.
12. When service operation is completed, make a final check to be sure service has
been done properly.

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