Motor DB58TIS PDF

65.
99897-8079
OPERATION and
MAINTENANCE MANUAL
DIESEL ENGINE
DB58
DB58S
DB58T
DB58TI
DB58TIS
Printed in Jan. 2003 PS-MMA0300-E1A

DB58/T/TI/TIS
Operation and Maintenance Manual
FOREWORD
This maintenance manual is designed to serve as a reference for DAEWOO Heavy
Industries Ltd's (here after DAEWOOs) customers and distributors who wish to gain basic
product knowledge on DAEWOO's DB58, DB58S, DB58T, DB58TI and DB58TIS Diesel
engine.
This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct
injection type) has been so designed and manufactured to be used for the overland transport
or industrial purpose. That meets all the requirements such as low noise, fuel economy, high
engine speed, and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools of manufacturer's
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental

damage;
z Take old oil to an old oil disposal point only.

z Ensure without fail that oil will not get into the sea or rivers and canals or the
ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the
disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
DAEWOO Heavy Industries & Machinery LTD.

Aug. 2003

DB58/T/TI/TIS
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
4.7. 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
4.12. Fuel injection pump 129

4.13. Feed pump strainer 129
4.14. Separator 129
4.15. Air bleeding 130
4.16. Belts 130
5. Maintenance of Major Components

5.1. Lubrication system 133
5.3. Fuel system 142
5.4. Turbocharger 172
5.5. Air Intake System 180
6. Special Tool List 183
Appendix 184
WORLDWIDE NETWORK

DB58/T/TI/TIS
1. GENERAL INFORMATION
1.1. Engine specifications
Engine
DB58/S DB58T DB58TI DB58TIS
Model Items
4 cycle in-line 4 cycle in-line, 4 cycle in-line,
Engine type Naturally Water-cooled Water-cooled type
aspirated Turbo charged Turbo charged & intercooled
Combustion chamber type Direct injection type
Cylinder liner type Dry type
Timing gear system Gear driven type
No. of piston ring 2 Compression 1 ring, oil ring
No. of cylinder-bore x stroke (mm) 6 102 118
Total piston displacement (cc) 5,785
Compression ratio 17.5 : 1 18.5
Engine dimension
1,173x666x793 1,172x724x912 1,184x657x934 1,184x690x970
(length X width X height) (mm)
Engine weight (kg) 450 480 505 480
Rotating direction (from fly wheel) counter clockwise
Fuel injection order 15-36-24
Fuel injection timing (B.T.D.C static) 15 or 18 13 11
Injection pump type Bosch in-line A type
Governor type Mechanical governor RSV type
Injection nozzle type Multi-hole type (5 hole) Multi-hole type (6 or 7 hole)
Fuel injection pressure (kg/cm2) 220 185 190
Compression pressure (kg/cm2) 28 (at 200 rpm)
Intake & exhaust valve clearance
0.4
(at cold) (mm)
Open at 28 B.T.D.C (DB58S : 17)
Intake valve
Close at 62 A.B.D.C (DB58S : 51)
Open at 70 B.B.D.C (DB58S : 60)
Exhaust valve
Close at 28 A.T.D.C (DB58S : 18)
Lubrication method Pressurized circulation
Oil pump type Gear type
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (oil pan) (lit) 14.5(13) or 20.5(19)
Oil cooler type Water cooled
Water pump Belt driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity(engine only) (lit) 12
Thermostat type Wax pallet type (71 85C or 82 95C)
Cooling fan 7-457 blower, 595, 625 or 8-685 sucker
Alternator voltage capacity (V - A) 24 60 or 24 - 50
Starting Motor
24 4.5
(voltage output) (V - kW)
Battery (capacity) (V - AH) 24 - 120
1 General information
DB58/T/TI/TIS
1. 2. Engine power
Production tolerance : 5%
Engine model Performance
Injection
Power Torque Low idle High idle
Model Suffix timing Remark
(PS/rpm) (kg.m/rpm) (rpm) (rpm)
(BTDC)
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
20
EAREB 775-825 2,370~2,470
EARFE 86025 2,42025
92/2,200 32/1,600
EARFI/J 16
80025 2,42050
DB58 EARFH 18 -
EARFF 20 85025 2,42025
EARFG 18 102/2,200 35.5/1,600
80025 2,42050
EARFK 16
EARLA/B 18 108/2,200 37.5/1,600 97525 2,42050
EARLC 16 98~102/2,200 38.0/1,600 97525 2,42050
ECRFA 102/2,200 37/1,600
2,42050
DB58S ECRFB 15 90/2,200 80025 TIER-II
33/1,600
ECRFC 94/2,400 2,64050
EATEA 18 44/1,600 925~975 2,370~2,470
EATEE 132/2,200 1,10025 2,24050
13 45/1,600
EATEH 950-980 2,370~2,470
EATEB 18 825~875 2,03550
111/1,850
EATEF 13 45/1,700 1,05010 2,03550
DB58T TIER-I
EATED 18 114/1,950 1,15025 2,14050
EATEG 120/2,050 45/1,600 1,15025 2,25550
13
EATEI 100+2/1,850 39.0/1,700 1,05010 2,03550
EATLA 18 139/2,300 45.5/1,600 875~925 2,48050
EATLB 13 132/2,200 45.0/1,600 97525 2,42050
EAOEA
13 150/2,000 57/1,600 1,15025 2,20050
EAOED
EAOEB 13 160/2,200 2,42050
DB58TI 1,20025 -
EAOEC 13 155/2,100 58/1,600 2,31050
EAOLA/B 13 145/2,000 975~1,025 2,370~2,470
EAOEE 13 160/2,000 59/1,600 1,15025 2,20050
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
60/1,500 1,200~1,225
ECOEG 11 158/2,100 2,260~2,360
TIER-II
DB58TIS ECOED 11 135/2,200 50/1,400 1,100~1,125 2,420~2,470
ECOEE 11 154/2,000 60,1,500 1,20025 2,20050
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
ECOLB 11 145/2,200 63/1,500 1,10025 2,42050
* Note : All data are based on operation without cooling fan at DIN 6270B
DB58/T/TI/TIS
1. 3. Performance curve
1. 3.1. Performance curve (DB58)
Performance DIN 6270B DIN 6270A
96 kW (130PS) / 85 kW (115PS) /
Output (rated)
2,800 rpm 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
1. 3.2. Performance curve (DB58T)
104 kW (142PS) / 90 kW (122PS) /

Output (rated)
2,500 rpm 2,500 rpm

DB58/T/TI/TIS
1. 3.3. Performance curve (DB58TI)
112 kW (152PS) / 102 kW (138PS) /

Output (rated)
2,200 rpm 2,200 rpm

DB58/T/TI/TIS
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
1.4. Engine assembly
1.4.1. Engine sectional view (DB58TI/TIS : air to water type)
7 8 9 10 11 12 20 21 22 23 24 25
19 26
18 27
17 28
6 16
5
4
3
2
13 14 15 29 30 31 32 33
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
DB58/T/TI/TIS
1.4.2. Engine sectional view (DB58TIS : air to air type)
7 8 9 10 11 12 20 21 22 23 24
19
25
18
26
17
27
16
6
5
4
3
2
1
13 14 15 28 29 30 31 32
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
DB58/T/TI/TIS
1.4.3. Engine assembly views

(1) DB58
3 4 5 6 7 8
14
2
15
1 9
10
11
12
13
16 17 18 24 25 26
19
20
21
22 23
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
DB58/T/TI/TIS
(2) DB58T
3 4 5 6 7 8 14
2 15
16
1
9
10
11
12 13
17 18 19 20 26 27 28
29
21
22
23
24 25
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
DB58/T/TI/TIS
(3) DB58TI/TIS
2 3 4 5 6
13
1
14
8
9
10 11 12
15 16 17 22 23 24 25 26
18
19
20
21
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
DB58/T/TI/TIS
(4) DB58TIS
3 4 5 6 7 17 18
2 16
1 8
19
15
9 10 11 12 13 14
20 21 22 23 27 28
24 25 26
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
DB58/T/TI/TIS
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 close-
fitting 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
DB58/T/TI/TIS
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 open-
end 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
DB58/T/TI/TIS
agent)
z Pay attention to cleanliness. The Diesel fuel must be free of water. See
"Maintenance and care".
z Have the engine maintained at the specified intervals.
z 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.
z Never put cold coolant into an overheated engine. See "Maintenance and care".
z 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.
z Always ensure that the testing and monitoring equipment (for battery charge, oil
pressure, and coolant temperature) function satisfactorily.
z Comply with instructions for operation of the alternator. See "Commissioning
and operation".
z Do not let the water pump run dry. If there is a risk of frost, drain the water when
the engine switched off.
1.5.4. Regulations designed to prevent pollution

a) Engine oil, filter element, fuel filter
z Take old oil only to an oil collection point. Take strict precautions to ensure that oil
does not get into the drains or into the ground.
z The drinking water supply may be contaminated.
z Oil and fuel filter elements are classed as dangerous waste and must be treated as
such.
b) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant local
authorities.
1.5.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases
the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also
contains dangerous substances which have caused skin cancer in animal experiments.
If the basic rules of hygiene and health and safety at work are observed, health risks
are not to the expected as a result of handling used engine oil.
<Health precautions>
z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
DB58/T/TI/TIS
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z 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.
DB58/T/TI/TIS
2. TECHNICAL INFORMATION
2.1. Engine model and serial number
The engine model and serial number is
located on the engine as illustrated.
These numbers are required when
requesting warranty and ordering parts.
They are also referred to as engine
model and serial number because of
their location.
z Engine serial No. (example 1 : DB58) Engine number

DB58 3 00001 FA
Engine suffix(EARFA)
Serial no.
Production year(2003)
Engine model
z Engine serial No. (example 2 : DB58)

DB58S 3 00001 FA
Engine suffix(ECRFA)
Serial no.
Engine model
z Engine serial No. (example 3 : DB58T)

DB58T 3 00001 EA <Name plate : EPA & CARB>
Engine suffix(EATEA)
Serial no.
Engine model
z Engine serial No. (example 4 : DB58TI)

DB58TI 3 00001 BA
Engine suffix(EAOEB)
Serial no.
Engine model
z Engine serial No. (example 5 : DB58TIS)

DB58TIS 3 00001 EC
Engine suffix(ECOEC)
Serial no.
Engine model
17 Technical information
DB58/T/TI/TIS
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 steel-
backed lead bronze ready-to fit type bearings.
2.3. Engine timing

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

Injection pump gear Idle gear Camshaft gear
(Z = 12)
(Z = 50) (Z = 51) (Z = 50)
P.T.O drive gear(Z=24)
Allowable torque :12kg.m
Crankshaft gear Oil pump gear P.T.O gear (Option)

(Z = 25) (Z = 9) (Z = 25)
DB58/T/TI/TIS
2.4. Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker
arms from the camshaft.
2.5. Lubrication system

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

Initial factory fill is high quality break-in oil for API Service. During the break-in period
(50 hours), frequently check the oil level. Somewhat higher oil consumption is normal
until piston rings are seated. The oil level should be maintained in the safe range
between the Min. and Max. marks on the dipstick. The safe range between the marks
represents approximately 3 liters. To obtain the best engine performance and engine
life, grade of engine oil is recommended. Engine oils are specified by API Service,
letter designations and SAE viscosity numbers. If the specified motor oil is not
available, use a reputable brand of engine oil labeled for API Service CH-4 and SAE
DB58/T/TI/TIS
viscosity 30 or 15W40. Refer to oil identification symbol on the container.
z Engine oil should be changed at the specified intervals.
Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating
First oil change After 50hr operation
DB58
DB58T every 200 Hour
Construction equipments DB58TI
DB58S
every 250 Hour
DB58TIS
z The following oils are also recommended

Engine oil capacity Recommend oil
Oil pan
Engine model Total
Max. SAE No. API No.
Min. (liter)
(liter) (liter)
DB58 Fork lift 13 11 14.5

DB58T SAE 15W40 above CD or CE
DB58TI Excavator 19 16 20.5
Fork lift 19 14 20.5

DB58S SAE10W40 ACEA-E2 or ACEA-E3
DB58TIS SAE15W40 (API CH-4)
Excavator 19 16 20.5
* If long oil change intervals are to be used, ACEA-E3 oil must be used.
DB58/T/TI/TIS
2.5.2. Oil cooler

An oil cooler is provided between the oil filter and the cylinder block. This cooler is a
flat tube type with turbulence inserts and operated by the coolant.
2.5.3. Oil filter

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

In case that elements are deformed,
damaged or if the air cleaner has a crack,
replace it.
By the definite interval, the elements must
be cleaned and replaced.
DB58/T/TI/TIS
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 flange-
mounted on the pump casing is a
variable range governor designed to
keep the speed set of varying load.
DB58/T/TI/TIS
2.7.2. Fuel filter

z This fuel filter has two functions not
only oil filtering but also water Air bleeding plug
separating
Seal ring
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. Head,
fuel filter
z Drain water in filter with loosening
the drain plug under filter manually
from time to time. Cartridge,
fuel filter
z The fuel filter element should be
replaced at every 200 hours.
Water drain plug
2.7.3. Fuel requirements

DAEWOO diesel engines was designed to use Number 2-D diesel fuel or equivalent
that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel
whenever possible. When temperatures are below -7 C (20 F), use Number 1-D fuel.
If Number 1-D fuel is not available, the mixture of one kerosene to two gallons of
Number 2-D fuel can be used. Once kerosene has been added, the engine should be
run for several minutes to mix the fuel.
2.7.4. How to select fuel oil

Fuel quality is an important factor in obtaining satisfactory engine performance, long
engine life, and acceptable exhaust emission levels. DAEWOO engines are designed
to operate on most diesel fuels marketed today. In general, fuels meeting the
properties of ASTM Designation D975 (grades 1-D and 2-D) have provided satisfactory
performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel
characteristics needed for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum
engine performance. Grade 2-D fuel is normally available for generator service. Grade
1-D fuel should not be used in pleasure craft engines, except in an emergency.
DB58/T/TI/TIS
Fuel Oil Selection Chart
General Fuel ASTM No. 1 No. 2

DIN 51601
Classification Test ASTM 1-D ASTM 2-D
Gravity, API #)
D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855
Flash Point
D 93 100 (38) 125 (52) 131 (55)
Min. F (C)
Viscosity, Kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 F (40 C )
Cloud Point F #) D 2500 See Note 1) See Note 1) See Note 1)
Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles D 2274 1.5 1.5
mg/100 ml, Max. #)
Ash, wt%, Max. D 482 0.01 0.01
Cetane Number, Min. +) D 613 45 45 > 45
Distillation D 86
Temperature, ()
IMP, Typican #) 350(177) 375(191)
10% Typical #) 385(196) 430(221)
50% Typical #) 45(218) 510(256) 680(360)
90% +) 500 (260) Max. 625(329) Max.
End Point #) 550(288) Max. 675(357) Max.
Water & Sediment

D 1796 0.05 0.05 0.05
%, Max.
#) Not specified In ASTM D 975

+) Differs from ASTM D 975
NOTE
1) The cloud point should be 6 C (10 F) below the lowest expected fuel temperature
to prevent clogging of fuel fitters by crystals.
DB58/T/TI/TIS
2.8. Cooling system
The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by
V-belt from the crankshaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the coolant
circuit can be equipped with temperature monitors which, in the event of loss of coolant,
shut the engine down.
z Check the coolant level of the expansion tank by removing the expansion tank filler
cap, and add coolant if necessary.
z When injecting antifreeze solution, first drain out the old coolant from the cylinder
block and radiator, and then clean them with cleaning solution.
z Be sure to mix soft water with antifreeze solution.
2.8.1 Cooling system (Type -1)
2.8.2 Cooling system (Type -2)
DB58/T/TI/TIS
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 slow-
opening 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
Cooling water (%) Anti-freeze (%)
Temperature (C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 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.
DB58/T/TI/TIS
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 Since DB58 cylinder liner is dry type, particularly the cooling water control should
be applied thoroughly.
z The density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit. (Fleetguard CC2602M)
z 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.
DB58/T/TI/TIS
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.
2.9. V-belt tension check and adjust

z V-Belt
By the finger-pressure the belt is
pressed by 10mm 15mm between
the fan pulley and the alternator
pulley in normal condition. For the
adjustment of the tension, loosen the
adjusting bolts which support the
alternator, adjust the tension and
tighten the bolts again.
z Poly belt
Poly belt will be properly tensioned if
the deflection force F is applied
midway between the belt`s tangent
points with the pulley.
T = 0.015 x S (about 1.5mm per 100mm)
2.10. Intercooler(Air to air)

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

Hot air by turbo charger
compressor
Cooled air to intake
manifold (max. 50C)
DB58/T/TI/TIS
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

2.6 0.5kg.m
lock nut torque
z After letting the #1 cylinder's piston

come at the compression top dead
center by turning the crankshaft,
adjust the valve clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the
feeler gauge of specified value
between a rocker arm and a valve
stem and adjust the clearance with adjusting screw respectively and then tighten
with the lock nut.
z As for the valve clearance, adjust it when in cold, as follows.
Model Intake Valve Exhaust Valve
DB58
DB58S
DB58T 0.4 mm 0.4 mm
DB58TI
DB58TIS
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.
DB58/T/TI/TIS
5) After reinsuring the valve clearances, retighten if necessary.
z No. 1 cylinder is located at the side where flywheel was installed.
Cooling fan Cylinder no. Exhaust valve Intake valve Fly wheel
2.12. Cylinder compression pressure

z Stop the engine after warming up,
and take out preheating plug and
injection pipe.
z Install the special tool

(compression gauge adapter) at
the preheating plug hole, and
connect the compression pressure
gauge there.
z Check the compression pressure

at gauge several times until highest
compression reading is reached.
Standard value 28kg/cm2 over

Limit value 24kg/cm2
Difference
Within 10 %
between each cylinder
z Condition : Water temperature 75C.
DB58/T/TI/TIS
2.13. Injection nozzle
z Install a nozzle on the nozzle tester.

z If the inspected injection pressure is less than the specified value, adjust using
the adjusting shims.
Injection nozzle
Engine model
pressure
DB58, DB58S, DB58T 220 kg/cm2
EAOEA/B/C/D, EAOLA/B 185 kg/cm2
DB58TI
EAOEF 200 kg/cm2
ECOLA 185 kg/cm2
DB58TIS
ECOEA/B/C/D/E/F/G, ECOLB 190 kg/cm2
z Check the atomizing state and replace it if abnormal.
2.14. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12
1.28), replenish.
2.15. Starting motor

z In case of engine maintenance, clean pinion and ring gear thoroughly putting in
the fuel, and coat them with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being
careful for water not to get in.
DB58/T/TI/TIS
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.
DB58/T/TI/TIS
DB58/T/TI/TIS
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DB58/T/TI/TIS
Condition Causes Remedies
1) Starting difficult
(1) Compression pressure z Valve's poor shut, stem distortion Repair or replace
z Valve spring damage Replace valve spring
z Cylinder head gasket's leak Replace gasket
z Wear of piston, piston ring or liner Adjust
2) Idle operation abnormal z Injection timing incorrect Adjust
z Air mixing at injection pump Remove air
3) Engine output insufficient
(1) Continuous output Insufficient z Valve clearance incorrect Adjust
z Valve tightness poor Repair
z Cylinder head gasket's leak Replace gasket
z Wear, stick, damage of piston ring Replace piston ring
z Injection timing incorrect Adjust
z Fuel injection amount insufficient Adjust injection pump
z Nozzle injection pressure improper or stuck Adjust or replace
z Supply pump's function lowered Repair or replace
z Fuel pipe system clogged Repair
z Air suction amount insufficient Clean or replace air cleaner
z Turbocharger poor Repair or replace
(2) Output insufficient Compression pressure insufficient Disassemble engine
when in acceleration
z Injection timing incorrect Adjust
z Fuel injection amount insufficient Adjust injection pump
z Injection pump timer's function insufficient Repair or replace
z Nozzle injection pressure, injection angle Repair, replace
improper
z Supply pump's function lowered Repair or replace
Air intake amount insufficient Clean or
replace air cleaner
4) Overheating z Engine oil insufficient or poor Replenish or replace
z Cooling water insufficient Replenish or replace
z Fan belt loosened, worn, damaged Adjust or replace
z Cooling water pump's function lowered Repair or replace
z Water temperature regulator's operation Replace
poor
z Valve clearance incorrect Adjust
z Exhaust system's resistance increased Clean or replace
DB58/T/TI/TIS
Condition Causes Remedies
5) Engine noisy For noises arise compositely such as rotating
parts, lapping parts etc., there is necessity to
search the cause of noises accurately.
(1) Crankshaft z As the wear of bearing or crankshaft Replace bearing & grind
progress, the oil clearances increase. crankshaft
z Lopsided wear of crankshaft Grind or replace
z Oil supply insufficient due to oil passage Clean oil passage
clogging
z Stuck bearing Replace bearing & grind
(2) Connecting rod and z Lopsided wear of connecting rod bearing Replace bearing
Connecting rod bearing
z Lopsided wear of crank pin Grind crankshaft
z Connecting rod distortion Repair or replace
z Stuck bearing Replace & grind crankshaft
z Oil supply insufficiency as clogging at oil Clean oil passage
passage progresses
(3) Piston, piston pin & z Piston clearance increase as the wear of Replace piston &
piston ring piston and piston ring progresses piston ring
z Wear of piston or piston pin Replace
z Piston stuck Replace piston
z Piston insertion poor Replace piston
z Piston ring damaged Replace piston
(4) Others z Wear of crankshaft, thrust bearing Replace thrust bearing
z Camshaft end play increased Replace thrust plate
z Idle gear end play increased Replace thrust washer
z Timing gear backlash excessive Repair or replace
z Valve clearance excessive Adjust valve clearance
z Abnormal wear of tappet, cam Replace tappet, cam
6) Fuel Consumption excessive z Injection timing incorrect Adjust
z Fuel injection amount excessive Adjust injection pump
7) Oil consumption excessive
excessive
(1) Oil level elevated z Clearance between cylinder liner & piston Replace
z Wear of piston ring, ring groove Replace piston, piston ring
z Piston ring's damage, stick, wear Replace piston ring
z Piston ring opening's disposition improper Correct position
z Piston skirt part damaged or abnormal wear Replace piston
z Oil ring's oil return hole clogged Replace piston ring
z Oil ring's contact poor Replace piston ring
(2) Oil level lowered z Looseness of valve stem & guide Replace in set
z Wear of valve stem seal Replace seal
z Cylinder head gaskets leak Replace gasket
(3) Oil leak z Looseness of connection parts Replace gasket, repair
z Various parts' packing poor Replace packing
z Oil seal poor Replace oil seal
DB58/T/TI/TIS
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.
: Check & adjust : Replace
Every Every Every Every Every
Inspection Daily Remark
50hrs 200hrs 400hrs 600hrs 1200hrs
Check for leakage(hoses, clamp)
Check the water level
Cooling Change the coolant water
System Every
Adjust the V-belt tension
2,000hrs
Clean the radiator
Check for leakage
Check the oil level gauge
Lubrication
Change the lubricating oil
System 1st

Replace the oil filter cartridge
1st
Check the leakage for intercooler
Intake &
(hoses, clamp)
Exhaust
Clean and change
System
the air cleaner element clean
Check the leakage fuel line
Clean the fuel strainer

of fuel feed pump
Remove sediment from fuel tank
Fuel Drain the water in separator
System Replace the fuel filter element
When
Check fuel injection timing
necessary
When
Check the injection nozzles
necessary
Check the state of exhaust gas
Check the battery charging
Engine When
Adjust Check the compression pressure
necessary
Adjust Intake/Exhaust When
valve clearance 1st necessary
2.18. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original
parts that the manufacture recommends to use is used, the engine trouble would be
preventively maintained and capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill
performance, it may rather bring early engine failure.
DB58/T/TI/TIS
3. Maintenance
3.1. Engine Disassembly
3.1.1. Major part fixing nuts and bolts
1) Cylinder head cover
(Unit : kg.m)
42 Engine disassembly
DB58/T/TI/TIS
2) Cylinder block
(Unit : kg.m)
DB58/T/TI/TIS
3) Oil pan and level gauge
(Unit : kg.m)
DB58/T/TI/TIS
4) Camshaft and rocker arm
(Unit : kg.m)
DB58/T/TI/TIS
5) Crankshaft, piston and flywheel
(Unit : kg.m)
DB58/T/TI/TIS
6) Thermostat and housing
(Unit : kg.m)
DB58/T/TI/TIS
7) Intake and exhaust manifold
(Unit : kg.m)
DB58/T/TI/TIS
(Unit : kg.m)
DB58/T/TI/TIS
(Unit : kg.m)
2.60.5
3.10.5
3.80.7
3.80.7
2.9
DB58/T/TI/TIS
9) Timing gear case and flywheel housing
(Unit : kg.m)
DB58/T/TI/TIS
10) Oil cooler, oil filter and oil pump
(Unit : kg.m)
DB58/T/TI/TIS
11) Fuel system
(Unit : kg.m)
DB58/T/TI/TIS
12) Engine repair parts
2 3 5
1 4
9 10
8
7
6
13 14 15
11 12
20 21 22
16 17 18
19
1 Cover to timing gear case gasket 12 Oil filter cover gasket

2 Gear case to cylinder block gasket 13 Oil cooler gasket
3 Timing gear case oil seal 14 Intake manifold gasket
4 Flywheel housing gasket 15 Oil pan gasket
5 Crank shaft rear oil seal 16 Turbocharger gasket
6 Cylinder head gasket 17 Turbocharger outlet gasket
7 Cylinder head cover gasket 18 Water pump gasket
8 Valve guide oil seal 19 Water pump housing gasket
9 Tappet chamber cover gasket 20 Exhaust manifold gasket
10 Air heater gasket 21 Thermostat gasket
11 Thermostat housing gasket 22 Oil pump hole cover gasket
DB58/T/TI/TIS
3.1.2. Main structure parts (1)
1. Rubber hose (Coolant by-pass) 9. Oil pump driving pinion

2. Rocker arm shaft assembly 10. Nut
3. Push rod 11. Crankshaft pulley and dust cover
4. Cylinder head bolt 12. Taper bushing
5. Cylinder head assembly 13. Timing gear cover
6. Cylinder head gasket 14. Oil thrower
7. Coolant pump assembly 15. Fly wheel
8. Tappet chamber cover
2) Rocker arm shaft

Loosen the rocker arm shaft fixing
bolts a little in numerical sequence
as specified.
DB58/T/TI/TIS
5) Cylinder head
Loosen the cylinder head bolts a
little in the numerical order shown in
the figure.
11) Crankshaft pulley

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

Use the taper bushing remover to
remove the crankshaft end taper
bushing.
15) Flywheel
Loosen the flywheel bolts a little in
the numerical order as specified.
DB58/T/TI/TIS
3.1.3. Main structure parts (2)
1. Oil cooler 9. Timing gear case

2. Oil pan 10. Idler gear shaft
3. Oil pump and coupling 11. Crank shaft bearing cap
4. Flywheel housing 12. Crank shaft bearing (lower part)
5. Piston and connecting rod 13. Thrust bearing
6. Idler gear 14. Crank shaft
7. Cam shaft 15. Crank shaft bearing (upper part)
8. Tappet
DB58/T/TI/TIS
6) Idler gear
Measure the following points before
disassembly.
<Idler gear end play>

Standard Limit
0.058 0.115 mm 0.2 mm
<Timing gear back lash>

Standard Limit
0.10 0.17 mm 0.3 mm
Includes the crankshaft gear, the

camshaft gear and the idler gear
7) Camshaft
Measure the following points before
disassembly.
<Cam Gear End Play>

Standard Limit
0.050 0.114 mm 0.2 mm
11) Crankshaft bearing cap

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

Standard Limit
0.15 0.33 mm 0.4 mm
DB58/T/TI/TIS
3.1.4. Rocker arm disassembly
1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft
DB58/T/TI/TIS
3.1.5. Cylinder head disassembly
1. Exhaust manifold and gasket 7. Spring seat (upper)

2. Intake manifold and gasket 8. Valve spring
3. Coolant outlet pipe 9. Spring seat (lower)
4.Thmostat 10.Valve
5. Thermostat housing and gasket 11. Valve stem oil seal
6. Valve cotter
Importance
6) Valve cotter
Use the valve spring compressor to
remove the valve cotter.
DB58/T/TI/TIS
3.1.6. Piston and connecting rod disassembly
1. Piston rings 4. Piston

2. Snap ring 5. Connecting rod bearing
3. Piston pin and connecting rod
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.
DB58/T/TI/TIS
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.
DB58/T/TI/TIS
3.2. Engine Inspection

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>
Standard Limit
Warpage 0.2 mm or less 0.3 mm
Thickness : t 89.95 90.05 mm 89.65 mm
63 Engine inspection
DB58/T/TI/TIS
3) Flatness
Measure flatness of the
intake/exhaust manifolds fitting
surfaces on the cylinder head using a
straight edge and a feeler gauge.
Standard Limit
0.05 mm 0.2 mm
4) Hydraulic test
Hydraulic test method for the cylinder
head is same as that for cylinder
block.
3.2.3. Valve stem and valve guide clearance

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

Standard Limit
Intake side 0.039 0.071mm 0.20mm

Exhaust side 0.064 0.096mm 0.25mm
DB58/T/TI/TIS
2) Measuring method II
z Measure valve stem outside
diameter.
z Measure valve guide inside
diameter by using of caliper
calibrator of telescoping gauge.
z The difference between the valve
stem outside diameter and the
valve guide inside diameter is the
valve stem clearance.
3) Valve guide replacement

z Removal of valve guide
z Pull out the valve guide, by using
hammer and valve guide remover,
from bottom of cylinder head.
z Install of valve guide

z The height from the bottom of the
cylinder head to the edge of valve
guide top should be 14.1mm.
4) Valve depression
z Install the valve to the cylinder
head.
z Measure valve depression by
using the depth gauge or
calibrator from the bottom of
cylinder head.
z Seat insert and valve must be
replaced if the measured value
exceed the specified limit.
z If the valve is replaced, the valve
guide must be also replaced.
DB58/T/TI/TIS
Standard Limit
Intake and exhaust
1.0 mm 2.5mm
valve depression
5) Valve contact width

z Inspect the valve contact faces
for the roughness and
unevenness.
Make valve contact surfaces
smooth.
z Measure the width of valve
contact.
Standard
Valve contact width, Intake 2.4mm
Valve contact width,
1.6mm
Exhaust
6) Valve seat replacement

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

z Carefully place Jig.
Caution:
The smooth face of jig must
contact the valve seat.
z Assemble valve insert by slowly

pressing it against the jig with the
bench press.
(The amount of needed pressure
is more than 2,500kg.)
DB58/T/TI/TIS
IMPORTANT:
Do not press the valve seat
excessively with the bench press.
It may damage the valve seat.
8) Valve seat correction

z Remove the carbon deposits
from the valve seat surface.
z Remove the rough areas by
using valve cutter. (30, 90 or
150)
Do not cut the valve seat too
much.
Angle Location Standard

Intake valve seat 90
Exhaust valve seat 90
IMPORTANT:
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to
wobble inside the valve guide.
z Spread compound on the surface

of valve seat.
z Insert valve into valve guide.
z Lap the valve and valve seat with
the lapping tool.
z Check that valve contact width is
correct.
DB58/T/TI/TIS
z Check that the entire surface of

valve seat is in contact with the
valve.
3.2.4. Valve spring

1) Valve spring free length
z Measure the valve spring with the
vernier caliper.
z Replace the spring if the
measured value is less than the
specified limit.
Standard Limit
Exhaust and intake
valve spring free 53.65 mm 52 mm
length
2) Valve spring inclination

z Measure the valve spring
inclination by the using of square.
z Replace the valve spring if the
measured value exceed the
specified limit.
Standard Limit
Valve spring
2.5 mm 3.5 mm
Inclination
3) Valve spring tension

z Measure the valve tension by
using spring tester.
z Replace the valve spring if the
measured value exceed the
specified limit.
DB58/T/TI/TIS
Standard Limit
Valve spring tension
22.5 kg 20.0 kg
at 44mm set length
3.2.5. Tappet
z Check the valve tappets for excessive
wear, damage or abnormalities.
z Measure the outside diameter of

tappet with the micrometer.
Standard Limit
Tappet outside
27.96 27.98mm 27.92mm
diameter
z Measure the clearance between

tappets and cylinder motion parts by
the using dial indicator.
Standard Limit
Tappet and tappet
0.020 0.054mm 0.1mm
bore clearance
3.2.6. Push rod

z Measure the run out of push rod
with the feeler gauge.
z Roll the push rod along a smooth
flat surface as shown in the figure.
Limit
Push rod of run-out 0.2mm
DB58/T/TI/TIS
3.2.7. Rocker arm correction

z Check the valve stem contact part
of rocker arm.
z Grind contact surface with an oil
stone if it is irregularly contacted.
z Replace the rocker arm if it is
extremely damaged.
1) Rocker arm and shaft

z Check the disassembled parts for
wear, damage and abnormalities.
2) Rocker arm shaft outside diameter

z Measure the outside diameter of
rocker arm with the micrometer.
z Replace shaft if measured value
Standard Limit
diameter of
18.98-19.00 mm 18.85 mm
rocker arm shaft
3) Rocker arm and shaft clearance

z Measure the inside diameter of
rocker arm bushing with the
vernier caliper.
z Measure the out side diameter of
rocker arm shaft.
Replace the rocker arm or rocker
arm shaft if measured value
DB58/T/TI/TIS
Standard Limit
Diameter of rocker 19.02 19.07
Arm bushing 19.05mm mm
Standard Limit
Rocker arm
bushing and 0.02 0.07
0.2 mm
rocker arm shaft mm
clearance
z Check the rocker arm oil port

whether alien substance is in it or
not.
z Clean the rocker arm oil port
with compressed air if necessary.
3.2.8. Idler gear and shaft

z Replace the idler gear shaft if the
measured value exceeds the
specified limit.
Standard Limit
Diameter of 44.945 44.975
44.9 mm
idler gear shaft mm

idler gear with the dial indicator,
Standard Limit
Clearance of
0.045 0.105
idle gear and 0.2 mm
mm
shaft
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.
DB58/T/TI/TIS
Standard Limit
Clearance of
cam journal and 0.03 0.09 mm 0.15 mm
cam bearing
z Align the camshaft bearing oil port

with the mating oil port (machined on
the cylinder block).
z Measure the cam lobe with the

micrometer.
Replace the camshaft if the
measured values exceed the
specified limit.
Standard Limit
Cam lobe height (C-D), In 7.44 mm 6.94 mm
Cam lobe height (C-D), Ex 7.71 mm 7.21 mm
Cam journal diameter 56.0 mm 55.6 mm
z Set up the camshaft on a measuring

stand.
z Measure the run out of camshaft with
the dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the
specified limit.
Limit
Camshaft run-out 0.12 mm
DB58/T/TI/TIS
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.
z Measured position: 20 mm from

the top of liner. (max. wear
portion)
z Replace the cylinder liner if the
measured value exceeds
specified limit.
Standard Limit
Diameter of
102.017102.046 mm 102.20 mm
cylinder liner bore
CAUTION:
The casting liner is specially honed without the chrome plating inside, so that
chrome plated ring (top ring and oil ring) must be used.
2) Cylinder liner inspection

z Set up the straight square along
the top edge of cylinder liner.
z Measure liner projection with the
feeler gauge.
Standard
Cylinder liner Cast liner 0.02 0.07 mm
projection Steel liner 0.015 0.115mm
z The difference in the liner

projection height between any two
adjacent cylinders must NOT
exceed 0.3mm
DB58/T/TI/TIS
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.

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 Calculate average value of four

measurements to determine the
correct cylinder liner grade.
DB58/T/TI/TIS
Grade marking Cylinder block bore diameter

1 105.090 106.000 mm
2 106.000 106.010 mm
3) Cylinder liner outside diameter

z Measure the liner outside
diameter at , and
measuring point across X-X, Y-Y.
Measuring Points :
20.0 mm
105.0 mm
185.0 mm
z Calculate the average value of 6 measurements to determine the correct

cylinder liner grade.
z Combination of the cylinder bore and the cylinder liner outside diameter.
Steel liner Cast iron liner

(tightness) (clearance)
Cylinder liner fitting clearance 0.001 0.019mm 0.005 0.026mm
<Cylinder bore and liner outside diameter>

(A) Steel cylinder liner
Grade Cylinder bore Cylinder liner outside diameter
1 105.001 105.010mm 105.011 105.020mm
2 105.011 105.020mm 105.021 105.030mm
3 105.021 105.030mm 105.031 105.040mm
(B) Cast iron cylinder liner

Cylinder liner diameter
Grade marking
position , position
D 102.020 102.031mm 102.017 102.035mm 1
(Inner diameter) 102.031 102.042mm 102.028 102.046mm 2
E 105.973 105.984mm 105.970 105.988mm A
(Outer diameter) 105.984 105.995mm 105.981 105.999mm B
DB58/T/TI/TIS
Part no of cylinder Cylinder liner diameter

Marking
liner grade Outer Inner
65.01201-0068 1 A 1A
65.01201-0069 1 A 1B
65.01201-0070 2 B 2A
65.01201-0071 2 B 2B
4) Cylinder liner assembly

z Carefully wipe away any foreign
material from the cylinder liner
inside and outside surfaces and
the cylinder bore.
z Cleanly wash cylinder liner and
bore surfaces with new kerosene
or diesel oil.
z Use a clean rag to remove all
traces of kerosene or diesel oil
from cylinder liner and bore
surfaces.
z Insert the cylinder liner into
cylinder block from the top of the
cylinder block.
z Set the cylinder liner installer to
the top of the cylinder liner.
z Position the cylinder body so that
the installer center is directly
beneath the bench press shaft
center.
z Check that the cylinder liner is
set perpendicular to the cylinder.
z Use the bench press to apply an
initial seating force of 500kg to
the cylinder liner.
z Use the bench press to apply a
final seating force of 2,500kg to
fully seat the cylinder liner.
z After installing the cylinder liner,
measure the cylinder liner
projection.
DB58/T/TI/TIS
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
z Measure cylinder liner bore at
measuring points and in
four different directions (X-X, Y-Y,
W-W and Z-Z).
z Calculate the average value of
the 8 measurements.
Standard
Cylinder liner bore 102.020 102.042 mm
CAUTION:
It is most important to use correct piston-liner combination. Incorrect
combination will result in piston seizure.
Always measure the cylinder bore and select the appropriate piston grade.
3.2.12. Piston
1) Piston outside diameter
z Piston outside diameter vary
depending on the piston type to
be used.
z Measure the piston outside
diameter (see figure).
<Piston grade>
Grade Limit
A 101.953 101.967 mm
B 101.963 101.977 mm
DB58/T/TI/TIS
<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
specified limit.
<Piston ring and piston groove clearance>

Standard Limit
Top ring 0.070 0.120 mm 0.20
2nd ring 0.050 0.085 mm 0.15
Oil ring 0.030 0.070 mm 0.15
3) Piston ring gap

z Insert the piston ring horizontally
(in the position it will assume if it
were installed to the piston) into
the cylinder liner.
z Push the piston ring with an
inverted piston into the cylinder
liner until it reaches measuring
point or .
DB58/T/TI/TIS
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 Measure piston ring gap with a feeler gauge.
z The piston ring must be replaced if the measured value exceeds the specified
limit.
Standard Limit
Top ring gap 0.25-0.45 mm 1.50 mm
2nd ring gap 0.40-0.60 mm 1.50 mm
Oil ring gap 0.20-0.40 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
specified limit.
Standard Limit
Piston pin
35.000 35.005mm 34.95 mm
outside diameter
5) Piston pin hole

z Measure diameter of the piston
pin hole with inside dial gauge.
Standard
Piston pin and piston clearance 35.010 35.018 mm
6) Piston pin and piston pin hole clearance

z Determine the clearance between
the piston pin and the piston pin
hole by calculating the difference
between the piston pin hole
diameter and the piston pin
outside diameter.
DB58/T/TI/TIS
Limit
Piston pin and piston pin
0.005 0.018 mm
hole clearance
z If an inside dial indicator is not

available, use the following
procedure to check the piston pin
fit.
(1) Heat piston to approximately
60C with the piston heater.
(2) Push strongly against the
piston pin with your thumb.
The piston pin fitting should
feel tight.
3.2.13. Maintenance of cylinder block, cylinder liner and piston

To maintain the engine in optimum condition and retain maximum performance for a
long time, the cylinder block, cylinder liner and piston which have the same grade
marking number (the same size tolerance) should be assembled. The marking
number (the parts grade) and marking position is as follows.
z Cylinder block
a) Marking number ; 1 or 2
(Size grade for of cylinder bore
diameter) Marking
b) Marking position ; Top of the
cylinder block side surface
z Cylinder liner
a) Marking number; 1A, 1B, 2A or 2B
1A
Can used the piston A grade
Can used the cylinder block 1 grade
b) Marking position ; Cylinder liner

lower surface
DB58/T/TI/TIS
z Piston
a) Marking number ; A or B
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper surface
z Assembly process of cylinder block, cylinder liner and piston

(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just
the same with it on the cylinder block.
(3) Assemble the piston whose marking is just same with the second digit (A or B)
of the assembled cylinder liners marking.
3.2.14. Connecting rod

1) Connecting rod alignment
z Measure the parallelism between
the connecting rod big end hole
and small end hole with a
connecting rod aligner.
z Replace the connecting rod if the
specified limit.
Standard Limit
Connecting rod
0.05mm or less 0.20 mm
parallelism
2) Piston pin and bush clearance

z Measure an inside of connecting
rod bushing and outside of piston
pin with the caliper gauge and
micrometer.
z Replace a connecting rod bush or
piston pin if the measured value
exceeds the specified.
Standard Limit
Piston pin and
0.012 0.030mm 0.05 mm
bushing clearance
3) Connecting rod bush replacement

z Connecting rod bush removal
1) Clamp the connecting rod in a vise.
2) Pull out connecting rod bush by using a brass bar with a bench press or a
hammer.
DB58/T/TI/TIS
z Connecting rod bush assembly

(1) Use special jig to assemble
the connecting rod bush.
IMPORTANT:
Align the connecting rod bush oil hole with the connecting rod oil hole.
(2) Use a piston pin hole grinder

fitted with a reamer or
an adjustable pilot reamer to
ream the piston pin hole.
Standard
Connecting rod bush
35.017 35.030 mm
inside diameter
4) Connecting rod bearing Inspection

z Fit the connecting bearing lower
half into the connecting rod
bearing cap.
z Check the tension of the
connecting rod bearing lower half.
If the tension is insufficient, the
bearing must be replaced.
z Tighten the connecting rod and
the bearing cap to the specified
torque.
A type B type
Connecting rod
12 00.25kg.m 9.750.25kg.m
bolt torque
A type :
B type : TY or TY
11 12
DB58/T/TI/TIS

the connecting rod bearing with
an inside dial gauge.
Standard
Connecting rod 63.974 64.005
bearing diameter mm
3.2.15. Crankshaft
1) Crankshaft and bearing inspection
z Check the crankshaft journal surfaces and pin surfaces for excessive wear and
damage.
z Check oil seal fitting surfaces of the crankshaft front and rear ends for
excessive wear and damage.
z Replace or repair the crankshaft if any excessive wear or damage is
discovered.
z Check the crankshaft oil ports for obstructions.
z Clean oil port with high pressure air if necessary.
2) Crankshaft journal and pin diameter

z Measure the crankshaft journal
outside diameter with the
micrometer across - and
-.
z Measure crankshaft journal
outside diameter at two points
and by using the micrometer.
z Repeat step 1 and 2 to measure
the crankshaft outside diameter.
The crankshaft must be reground
if the measured value of the
crank pin outside diameter and/or
crankshaft journal diameter
exceeds the specified limit.
Standard
Crankshaft journal
79.905 79.925mm
outside diameter
Standard
Crankshaft pin
63.924 63.944 mm
outside diameter
DB58/T/TI/TIS
z Measure the crankshaft journal outside diameter (and/or crankshaft pin outside
diameter) and bearing inside diameter to determine the bearing clearance.
3) Crankshaft journal and bearing clearance

z If the bearing clearance exceeds the specified limit, the crankshaft must be
reground and/or the bearing must be replaced.
Standard Limit
Main bearing
0.025 0.090 mm 0.11 mm
clearance
Standard Limit
Rod bearing
0.03 0.073 mm 0.10 mm
clearance
4) Crankshaft bearing diameter

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

24.11kg.m
torque
Main bearing diameter 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
DB58/T/TI/TIS
the specified limit.
Standard Limit
Crankshaft run-out 0.05 mm 0.40 mm
z If the repaired crankshaft

generated a crack, replace it.
6) Main bearing and con-rod bearing tension

z Check to see if the bearing has
enough tension, and set bearing
into its regular position with the
finger pressure.
7) Crankshaft regrinding
z Pay close attention to the
following steps in order to ensure
the reground-crankshaft reliability.
Undersize bearing
0.25 mm 0.50 mm
Availability
<Crankshaft regrinding procedure>

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

0.4 or less
crank pin roughness
(4) Measure the clearance between

crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.
DB58/T/TI/TIS
8) Crankshaft grinding limit
Classification Limit
Crank journal outside
79.419 mm
Diameter
Crank pin outside
63.424mm
Diameter
z 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 Limit
Main bearing
0.039 0.098 mm 0.11 mm
clearance
Standard Limit
Connecting
0.03 0.073 mm 0.10 mm
rod bearing
9) Crankshaft gear replacement

z Visually inspect the crankshaft gear.
z Replace the crankshaft gear as

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

gear by using the crankshaft
remover.
(2) Replace new part.

(3) Heat the crankshaft gear for at
least 10 minutes to 120oC
(4) Use the crankshaft gear
installer to install the crankshaft
gear.
DB58/T/TI/TIS
3.2.16. Flywheel and flywheel housing

1) Ring gear inspection
z Inspect the ring gear.
z If the ring gear teeth are broken
or excessively worn the ring gear
must be replaced.
2) Ring gear replacement

z Strike around the edges of the
ring gear with a hammer and
chisel to remove it.
3) Ring gear installation

z Heat the ring gear evenly with a
gas burner to invite thermal
expansion.
Pay attention that temperature of
ring gear is not exceeded 200C.
z Use a hammer to install the ring
gear when it is sufficiently heated.
4) Oil seal replacement (rear)

z Use a pry bar to remove the
flywheel housing oil seal.
z Assemble the oil seal to flywheel
housing by using the oil seal
assemble jig.
5) Oil seal replacement (front)

z Use an adapter and a hammer to
remove the crankshaft front end
oil seal.
z Assemble the oil seal to flywheel
housing by using the oil seal
assemble jig.
DB58/T/TI/TIS
3.3. Engine Reassembly
3.3.1. Piston and connecting rod assembly
1. Piston 4. Piston ring

2. Piston Pin and connecting rod 5. Connecting rod bearing
3. Snap ring 6. Connecting rod bolt
1) Piston
z Use a piston heater to heat piston
to approximately 60C.
88 Engine reassembly
DB58/T/TI/TIS
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 way
because it is not indicated.
z Lubricate the surface of piston ring with
engine oil.
z Check it whether piston rings are
smoothly rotating in the piston ring
grooves.
5) Connecting rod bearing

z Assemble the connecting rod bearing to the big end and the cap.
z Lubricate the bearing with engine oil.
z Assemble the connecting rod and connecting rod bearing, and tighten cap bolt
as the specified torque.
DB58/T/TI/TIS
3.3.2. Cylinder head assembly parts
1. Valve stem oil seal 7. Thermostat housing and gasket

2. Intake and exhaust valve 8. Thermostat
3. Spring seat (lower) 9. Cooling water outlet
4. Intake and exhaust valve spring 10. Intake manifold and gasket
5. Spring seat (upper) 11. Exhaust manifold and gasket
6. Valve cotter
1) Valve stem oil seal

z Lubricate the oil seals and valve
stem sealing area with engine oil.
z Assemble the valve stem oil seal
by using oil seal installer.
DB58/T/TI/TIS
2) Intake and exhaust valves

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

z Assemble the valve spring with
their painted end facing top.
5) Spring seat
6) Valve cotter
z Use a spring compressor to push
the valve spring into position.
z Install the spring seat split collar.
z Set the spring seat split collar by

tapping lightly around the head
of the collar with a rubber
hammer.
DB58/T/TI/TIS
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 Assemble the intake manifold.

z Tighten the intake manifold bolts
to the specified torque a little at a
time in the numerical order. (see
figure)
Intake manifold
2.2 kg.m
bolt torque
11) Exhaust manifold and gasket

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

z Tighten the exhaust manifold
bolts to the specified torque a
little at a time in the numerical
order. (see figure)
Exhaust manifold
2.2 kg.m
bolt torque
DB58/T/TI/TIS
3.3.3. Rocker arm and shaft assembly
1. Rocker arm shaft 3. Rocker arm

2. Spring 4. Bracket
1) Rocker arm shaft

z The rocker arm shaft must be
installed with the oil holes facing up.
DB58/T/TI/TIS
3.3.4. Main components
2. Crankshaft bearing (lower) 9. Idler gear shaft

3. Crank shaft 10. Idler gear
4. Thrust washer 11. Piston and connection rod
5. Crank shaft bearing (upper) and cap 12. Oil pump and coupling
6. Timing gear case 13. Flywheel housing
7. Tappet 14. Oil pan
8. Camshaft 15. Oil cooler
* The tappet must be installed before the camshaft installation.
DB58/T/TI/TIS
2) Crankshaft bearing (lower)

z There is no oil hole and oil
groove on the lower bearing. But
opposite upper bearing has oil
hole and oil groove.
3) Crankshaft
z Assemble the crankshaft gear in
front side.
CAUTION:
Make sure the part number of
crankshaft because its
counterweight size may be
different depending upon engines.
4) Thrust washer
z Assemble thrust washer with the
oil groove side facing the
crankshaft sliding face.
5) Crankshaft bearing cap

z Lubricate the bearing cap bolts
with engine oil.
z Assemble the bearing caps to
the crankshaft.
The arrow mark must be pointing
to the front of the engine.
DB58/T/TI/TIS
z Tighten the bearing cap bolts to

the specified torque a little at a
figure)
Crankshaft bearing
24.01kg.m
cap bolt torque
z Check that the crankshaft turns

smoothly by manually rotating it.
6) Timing gear case

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

2.2 kg.m
bolt torque
z Apply silicon to the indicated

area. (see figure)
8) Camshaft
z Tighten thrust plate bolt through
the camshaft gear hole.
Thrust plate bolt

2.2 kg.m
torque
Camshaft gear bolt

13 kg.m
torque
9) Idler gear shaft

z Assemble an idler gear shaft by
using the thrust collar fixing bolt
as a guide.
z The oil hole must be facing the
camshaft.
z Lubricate the idle gear shaft with
engine oil.
DB58/T/TI/TIS
10) Idler gear

z Assemble the idle gear.
Set the timing marks A, B,
and C as shown in the figure.
z Tighten the idle gear bolts
seating the thrust collar to the
specified torque.
z The thrust collar must be
installed with the chamfered side
facing the front of the engine.
Idle gear bolt torque 4.4 kg m
11) Piston and connecting rod

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

towards the front of the engine.
z Use the piston ring compressor
to compress the piston rings.
z Push the piston in until it makes
contact with the crank pin by
using a hammer grip.
At the same time, rotate the
crankshaft until the crank pin
reaches its highest point.
z Set the bearing cap cylinder

number marks and the
connecting rod cylinder number
marks.
z Lubricate the connecting rod cap
bolt threads and setting face with
MoS2 grease.
z Tighten the connecting rod cap bolts to

the specified torque.
Refer to the following table.
DB58/T/TI/TIS
Torque 120.25kg.m 9.750.25kg.m
Bolt
head
TY
11 TY
12
12) Oil pump assembled

z Lubricate the oil pump with the
specified engine oil.
z Install the oil pump with the
coupling.
z Tighten the oil pump bolts to the
specified torque.
Oil pump bolt torque 5.0 kg.m
13) Flywheel housing

z Apply silicon to the shaded area.
(see figure)
z Install the flywheel housing.
Tighten the flywheel housing bolts
to the specified torque.
M14 x 1.5 13 kg.m

M14 x 1.5 18 kg.m
14) Oil pan

z Apply liquid gasket to the area
indicated by the arrows in the
figure.
z Install the gasket and oil pan.
z Tighten the oil pan bolts to the
specified torque.
Oil pan bolt torque 2.2 kg m
DB58/T/TI/TIS
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 2.2 kg m
DB58/T/TI/TIS
3.3.5. Major component assembly
1. Flywheel 9. Oil pump driving pinion

2. Crankshaft pulley nut 10. Push rod
3. Tappet chamber cover 11. Taper bushing
4. Water pump 12. Crankshaft pulley and dust cover
5. Cylinder head gasket 13. Timing gear cover
6. Cylinder head bolt 14. Oil thrower
7. Cylinder head 15. Rubber hose
8. Rocker arm shaft Assembly

DB58/T/TI/TIS
1) Flywheel
z Lubricate the flywheel bolt with
engine oil.
z Install the flywheel.

Tighten the flywheel bolts to the
specified torque in the numerical
order. (see figure)
Flywheel Bolt torque 18 kg.m
2) Injection pump
z Align the injection pump gear "C"
timing mark with the idler gear
C timing mark.
z Tighten the injection pump bolts

Injection Pump Bolt Torque 2.2 kg.m
3) Crankshaft pulley nut

z Tighten the crankshaft pulley nut
to the specified torque by using a
wrench.
Crankshaft pulley nut torque 60 kg.m

DB58/T/TI/TIS
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

2.2 kg.m
bolt torque
4) Water pump
z Apply silicon to the pump gasket
before installing the water pump.
5) Cylinder head gasket

z The gasket TOP" mark should
be faced up and "FRONT" mark
is towards the front of the engine.
6) Cylinder head bolts

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

DB58/T/TI/TIS
Bolt type Torque

1st step : 7.0kg.m
hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step : 4.4 kg.m

Dodecagonal bolt 2nd step : 90
3rd step : 90
<12-gonal bolt limited value>

Standard(mm) Limit(mm)
115 116.2
102 103.2
z Apply engine oil to the cylinder

head bolts threads and setting
faces.
8) Rocker arm shaft assembly

z Tighten the rocker arm bolts to
the specified torque a little at a
figure)
Rocker arm shaft bracket bolt

3.1 kg m
torque
z Lubricate the rocker arm and the

rocker arm shaft with engine oil.
z Adjust valve clearance.

DB58/T/TI/TIS
3.3.6. External parts
3 4 5 6 7 17 18
2 16
1 8
19
15
9 10 11 12 13 14
20 21 22 23 27 28
24 25 26
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 nozzle

DB58/T/TI/TIS
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
Hex nut
the injection nozzle gaskets. Spring washer
Injection nozzle nuts torque 2.2 kg.m
O-ring
z Be careful not to damage the Injection nozzle
nozzle tips. Seal ring
4) Fuel injection pipe

z Install the fuel injection pipes
and tighten the bolts to the
specified torque.
Injection pipe torque 3.0 kg.m
z Carefully position and set the

1
Engine reassembly
105
DB58/T/TI/TIS
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.
z Install the fuel return pipes.
5) Oil filter
z Install the oil filter assembly with
tightening the bolts securely.
Oil filter assembly

5.0 kg.m
mounting bolts torque
Head, oil filter
Cartridge,
Oil filter
6) Fuel pipe
z Install the fuel pipe and tighten the fuel
pipe joint bolts to the specified torque.
Take care not to interchange the check
valves and joint bolts.
Fuel pipe joint bolt

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

4.2 kg.m
torque

DB58/T/TI/TIS
8) Intake pipe
z Install the intake pipe and tighten
the intake pipe flange bolts to the
specified torque.
Intake pipe flange bolt

2.2 kg m
torque

DB58/T/TI/TIS
3.4. Electrical Equipments
3.4.1. Wiring circuit

a) Glow plug system (type - 1)
b) Glow plug system (type - 2)
107 Electrical equipments

DB58/T/TI/TIS
c) Air heater system (type - 3)
3.4.2. Starting of winter
CAUTION :
1. Preheating devices are attached to the engine for improving the
starting abilities at extremely low temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails
regardless of the preheating, start the preheating again after 30
seconds.
Operation 1 : Turn the key switch to the HEAT position, then the pilot lamp lights
up for about 20 seconds When the pilot lamp is extinguished, do
operation 2
Behavior - When the coolant temperature is below 10 C in cold weather, youd
better operate the pre-heating system (Air heater)
- If the pre-heating is not necessary, the pre-heating system is not
operated with the pilot lamp.
Operation 2 : After checking the pilot lamp, turn the key switch to the START
position to crank the engine, at once.
Behavior - When the key switch is placed in the START position, air heater is
continuously heated to facilitate starting operation and to reduce
white smoke during 30 seconds automatically.
- If the coolant temperature is above 15 C, air eater needs not be
heated.
Operation 3 : After the engine is cranked, convert the key switch to the ON position.
Behavior - As the engine is cranked, air heater is heated for 30 seconds (after-
heating) to reduce and to element quickly white smoke.
DB58/T/TI/TIS
3.4.3. Alternator
The alternator is fitted with integral silicon rectifiers. A transistorized regulator
mounted on the alternator body interior limits the alternator voltage. The alternator
should not be operated except with the regulator and battery connected in circuit to
avoid damage to the rectifier and regulator.
a) 24V x 45A Alternator
24V 45A
The alternator is maintenance-free, nevertheless, it must be protected against dust

and, above all, against moisture and water.

DB58/T/TI/TIS
NOTE:
Operate the alternator according to the instructions given in the chapter.
1 Hex nut 13 Frame

2 Pulley 14 Bushing
3 Fan 15 Needle bearing
4 Collar 16 Rectipier
5 Bearing ass`y 17 Screw
6 Rotor ass`y 18 Regulator
7 Stator ass`y 19 Brush set ass`y
8 Cover 20 Brush holder
9 Pin 21 Spring
10 Stud bolt 22 Brush
11 Insulator 23 Brush
12 Bolt 24 Baffle

DB58/T/TI/TIS
b) 24V x 60A Alternator
24V 60A
Wiring Diagram

DB58/T/TI/TIS
3.4.4. Starting motor
The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-
hand side. As parts of every engine overhaul, the starter pinion and ring gear should
be cleaned with a brush dipped in fuel and then a coat of grease should be applied
again.
24Vx4.5kW
30 Terminal
(M10x1.5)
50 Terminal
(M5x0.8)
Wiring Diagram
50
30
Always protect starter motor against moisture.
WARNING:
Always disconnect the battery earth cable before starting work on the electrical
system. Connect up the earth cable last, as there is otherwise a risk of short-
circuits.

DB58/T/TI/TIS
1. Yoke assembly 14. Coil spring

2. Bush holder assembly 15. Pinion starter
3. End frame 16. Pinion stop nut
4. Through bolt 17. Snap ring
5. Armature assembly 18. Snap ring
6. snap retainer 19. Snap retainer
7. Idle gear 20. Coil spring
8. Clutch roller 21. Housing
9. Retainer 22. Terminal cap
10. Coil spring 23. Screw
11. Steel ball 24. Cover
12. Clutch assembly 25. Through bolt
13. Clutch shaft 26. Magnet switch assembly

DB58/T/TI/TIS
4. Commissioning and Operation
4.1. Preparation
At the time of initial commissioning of a new or overhauled engine make sure to have
observed the "Technical Information for the installation DAEWOO generator engines".
z Oil filler neck on cylinder head cover

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

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

4.2.1. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened.
Therefore the following things must be obeyed by all means.
Up to the first 150 hours (2,000km)

z Engine should be run at fast idling until the temperature of the engine
becomes normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
4.2.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant
as follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between the
"min." and max." marks on dipstick.
Note:
If you have a problem getting a good oil level reading on dipstick, rotate
dipstick 180 and re-insert for check.
DB58/T/TI/TIS
When adding engine oil, refer to Lubrication Section.
b)Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil dipstick. Add oil to the oil pan, if required.
Do not overfill. If level is correct and the status still exists, see your DEALER for
possible switch or oil pump and line malfunction.
Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In
addition, cold oil will generally show higher oil pressure for any specific RPM
than hot oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter
element. Fill oil pan with recommended engine oil. Refer to Lubricating System.
z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating
First oil change After 50hr operation
DB58
DB58T every 200 Hour
Construction equipments DB58TI
DB58S
every 250 Hour
DB58TIS
z The following oils are also recommended

Recommend oil
Engine model
SAE No. API No.
DB58
DB58TI
* If long oil change intervals are to be used, ACEA-E3 oil must be used.

DB58/T/TI/TIS
4.3. Inspections after starting
z It is advisable to operate an engine at idling until the engine reaches up to normal
operating temperature.
z Engine should be stopped if the color, the noise or the odor of exhaust gas is not
normal.
z Confirm the following things through warning lamps and gauge panel.
- Pressure of lubricating oil
The normal pressure comes up to 100 kPa (1.0 bar) at idling and 300 ~ 480 kPa
(3.0 ~ 4.8 bar) at maximum speed. If the pressure fluctuates at idling or does not
reach up to the expected level at high speed, shut down the engine immediately
and check the oil level and the leakage.
- Temperature of cooling water
The cooling water temperature should be 80 ~ 95 C in normal operating
conditions. Abnormally high cooling water temperature could cause the
overheating of engine and the sticking of cylinder components. And excessively
low cooling water temperature increases the fuel consumption, accelerates the
wears of cylinder liners and shortens the engine life-time.
NOTE:
When engine is overheated, do not stop the engine immediately. Lower the
engine load and run the engine and its cooling systems continuously.
4.4. Operation in winter time

Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.
4.4.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely
discharge the whole cooling water after Cooling water
drain valve
engine running. The freeze of cooling
water causes the fatal damages of the
engine. Because the anti-freeze is used
to prevent cooling water from freeze,
consult "The amount of anti-freeze".
4.4.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption,
therefore prevent the engine from excessive cooling. If the temperature of coolant does
not reach to normal condition (80 ~ 95 C) after continuous operation, examine the
thermostat or the other cooling lines.
4.4.3. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after
starting. Therefore the lubricating oil for winter should be used to prevent this
unstability. Refer to Lubrication System section.
DB58/T/TI/TIS
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, antifreeze, etc.

DB58/T/TI/TIS
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

DB58/T/TI/TIS
z Refill with new engine oil at the oil Oil filler cap
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 Cylinder head cover
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.
4.5.4. Replacement of oil filter cartridge

At the same times of oil exchanges,
replace the oil filter cartridge.
IMPORTANT:
Don't forget tightening the drain
valve after having drained engine
oil.
z Loosen the oil filter by turning it

counter-clockwise with a filter
wrench.
z With a rag wipe clean the fitting face
of the filter body and the oil filter
body so that new oil filter cartridge
can be seated properly.
z Lightly oil the O-ring and turn the oil
filter until sealing face is fitted Head, oil filter
against the O-ring. Turn 1-1/4 turns
further with the filter wrench.
Cartridge,
Oil filter
IMPORTANT:
It is strongly advisable to use DAEWOO genuine oil filter cartridge for
replacement.
DB58/T/TI/TIS
4.6. Cooling system

The coolant must be changed at intervals of 1,200 hours operation or six months
whichever comes first. If the coolant is being fouled greatly, it will lead an engine
overheat or coolant blow off from the expansion tank.
4.6.1. Coolant draining

z Remove the pressure cap.
z Open the drain valve at the
radiator lower part to drain the
coolant as the right figure.
z Loosen the coolant drain plug of the

cylinder block and oil cooler.
CAUTION:
When removing the pressure filler Cooling water
drain valve
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.
4.6.2. Cleaning of the cooling inside system circuit

(by authorized specialist personnel)
When the cooling system circuit are fouled with water scales or sludge particles, the
cooling efficiency will be lowered.
Investigations have shown that in many cases the poor condition of the coolant and /or
the cooling system accounts for damage to the water pump mechanical seal, The poor
condition of the cooling system is normally due to use of unsuitable or no anti-freezing
DB58/T/TI/TIS
agents and corrosion inhibitor or defect, not early enough replaced covers for filler
neck and working valves.
If twice in a short time the water pump of an engine develops leases or the coolant is
heavily contaminated (dull, brown, mechanically contaminated, grey or black sings of a
leakage on the water pump casing) clean the cooling system prior to removing that
water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown
through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of
cleaner. (Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60C is reached, run engine
for a further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Flush cooling system.
h) Replace drain plug by drain plug with a bore of 8mm diameter.
i) Fill cooling system with hot water.
j) Run engine at idle for 30 minutes. At the same time continuously replenish the
water leaking from the bore in drain plug by adding fresh water.
CAUTION:
Periodically clean the circuit interior with a cleaner.
4.7. Valve clearance and adjustment
NOTE:
The cylinder head bolts were
previously tightened with the
torque wrench. Therefore it is not
necessary to retighten the cylinder
head bolts before adjusting the
valve clearance.
Rocker arm screw

2.6 kg.m
lock nut torque
z After letting the #1 cylinder's piston

come at the compression top dead
center by turning the crankshaft,
adjust the valve clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the
feeler gauge of specified value

DB58/T/TI/TIS
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 Intake Valve Exhaust Valve
DB58
DB58S
DB58T 0.4 mm 0.4 mm
DB58TI
DB58TIS
1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then
#1 cylinder become the compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to of lower
figure. At this time there are no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression
state of top dead center.
4) Thereafter adjust the valve clearances corresponding to of lower
figure.
5) After reinsuring the valve clearances, retighten if necessary.
z No. 1 cylinder is located at the side where flywheel was installed.
Cooling fan Cylinder no. Exhaust valve Intake valve Fly wheel

DB58/T/TI/TIS
4.8. Injection timing
CAUTION:
Take care to avoid entry of dust or foreign particles into the pump interior
when the timing adjustment is made.
<Check procedure>
z Align the crankshaft pulley TDC
mark with the pointer.
z Remove the inspection hole cover
at the front of the injection pump on
the timing gear case cover.
z Check the alignment between the

pointer on the injection pump
gear nut lock plate and the
projection area mark on the
injection pump gear case.
z If it is in misalignment, recheck with
turning the crankshaft pulley one
more turn to repeat the foregoing
procedure to mark sure that it is in
alignment.
z Check the alignment of the
notched lines and . (These
notched lines were aligned at the
factory to set the injection pump
body and the mounting flange.)
Next, inspect the crank angle
position of the injection timing.
<Check procedure>
z Turn the crankshaft pulley
counterclockwise about 30 crank
angle.

DB58/T/TI/TIS
z Disconnect the injection pipe from

the No.1 plunger.
This will allow you to visually check
the full injection starting flow at No.
1 plunger.
z Remove the delivery valve holder,

the valve seat, valve spring,
and the delivery valve from the
No.1 plunger.
z Assemble the delivery holder
and tighten it to the specified torque.
Do not reassemble the delivery
valve, the delivery valve spring and
the valve seat.
These parts will be reassembled later.
z Hold the fuel control lever at the

fully open position.
z Slowly turn the crankshaft pulley
clockwise, at the same time,
continue to feed the fuel with
pumping the priming pump.
When the fuel stop to flow out from
the No.1 delivery valve holder, stop
the pump instantaneously.
This crank angle position is the
injection starting of the engine.
z Observe and make sure that mark

(injection starting angle line o) on
the crankshaft pulley is aligning
with the pointer.
Blow out the remaining fuel from
the delivery valve holder.
Make sure that there is no fuel
being delivered from the priming
pump.

DB58/T/TI/TIS
z Fuel injection timing angle
DB58/S DB58T DB58TI DB58TIS

Fuel injection timing (BTDC)

- Refer to the 1. 2. Engine power
z Remove the delivery valve holder

from the No.1 plunger
z Reassemble the delivery valve
internal parts to the delivery valve
holder.
z Reassemble the delivery valve
holder assembly to the No.1
plunger and tighten it to the
specified toque.
Delivery valve holder torque 4.25 kg m
z Assemble the No.1 cylinder injection pipe and tighten it to the specified torque.
Injection pipe nut torque 3.1 kg m
INPORTANT:
1) Do not overtighten the injection pump body. The injection pump body is
made of aluminum.
2) Overtighten will distort the injection pump body shape and adversely affect
control rack operation.
<Adjusting procedure>
z Align the pointer and the specified timing mark on the crank pulley.
z Perform the steps of checking procedure of Injection Timing.
z Loosen the 4 injection pump fixing nuts.
z Timing adjustment
To advance the timing
Pivot the injection pump at the
pump drive shaft toward out.
To retard the timing
Pivot the injection pump at the
pump drive shaft toward in. (toward
the cylinder block)

DB58/T/TI/TIS
IMPORTANT:
The 1 mm misalignment between the two setting mark lines corresponds to
about 2o in crank angle.
z Do a fine injection pump position adjustment, while continue the pumping

operation to feed the fuel, and stop to pivot the injection pump when the fuel stop
to flow out from the No. 1 delivery valve holder.
z Tighten the four injection pump fixing nuts.
z Once remove the No. 1 delivery valve holder, and reassemble the delivery valve,
spring and the valve holder with the specified torque.
z Install the No.1 injection pipe and tighten it to the specified torque.
4.9. Tightening the cylinder head bolts

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

1st step : 7.0kg.m
hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step : 4.4kg.m
dodecagonal
2nd step : 90
bolt
3rd step : 90
<Dodecagonal bolt limited value>

Standard(mm) Limit(mm)
115 116.2
102 103.2

DB58/T/TI/TIS
4.10. Fuel injection pump

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

z Release joint bolt A.
z Remove the strainer with a
screwdriver and wash the strainer
with clean diesel fuel.
4.12. Separator (Add if necessary)

z Check water level of the separator.
z Release the plug at the bottom to
eliminate water when water level
(floating) reaches the warning point.
Elimination plug torque 1.2 kg.m

DB58/T/TI/TIS
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)
DB58/T/TI/TIS
* (D d )2
S= C 2
(mm)
2
C : Distance of pulleys (mm),
D : Large pulley diameter (mm),
d : Small pulley diameter (mm)
4) Measuring tension
Lower indicator arm (1) into the
scale.
z Apply tester to belt at a point
midway between two pulleys so
that edge of contact surface (2) is
flush with the V- belt.
z Slowly depress pad (3) until the
spring can be heard to disengage.
This will cause the indicator to
move upwards.
If pressure is maintained after the
spring has disengaged a false
reading will be obtained!
Reading of tension
z Read of the tensioning force of the
belt at the point where the top
surface of the indicator arm (1)
intersects with the scale.
z Before taking readings make
ensure that the indicator arm
remains in its position.
z V-belt tension
Tensioning forces on the tester
new installation
Type Drive belt width When servicing after
After 10 min.
Installation long running time
running time
M 9.5 mm 50 kg 45 kg 40 kg
A 11.8 mm 55 kg 50 kg 45 kg
B 15.5 mm 75 kg 70 kg 60 kg
C 20.2 mm 75 kg 70 kg 60 kg

DB58/T/TI/TIS
z Poly belt tension

No of rib
Force(kgf)
(PK type)
3 20 - 27
4 27 - 36
5 34 45
6 41 57
7 48 66
8 59 - 73
5) Tensioning and changing belts

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

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

DB58/T/TI/TIS
5. Maintenance of Major Components
5.1. Lubrication system

5.1.1. Oil pump
1) Disassembly
1. Oil suction pipe 4. Pinion Gear

2. Cover and dowel 5. Pinion gear shaft
3. Drive shaft and gear
133 Maintenance of major components

DB58/T/TI/TIS
2) Inspection
z Visually inspect the disassembled
parts for the excessive wear and
damage.
z Correct or replace the parts if the
wear or damage is discovered
during inspection.
3) Oil Pump Drive Gear

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

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

specified limit, the pinion gear
and/or the oil pump cover must
be replaced.
Limit
0il pump cover and
0.12 mm
pinion gear clearance
5) Oil pump reassembly

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

DB58/T/TI/TIS
5.1.2. Oil cooler
1) Disassembly
1. Oil cooler element 4. O-ring

2. Gasket 5. By-pass valve spring
3. By-pass plug 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
Oil cooler element

2.2 kg.m
fixing bolts torque
4) Oil cooler reassembly

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

DB58/T/TI/TIS
5.2. Cooling system
5.2.2. Water pump
2
8
1
7
1) Disassembly
1. Pulley flange 5. Impeller
2. Snap ring 6. Pump housing
3. Unit bearing 7. Cover
4. Mechanical seal 8. Gasket
(1) Impeller
z Remove the impeller by using
the jig.
(2) Unit bearing

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

DB58/T/TI/TIS
(3) Mechanical seal

z Remove the mechanical seal
by using a suitable remover.
(4) Hub
z Remove the hub by using a
bench press and a suitable rod.
(5) Snap ring

z Remove the snap ring by using
a pair of the snap ring plier.
2) Inspection
(1) Unit bearing
z Correct or replace the part if
the wear, defect or other
damage is discovered during
inspection.

DB58/T/TI/TIS
3) Water pump reassembly

(1) Unit bearing
z Lubricate the bearing with
multipurpose grease.
z Use a bench press to
assemble the unit bearing at
the pump.
(2) Snap Ring

z Use a pair of snap ring plier to
install the snap ring.
(3) Hub
z Use a bench press and a bar
to install the hub.
(4) Mechanical seal

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

DB58/T/TI/TIS
z Use a bench press and a bar

to install the seal unit into the
pump body.
(5) Impeller
z Use a bench press to install
the impeller to the shaft.
z Use a feeler gauge to measure
the clearance between the
impeller and the pump body.
Clearance
between impeller and 0.3 ~ 0.8mm
pump body
(6) Pulley
z Install the pulley and tighten
the pulley bolts to the specified
torque.
Fan flange
Pulley fixing bolts

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 Lift

Close 71C 82C
Standard 85C 95C 10mm
Maximum 110C 110C less
16mm

DB58/T/TI/TIS
5.3. Fuel system
5.3.1. Fuel filter
1) Cartridge type
Air vent plug
Fuel filter head
Cartridge,
fuel filter
Water drain plug
2) Paper element type

1. Drain plug 5.Fuel filter element
2. Center bolt 6.Spring seat
3. Fuel filter body 7.spring
4. Body cover gasket

DB58/T/TI/TIS
3) Inspection
z Make the necessary adjustments,
repairs and part replacements if
excessive wear or damage is
discovered during inspection.
4) Fuel filter reassembly

z To reassemble the fuel filter, follow
the disassembly procedure in the
reverse order.
5.3.2. Injection nozzle

1) Disassembly
1. Nozzle holder body 7. Push rod spring

2. Seal ring 8. Spring seat
3. Injection pipe connector 9. Nozzle adjusting screw
4. Injection nozzle 10.Cap nut gasket
5. Retaining nut 11. Nozzle holder cap nut
6. Nozzle holder push rod

DB58/T/TI/TIS
2) Injection nozzle
Remove the nozzle assembly from the nozzle body. Keep the parts separately to
maintain the proper needle valve to body combination.
3) Inspection
Make the necessary adjustments, repairs and parts replacements if excessive
wear or damage is discovered during inspection.
(1) Push rod spring

z Check the push rod spring for
wear, weakness and corrosion.
(2) Nozzle holder push rod

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

z Check the injection nozzle
needle valve, the valve seat,
and the injection nozzle hole for
carbon deposits.
If carbon deposits are present,
the injection nozzle and the
needle valve must be replaced.
z Hold the nozzle body vertically.
Pull the needle valve about one-
third of the way out of the nozzle body. Release the needle valve.
DB58/T/TI/TIS
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
5.5 kg.m
connector torque
(2) Injection nozzle

z There must be no oil on the
contact surface of the injection
nozzle and the injection nozzle
holder.
Clean these contact surface
with diesel fuel before
installation.
z The nozzle dowel pin must be
aligned with the dowel hole in
the nozzle holder body.
(3) Retaining nut

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

7 kg.m
Torque
(4) Nozzle holder cap nut

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

DB58/T/TI/TIS
Nozzle holder cap nut

4.5 kg.m
torque
(5) Nozzle adjusting screw (injection starting pressure check)

z Attach the injection nozzle
holder to the injection nozzle
tester.
z Loosen the adjustment screw

.
z 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)
z Adjust the injection nozzle starting pressure.

Turn the adjusting screw clockwise while operating the injection nozzle tester
handle.
CAUTION:
Keep away your skin from the tester because pressure of nozzle tester is very
high when inject.

DB58/T/TI/TIS
5.3.3. Parts no of injection system

1) Injection pump assembly
Engine model Part no. Suffix
EARDA/EAREA/B/EARFA/B/C/D/E/F/H/I/J
DB58 65.11101-7380
EARLA/B/C
DB58S 65.11101-7399 ECRFA/B/C/ECRLA
65.11101-7655 EATEA/B/C/D/EATLA
DB58T
65.11101-7375 EATEE/F/G/H/I/J/EATLB
65.11101-7327 EAOEA/D/E/F
DB58TI 65.11101-7374 EAOEB/C/G
65.11101-7353 EAOLA/B
65.11101-7391 ECOEA/B
65.11101-7389A ECOEC/D/E/F/G
DB58TIS
65.11101-7392 ECOLA
65.11101-7390 ECOLB
2) Injection nozzle assembly
EARDA/EAREA/B
DB58
65.10101-7295 EARFA/B/C/D/F/G/K/EARLA/B/C
DB58T
EATEA/B/C/D/E/F/G/H/I/J/EATLA/B
DB58 EARFE/H/I/J
65.10101-7086
DB58S ECRFA/B/C/ECRLA
DB58TI 65.10101-7058 EAOEA/B/C/D/E/G/EAOLA/B

DB58TIS 65.10101-7092 EAOEF/ECOEA/B
DB58TIS 65.10101-7091 ECOEC/D/E/F/G/ECOLB
3) Injection pipe assembly

EARDA/EAREA/B
DB58
65.10301-6144 EARFA/B/C/D/E/F/G/H/I/J/K
DB58S
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

65.10301-6088
DB58TIS ECOEA/B/C/D/E/F/G/ECOLA/B
65.10301-6089

DB58/T/TI/TIS
5.3.4. Injection pump calibration

1) DB58 engine
(1) Injection pump assembly : 65.11101-7380 (101605-996F DOOWON)
- Injection pump : KP-PES6A95C410RS2000 (101062-8300)
- Governor : KP-EP/RSV200-1450AQ43A311 (105419-1340)
- Plunger and barrel : 131151-3200, 131100-7900
- Delivery valve : 131160-1120
- Feed pump : KP-FP/KS-A (105220-6290)
- Prestroke : 3.60.05mm
- Coupling : 156639-9820
(2) Nozzle holder assembly : 65.10101-7295 (105160-4650 DOOWON)
(3) Nozzle : 65.10102-6044 (105025-138A DOOWON)
(4) Injection pipe : 65.10301-6144
(5) Injection order :153624
Nozzle & holder assy 105780-8140 Opening pressure :175kg/cm2

(A) Test condition
Injection pipe(IDxODxL) - 2.0 x 6.0 600 mm
for injection pump
Test oil 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)
Injection Q`ty on RIG
Rack Pump
Check (mm3 / 1,000st) Press.
position speed
Point (A) Test condition (B) Engine (mmHg)
(mm) (rpm)
for inj. pump standard parts
A 8.8 1,100 55.0 1 59.4 2 -
B 9.1 800 (56.0) 2 62.7 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
Boost pressure : zero boost

Fuel injection pump
43mm3/st(6x1.5mm)
Plunger 9.5 Left hand 20 lead retraction pressure
t=0.99
Max. pump speed
2,290 rpm Delivery valve opening pressure 25.9 kgf/cm2
(limit plunger bouncing)
Holder delivery valve
- Spring k=1.63 kgf/mm
with damping valve
Governor
Governor weight 740 g Lever ratio (min. speed / max. speed) 1 : 1.2 / 1 : 1.2
Governor spring k=12 kgf/mm Idling sub spring k=2.1 kgf/mm
Start spring k=0.005 kgf/mm Adapter spring k=11 kgf/mm
Feed pump
Max. operating pressure 3.4 kgf/cm2 Piston spring k=0.735 kgf/mm

DB58/T/TI/TIS
6) Rack diagram and setting valve at each point

a) DB58 : EARDA
Rack position Pump speed Injection Q`ty on RIG Pressure
Check Point 3
(mm) (rpm) (mm / 1,000st) (mmHg)
A 8.8 1,100 58.0 1 -
B 9.1 800 (56.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
b) DB58 : EAREA
Rack position Pump speed Injection Q`ty on RIG Pressure
Check Point 3
(mm) (rpm) (mm / 1,000st) (mmHg)
A 8.8 1,100 61.0 1 -
B 9.1 800 (59.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
c) DB58 : EAREB/RFE/RFI/RFJ/RFH
Check Rack position Pump speed Injection Q`ty on RIG Pressure
3
Point (mm) (rpm) (mm / 1,000st) (mmHg)
A 8.8 1,100 50.0 1 -
B 9.1 800 (50.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
d) DB58 : EARFF
Point (mm) (rpm) (mm3 / 1,000st) (mmHg)
A 8.8 1,100 55.0 1 -
B 9.1 800 (56.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
e) DB58 : EARLA/B
3
A 8.8 1,100 58.0 1 -
B 9.1 800 (58.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
f) DB58 : EARLC
A 8.8 1,100 55.0 1 -
B 9.1 800 (59.0) 2 -
C 6.7 415 8.0 1.3 -
D - 100 100 10 -
g) Rack curve of standard injection pump (65.11101-7380)

DB58/T/TI/TIS
2) DB58 engine (EARFG/EARFK)
1. Injection pump assembly : 65.11101-7398 (101605-996G DOOWON)
- Governor : KP-EP/RSV200-1450AQ43A311 (105419-134A)
- Coupling : 156639-9820
2. Nozzle holder assembly : 65.10101-7295 (105160-4650 DOOWON)
3. Nozzle : 65.10102-6044 (105025-138A DOOWON)
4. Injection pipe : 65.10301-6144
5. Injection order :153624

(A) Test condition
for injection pump
65.10102-6044 Nozzle (5 x 0.27)
Rack Pump
position speed
(mm) (rpm)
A 8.9 1,100 58.0 1 -
B 9.2 800 (59.0) 2 -
C 6.6 400 8.0 1.3 -
D - 100 100 10 -

Fuel injection pump
43mm3/st(6x1.5mm)
t=0.99
Max. pump speed
with damping valve
Governor
Idle spring k=1.9 kgf/mm Start spring k=0.005 kgf/mm
Adapter spring k=11 kgf/mm
Feed pump

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

DB58/T/TI/TIS
3) DB58S engine (ECRFA/B/C)

1) Injection pump assembly : 65.11101-7399 (101605-996X DOOWON)
- Injection pump : KP-PES6A95C410RS2000 (101062-830A)
- Governor : KP-EP/RSV200-1450AQ43A311 (105419-1340)
- Coupling : 156639-9820
2) Nozzle holder assembly : 65.10101-7086 (105160-465B DOOWON)
3) Nozzle : 65.10102-6056 (105025-138B DOOWON)
4) Injection pipe : 65.10301-6144
5) Injection order :153624

(A) Test condition
for injection pump
65.10102-6056 Nozzle (5 x 0.22)
Rack Pump
position speed
(mm) (rpm)
A 10.1 1,100 58.0 1 -
B 6.8 400 8.0 1.3 -
C 10.7 700 (68.0) -
D - 100 100 10 -

Fuel injection pump
59mm3/st(6x1.5mm)
t=0.09
Max. pump speed
with damping valve
Governor
Idle spring k=1.9 kgf/mm Start spring k=0.005 kgf/mm
Adapter spring k=11 kgf/mm
Feed pump

DB58/T/TI/TIS
6) Rack curve of standard injection pump (65.11101-7399)
a) DB58S : ECRFA
3
A 10.1 1,100 58.0 1 -
B 6.8 400 8.0 1.3 -
C 10.7 700 (68.0) -
D - 100 100 10 -
b) DB58S : ECRFB
3
A 8.8 1,100 73.5 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) -
D - 100 (43.6) 10 -
c) DB58S : ECRFC
A 8.8 1,100 73.5 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) -
D - 100 (43.6) 10 -

DB58/T/TI/TIS
4) DB58T engine (EATEA/B//D/TLA)

(1) Injection pump assembly : 65.11101-7655 (101605-9760 DOOWON)
- Governor : KP-EP/RSV200-1350AQ49A311(105411-1820)
- Coupling : 156639-4220
(3) Nozzle : 65.10102-6044 (105025-138A DOOWON)
(4) Injection pipe : 65.10301-6289

(A) Test condition
for injection pump
65.10102-6044 Nozzle (5 x 0.27)
Rack Pump
position speed
(mm) (rpm)
A 9.1 1,100 73.5 2.5 67.1 2 Above 300
B 5.7 550 9.4 1.3 -

C 9.1 800 (63) 68.1 Above 300
D 9.1-0.25 500 (43.6) 2 58.1 -

E - 100 65
Fuel injection pump
Plunger 9.5 Left hand 20 lead retraction pressure 51mm3/st(6x1.8mm)
Max. pump speed
2,290 rpm opening pressure 17.0 kgf/cm2
(limit plunger bouncing) Delivery valve
with damping valve
Governor
Start spring k=0.005 kgf/mm Boost compensator spring k=0.6 kgf/mm
Feed pump

DB58/T/TI/TIS

a) DB58T : EATEA
3
A 8.8 1,100 73.5 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) -
D - 100 (43.6) 2 -
b) DB58T : EATEB
3
A 8.8 1,100 73.5 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) -
D - 100 (43.6) 10 -
c) DB58T : EATED
A 8.8 1,100 72.0 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (62) -
D - 100 (42) 10 -
c) DB58T : EATLA
3
A 8.8 1,100 73.5 1.5 -
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) -
D - 100 (43.6) 10 -
e) Rack curve and boost pressure of standard injection pump(65.11101-7655)

DB58/T/TI/TIS
5) DB58T engine (EATEE/F/G/H/I/EATLB)
- Coupling : 156639-7620
(3) Nozzle : 65.10102-6044 (105025-138A DOOWON)
(4) Injection pipe : 65.10301-6289

(A) Test condition
for injection pump
65.10102-6044 Nozzle (5 x 0.27)
Rack Pump
position speed
(mm) (rpm)
A 9.1 1,100 73.5 1.5 67.1 2 Above 300
B 5.7 550 9.4 1.3 -

C 9.1 800 (63) 68.1 Above 300
D 9.1-0.25 500 (43.6) 2 58.1 -

E - 100 65
Fuel injection pump
Plunger 9.5 Left hand 20 lead retraction pressure 51mm3/st(6x1.8mm)
Max. pump speed
with damping valve
Governor
Idling spring k=2.6 kgf/mm Start spring k=0.005 kgf/mm
Boost compensator spring k=0.6 kgf/mm - -
Feed pump

DB58/T/TI/TIS
a) DB58 : EATEE/TEH/TLB
A 8.8 1,100 73.5 1.5 Above 300
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) Above 300
D - 100 (43.6) 2 -
b) DB58 : EATEF
3
A 8.8 1,100 73.5 1.5 Above 300
B 9.1 800 9.4 1.3 -
C 6.7 415 (63) Above 300
D - 100 46.6 10 -
c) DB58 : EATEG
A 8.8 1,100 72.0 1.5 Above 300
B 9.1 800 9.4 1.3 -
C 6.7 415 (60) Above 300
D - 100 53 10 -
d) DB58 : EATEI
A 8.8 1,100 67.0 1.5 Above 300
B 9.1 800 9.4 1.3 -
C 6.7 415 (57) Above 300
D - 100 50 10 -
e) Rack curve and boost pressure of standard injection pump(65.11101-7374)

DB58/T/TI/TIS
6) DB58TI engine (EAOEA/D/E/F)
- Injection pump : KP-PES6AD100B410R (101062-8260)
- Feed pump : KP-FP/KS-AD (105220-6490)
- Coupling : 156639-8820
(2) Nozzle holder assembly : 65.10101-7058 (105160-466A DOOWON) : EAOEA/D/E
65.10101-7092 (105160-5420 DOOWON) : EAOEF
(3) Nozzle : 65.10102-6054 (105025-139A DOOWON) : EAOEA/D/E
65.10102-6064 (105025-4200 DOOWON) : EAOEF
(4) Injection pipe : 65.10301-6072

(A) Test condition
for injection pump
Nozzle & holder assy 65.10102-6054 Nozzle (6 x 0.235)
(EAOEA/D/E) 65.10101-7058 185 kg/cm2
(B) Engine standard parts Nozzle & holder assy 65.10102-6064 Nozzle (7 x 0.22)
(EAOEF) 65.10101-7092 200 kg/cm2
Rack Pump
position speed
(mm) (rpm)
A R1(9.8) 1,000 97.5 1.5 80.7 2
B 6.9 550 22.0 1.5
C (R1) 750 (63) 86.4
E - 100 70 0+10

Fuel injection pump
Plunger 10 Left hand 20+50 lead retraction pressure 59mm3/st(6x2.1mm)
Max. pump speed
with damping valve
Governor
Feed pump

DB58/T/TI/TIS

a) DB58TI : EAOEA/OED
3
A 8.8 1,100 97.5 1.5 -
B 9.1 800 22.0 1.5 -
C 6.7 415 (93.5) -
D - 100 75 5.0 -
b) DB58TI : EAOEE
3
A 8.8 1,100 104.5 1.5 -
B 9.1 800 22.0 1.5 -
C 6.7 415 (100) -
D - 100 75 5.0 -
c) Rack curve of standard injection pump(65.11101-7374)
Rack curve

DB58/T/TI/TIS
7) DB58TI engine (EAOEB/OEC)

(1) Injection pump assembly : 65.11101-7374 (101605-983X DOOWON)
- Coupling : 156639-8820
(2) Nozzle holder assembly : 65.10101-7058 (105160-466A DOOWON)
(3) Nozzle : 65.10102-6054 (105025-139A DOOWON)
(4) Injection pipe : 65.10301-6072

(A) Test condition
for injection pump
65.10102-6054 Nozzle (5 x 0.28)
Rack Pump
position speed
(mm) (rpm)
A 9.6 1,100 95.0 1.5 80.8 2 Above 350
B 6.9 550 22.0 1.5 -

C R1(9.6) 500 (85.0) 76.7 Above 350
E - 100 77 +10
5

Fuel injection pump
Max. pump speed
with damping valve
Governor
Feed pump

DB58/T/TI/TIS

a) DB58TI : EAOEB
3
A 9.6 1,100 95.0 1.5 Above 350
B 6.9 550 22.0 1.5 -

C R1(9.6) 500 (85.0) Above 350
E - 100 77 -
b) DB58TI : EAOEC
3
A 9.6 1,100 97.0 1.5 Above 350
B 6.9 550 22.0 1.5 -

C R1(9.6) 500 (87.0) Above 350
E - 100 77 -
c) Rack curve and boost pressure of standard injection pump (65.11101-7374)
Rack curve
Boost pressure

DB58/T/TI/TIS
8) DB58TI engine (EAOLA/OLB)

- Coupling : 156639-8820
(2) Nozzle holder assembly : 65.10101-7058 (105160-466A DOOWON)
(3) Nozzle : 65.10102-6054 (105025-139A DOOWON)
(4) Injection pipe: : 65.10301-6072
(5) Injection order: :153624

(A) Test condition
for injection pump
65.10102-6054 Nozzle (5 x 0.28)
Rack Pump
position speed
(mm) (rpm)
A 9.2 1,100 88 1.5 71.5 2 Above 500
B 7.0 488 22.0 2.0 -

C R1(9.8) 750 (92.0) 83.4 Above 500
D R1-0.6 550 (72.0) 2.0 -

E - 100 80.010 -
Fuel injection pump
Max. pump speed
with damping valve
Governor
Angleich spring k=5.4 kgf/mm Boost compensator spring k=0.6 kgf/mm
Feed pump

DB58/T/TI/TIS

a) DB58TIS : EAOLA/OLB
A 9.2 1,100 88 1.5 Above 500
B 7.0 488 22 2.0 -
C R1(9.8) 750 (92) Above 500
D R1-0.6 550 (72) 2.0 -
E - 100 8010
b) Rack curve and boost pressure of standard injection pump (65.11101-7353)
Rack curve
Boost pressure

DB58/T/TI/TIS
9) DB58TIS engine (ECOEA/OEB)

(1) Injection pump assembly : 65.11101-7391 (101605-830A DOOWON)
- Injection pump : KP-PES6AD100B410R (101062-826A)
- Plunger and barrel : 131150-2600 131100-8600
- Coupling : 156639-882C
(3) Nozzle : 65.10102-6064 (105025-4200 DOOWON)
(4) Injection pipe: : 65.10301-6088, 65.10301-6089

(A) Test condition
for injection pump
65.10102-6064 Nozzle (7 x 0.22)
Injection pipe(IDxODxL) 65.10301-6088,6089 1.8x6.0x912mm
Rack Pump
position speed
(mm) (rpm)
A R1(10.6) 1,000 112 1.5 92
B 6.7 550 22 2.0 -
C 6.7 550 (103) Above 400
D (R1-0.9) 550 (84) 82 -

E - 100 9510 -
Fuel injection pump
Max. pump speed
with damping valve
Governor
Boost compensator spring k=0.6 kgf/mm
Feed pump

DB58/T/TI/TIS

a) DB58TIS : ECOEA
A R1(10.6) 1,000 112 1.5 -
B 6.7 550 22 2.0 -
C 6.7 550 (103) Above 400
D (R1-0.9) 550 (84) -
E - 100 9510
b) DB58TIS : ECOEB
3
A R1(10.6) 1,000 105 1.5 -
B 6.7 550 22 2.0 -
C 6.7 550 (96) Above 400
D (R1-0.9) 550 (81) -
E - 100 9510
c) Rack curve and boost pressure of standard injection pump (65.11101-7391)
Rack curve
Boost pressure

DB58/T/TI/TIS
10) DB58TIS engine (ECOEC/D/E/F/G)
(1) Injection pump assembly : 65.11101-7389A (101605-810A DOOWON)
- Injection pump : KP-PES6AD100B410R (101062-826A)
- Coupling : 156639-882C
(3) Nozzle : 65.10102-6061 (105025-4000 DOOWON)
(4) Injection pipe: : 65.10301-6088, 65.10301-6089

(A) Test condition
for injection pump
65.10102-6061 Nozzle (6 x 0.235)
Power Injection Q`ty on RIG
Rack Pump
position speed
(mm) (rpm)
A R1(10.3) 1,100 109 1.5 85.8 2 Above 450
B 6.6 600 22 2.0 -

C R1 500 (97) 95.2 Above 450
D (R1-1.5) 500 (61) 69.9 -

E - 100 9610 -
Fuel injection pump
Max. pump speed
with damping valve
Governor
Feed pump

DB58/T/TI/TIS
a) DB58TIS : ECOEC
A R1(10.3) 1,100 109 1.5 Above 450
B 6.6 600 22 2.0 -
C R1 500 (97) Above 450
D (R1-1.5) 500 (61) -
E - 100 9610
b) DB58TIS : ECOED
3
A R1(10.3) 1,100 91 1.5 Above 450
B 6.6 600 22 2.0 -
C R1 500 (81) Above 450
D (R1-1.5) 500 (53) -
E - 100 9610
c) DB58TIS : ECOEE
A R1(10.3) 1,100 113 1.5 Above 450
B 6.6 600 22 2.0 -
C R1 500 (101) Above 450
D (R1-1.5) 500 (61) -
E - 100 9610
d) DB58TIS : ECOEF
3
A R1(10.3) 1,100 95 1.5 Above 450
B 6.6 600 22 2.0 -
C R1 500 (84) Above 450
D (R1-1.5) 500 - -
E - 100 9610
e) DB58TIS : ECOEG
A R1(10.3) 1,100 111 1.5 Above 450
B 6.6 600 22 2.0 -
C R1 500 (99) Above 450
D (R1-1.5) 500 (61) -
E - 100 9610
f) Rack curve and boost pressure of standard injection pump(65.11101-7389)

DB58/T/TI/TIS
11) DB58TIS engine (ECOLA)
- Injection pump : KP-PES6AD105B410RS2 (101061-882B)
- Governor : KP-EP/RSV200-1350AQ49A311(105411-224A)
- Plunger and barrel : 131151-2700 131100-7800
- Feed pump : KP-FP/KS-ADS (105210-5280)
- Prestroke : 4.3 0.05mm
- Coupling : 156639-8820
(3) Nozzle : 65.10102-6064 (105025-4200 DOOWON)
(4) Injection pipe: : 65.10301-6088, 65.10301-6089
Nozzle & holder assy Opening pressure :175kg/cm2

105780-8140
(A) Test condition
for injection pump
65.10102-6061 Nozzle (7 x 0.22)
Rack Pump
position speed
(mm) (rpm)
A R1(10.6) 1,100 128 1.5 88 2 Above 450
B 6.8 550 20 1.5 -

C R1 550 (130) Above 450
D (R1-1.6) 1,100 (95) 86 -

E - 100 11010 -
Fuel injection pump
70mm3/st(6x2.5mm)
Plunger 10.5 Left hand 20+40 lead retraction pressure
t=0.11mm
Max. pump speed
1970 rpm Delivery valve opening pressure 23.1 kgf/cm2
with damping valve
Governor
Feed pump

DB58/T/TI/TIS
(6) Rack curve

a) Rack curve and boost pressure of standard injection pump(65.11101-7392)
Rack curve
Boost pressure

DB58/T/TI/TIS
12) DB58TIS engine (ECOLB)

- Coupling : 156639-882C
(3) Nozzle : 65.10102-6061 (105025-4000 DOOWON)
(4) Injection pipe: : 65.10301-6088, 65.10301-6089

(A) Test condition
for injection pump
65.10102-6061 Nozzle (6 x 0.235)
Rack Pump
position speed
(mm) (rpm)
A 9.8 1,100 97 1.5 76.6 2 Above 500
B 6.8 550 22 2.0 -

C R1(10.1) 600 (92) 97 Above 500
D (R1-1.5) 600 (58) -

E - 100 7210 -
Fuel injection pump
Plunger 10 Left hand 20+50 lead Retraction pressure 59mm3/st(6x2.1mm)
Max. pump speed
with damping valve
Governor
Feed pump

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

DB58/T/TI/TIS
13) Injection pump
1. Pump housing 56. Shim 117a. Connection bolt

2. Cover assembly 61. Plunger spring 118a. Gasket
3. Bolt, cover 62. Seat, spring(upper) 121. Plug screw
4. O-ring 63. Seat, spring(lower) 122. Gasket
5. Gasket 67. Control rack 130. Connect
16. Screw, plug 68. Stop bolt 130a. Adapter
18. Bolt, stud 76. Pinion 131a. Bolt
20. Spring washer 77. Sleeve 132a. Gasket
21. Nut 78. Bolt 133a. Gasket
23. O-ring 90. Camshaft 145. Plug screw
30. Plunger 91.91a. Taper roller bearing 146 Gasket
36. Delivery valve 92.92a Camshaft ring 152. Connection bolt
37. Delivery valve spring 93.93a. Shim 154. Packing
40. Delivery valve holder 95. Center bearing 191. Bracket
45. Lock plate assembly 101a. Bearing cover 192. O-ring
49. O-ring 104a Bolt 194. Washer
55. Tappet 112a. Woodruf key 195. Spring washer
115a. Adapter 196. Nut

DB58/T/TI/TIS
14) Governor
1. Governor housing 80. Cover 182. Lever shaft

4. Plate 82. Bolt 183. Collar
6. Adapter 83. Bolt 190. Control lever
7. Bolt 100.Fly wheel 192. Nut
9. Spring 101. Woodruf key 195. Return spring
10. Bolt 102. Spring washer 198. Spring washer
13. Nut 103. Nut 201. O-ring
19. Adapter 117. Sleeve 202. Bush
20. Bolt 118. Shim 203. Shim
21. Gasket 130. Governor spring 205. Shaft lever
35. Governor cover 132. Starting spring 207. Support lever
38. Tension lever bolt 136. Nut 211. Snap ring
39. Nut 137. Gasket 220. Damper spring
44. Stop bolt 138. Cap 236. Gasket
46. Cap 140. Idle spring 239. Gasket
47. Plug 141. Nut 240. Lead seal
48. Adjusting bolt 150. Speed setting lever 241. Wire, lead seal
49. Nut 170. Guide lever 255. Bracket
50. Stop bolt 173. Split pin 331. Angleich spring
51. Bolt 174. Floating lever link 332. Connection nut
52. Bolt 181. Tension lever

DB58/T/TI/TIS
5.4. Turbocharger
5.4.1. Main data and specifications
1) Main data and specifications
Specification DB58T DB58TI DB58TIS
HOLSET HOLSET HOLSET

Turbocharger Model
3539678 3539678 3598337
Air pressure
1.3 kg/cm2 1.50 kg/cm2 1.70 kg/cm2
at at compressor outlet
maximum
Air suction volume 11.5 m3/min 12.5 m3/min 13.5 m3/min
output
Speed of turbine revolution 95,00 rpm 100,000 rpm 105,000 rpm
Maximum allowable speed 127,500 rpm 127,500 rpm 127,500 rpm
Max. allowable temperature of exhaust

750 C
gas at turbine inlet 750 C 750 C
Lubricating system External oil supply External oil supply External oil supply
Weight 9.7 kg 9.7 kg 9.7 kg
2) Construction
1. Impeller casing A. Air inlet

2. Turbine casing B. Gas outlet
3. Bearing casing C. Gas inlet
4. Impeller D. Oil supply
5. Turbine E. Oil return

DB58/T/TI/TIS
3) Construction
4 Bearing housing 32 O-ring 67 Hex bolt

5 Turbine housing 33 Oil baffle 74 Actuator ass`y
6 Turbine wheel ass`y 34 Inlet baffle 75 Hose clamp
7 Compressor wheel 36 Thrust collar 77 Actuator clip
8 Compressor housing 38 Heat protector cover 80 Cover plate
11 Journal bearing 43 Oil seal plate 81 Hose
12 Thrust bearing 46 Gasket 82 Elbow
13 Piston ring seal(turbine) 57 Hex bolt 83 Hex nut
16 Piston ring seal 61 Lock nut 88 Clamp plate
22 Retainer ring 64 Snap ring 91 Retaining ring
31 Oil stopper

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

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

DB58/T/TI/TIS
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 1) Check oil level
the engine
2) Crank the engine with starter to 2) Abrupt starting of the engine
check the increase in oil causes the engine to rotate with
pressure(until the needle of oil not being distributed not only
pressure gauge starts to move or to each part but also to the
pressure indicator lamp is turbocharger, resulting in
actuated) before starting the abnormal wear or seizure on the
engine. bearing due to insufficient supply
of oil.
3) When having replaced oil, oil 3) In the case of the engine stopped
filter element, or lubricating for extended time or in a cold
parts, or when having stopped place, oil fluidity within the
the engine for extended period of pipes can be deteriorated
time, or in a cold place, loosen
the oil pipe connections and
operate the starter motor until oil
is discharged. After completing
DB58/T/TI/TIS
the operation, be sure to retighten
the oil pipe connections portion
before starting the engine.
Immediately 1) Run the engine at idle for 5 1) Applying load abruptly If load is
after starting minutes after starting off. abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of 2) Leakage of oil, gas, and air
oil, gas, and air, and take proper (especially, oil leak) causes drop
measure. in oil pressure and loss of oil
results in seizure of the bearing.
During operation Check the followings:
1) Oil pressure At idle: 0.8 kg/cm2 1) Excessively low oil pressure
or more At full load: 3.04.8 causes unusual wear or seizure of
kg/cm2 the bearing. Too high pressure
causes oil leakage.
2) If unusual sound or vibration is 2) The engine Is operated
heard or felt, reduce engine continuously with unusual sound
revolutions slowly and locate the or vibration not corrected, it can
cause. be damaged beyond repair.
When stopping 1) Run the engine at idle for 5 1) If the engine is put to a stop after
the engine minutes before stopping. being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.
5.4.5. Walk-around check and servicing

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

DB58/T/TI/TIS
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 Recommend oil

model SAE No. API No.
DB58
DB58TI
5.4.6. Periodical checking and servicing

Make it a rule to check the turbocharger assembly for condition and contamination
periodically.
1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by
the degree of unusual sound. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch
sound is heard continuously, it means that the rotor assembly is not normal. In this
case, as the metal bearing and rotor are likely to be in abnormal conditions, the
turbocharger should be replaced or repaired.
2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play and
radial play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
with taps, etc.

DB58/T/TI/TIS
(1) Rotor axial play
(2) Rotor radial play
(3) If the measured axial and radial plays are beyond the limit of wear, replace or
repair the turbocharger.
3) Guide for disassembling/cleaning and checking the turbocharger

First, disassemble the turbocharger from the engine and clean/check it with the oil
inlet and outlet plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto the engine

For reassembly of the turbocharger or handling it after reassembly operation, be
sure to observe the following precautions:
Especially, exercise extreme care to prevent foreign matters from entering the
inside of the turbocharger.
(1) Lubricating system

z Before reassembling the turbocharger onto the engine, inject new oil in the
oil inlet port and lubricate the journal and thrust bearings by rotating them
with hand .
z Clean not only the pipes installed between the engine and oil inlet port but
also the oil outlet pipe and check them for damage or foreign matters.
z Assemble each joint on oil pipes securely to prevent oil leaks.

DB58/T/TI/TIS
(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 Possible causes Corrections

1. Excessive black smoke 1) Air cleaner element clogged Replace or clean
2) Restrictions in air duct Check and correct
3) Leakage at intake manifold Check and correct

Disassemble/repair
4) Turbocharger seized up and not rotating
or replace
5) Turbine blades and compressor blades coming in Disassemble/repair
contact with each other or damaged or replace
6) Exhaust piping deformed or clogged Check and correct
2. Excessive white smoke Disassemble/repair
1) Oil leak into turbine and compressor
or replace
2) Worn or damaged seal ring due to excessive wear Disassemble/repair
of bearing or replace
3. Low engine output 1) Gas leak at each part of exhaust system Check and correct
2) Air cleaner element restricted Replace or clean

Disassemble/repair
3) Turbocharger fouled or damaged
or replace
4) Leakage at discharge port on compressor side Check and correct
4. Unusual sound or Disassemble/repair
1) Rotor assembly coming in contact
vibration or replace
Disassemble/repair
2) Unbalanced rotation of rotor
or replace
Disassemble/repair
3) Seized up
or replace
4) Each joint loosened Check and correct

DB58/T/TI/TIS
5.5. Air Intake System
5.5.1. Maintenance
(only when engine is switched off)
Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway
with dust.
On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover
(6) of the dust bowl and empty.
Be careful to assemble cover and bowl correctly.
There is a recess in the cover rim and a lug on the collector which should register.
Where the filter is installed horizontally, watch for top mark on cleaner bowl.
1. Connection port,
fouling indicator
2. Cleaner housing
3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl
5.5.2. Changing filter element

z On removing the hexagon nut, take
out the dirty cartridge and renew or
clean.
z Wipe the cleaner housing with a
damp cloth, in particular the sealing
surface for the element.
NOTE:
Do not allow dirt to get into the
clean air end.

DB58/T/TI/TIS
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.
DB58/T/TI/TIS
6. Special Tool List
No. Part No. Figure Tool Name Remark
1 EU.2-0529 Compression gauge adapter
2 EF122-249 Valve spring compressor
3 EF.122-265 Crankshaft gear punch
4 EF.122-253 Crankshaft pilot bearing remover
5 EF.122-251 Pilot bearing punch
6 EF.122-262A Crankshaft rear oil seal installer
7 EF.122-255 Crankshaft front oil seal installer
8 EF.122-289 Valve stem oil seal installer
182 Special tools

DB58/T/TI/TIS
No. Part No. Figure Tool Name Remark
9 E1.03901-0124 Piston insert sleeve
10 EF.122-281 Cylinder liner remover
11 EF122-261 Cylinder liner installer
12 EU.1-0022 Pulley bush puncher
13 EU.2-0328 Pulley bush puller
14 60.99901-0027 Feeler gauge
15 T7610001E Snap ring plier
16 T7621010E Piston ring plier
183 Special tools

DB58/T/TI/TIS
Appendix
1) Tightening torque for major parts

Screw Strength Tightening
Major Parts Remarks
(Diameter x pitch) (grade) Torque
DB58/S/T/TI
1st : 4.4 kg.m
2nd : 150
(Angle method)
Cylinder head bolt M12 x 1.5 10.9T DB58TIS
1st : 4.4 kg.m
2nd : 90
3rd 90
(Angle method)
Connecting rod bearing cap bolt M12 x 1.5 12.9T 9.75 kg.m
Crankshaft main bearing cap bolt M16 x 2 12.9T 24.0 kg.m
Flywheel housing fixing bolt M14 x 1.5 10.9T 13 kg.m
M16 x 1.5 10.9T 16 kg.m
Flywheel fixing bolt M16 x 1.5 10.9T 18 kg.m
Crankshaft pulley fixing nut M36 x 1.5 8.8T 60 kg.m
Oil spray nozzle hollow screw

M10 x 1.25 - 2.1 kg.m
(Relief valve assembly)
2) Tightening torque for fuel injection pump system

Screw Strength Tightening
Major Parts Remarks
(Diameter x pitch) (grade) Torque
Injection nozzle nut M28 x 1.5 - 7.0 kg.m
Injection pump bracket bolt M10 8.8T 4.4 kg.m
Injection pump coupling bolt - - 6.0 ~ 6.5 kg.m
Injection pump driving gear nut M24 x 1.5 8.8T 25.0 kg.m
Injection pipe nut M14 x 1.5 8.8T 3.0 kg.m
Injection pump delivery valve holder - - 11.0 ~ 12.0 kg.m
184
DB58/T/TI/TIS
3) Standard bolt tightening torque table

Refer to the following table for bolts other then described above
Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter
x (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm2)
(mm)
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8x1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10x1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12x1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14x1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16x1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18x1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20x1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22x1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24x1.5 23 25 37 31 45 38 61 67 74 93 103
Others :
1. The above torque rating have been determined to 70% or so of the limit value for
bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the
standard value.
4) Tightening torque for hollow screw(4-hole)

Material M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
: Adopted in DAEWOO engine
185
5) Engine assembly DB58-Fork lift RFJ
a) DB58-Fork lift : EARFJ
186
b) DB58T- Excavator : EATEI
187
c) DB58TI Excavator : EAOLB
188
d) DB58TIS Excavator : ECOEB
189
e) DB58TIS Excavator : ECOEG
190
z Parts Center
z Applications for Daewoo Engine
z Worldwide Network
Parts center
85-1 Palgok Ei-dong, Sangnok-gu Ansan-shi Kyunggi-do, Korea
Tel. : 82-31-400-2206
Fax. : 82-31-400-2255
http://www.dhiltd.co.kr , http://cs.dhiltd.co.kr
Applications for Daewoo Engine
Automotive & Industrial Engines Marine Propulsion Engines

Power Power
Model Model Model Power kW(PS)/rpm Model Power kW(PS)/rpm
kW(PS)/rpm kW(PS)/rpm
D1146 133(181)/2,500 DE12TI 250(340)/2,100 L034 51(70)/3,000 L126TIH 265(360)/2,000
D1146TI 158(215)/2,200 DE12TIS 250(340)/2,100 L034TIH 88(120)/3,000 L126TIM 294(400)/2,100
For DE08TIS 176(240)/2,300 GE12TI 250(340)/2,100 MD136 118(160)/2,200 V158TIH 353(480)/1,800
Vehicle GE08TI 191(260)/2,300 DV15T 272(370)/2,300 MD136T 147(200)/2,200 V158TIM 397(540)/2,100
DE12 169(230)/2,200 DV15TI 309(420)/2,100 MD136TI 169(230)/2,200 V180TIH 441(600)/1,800
DE12T 220(300)/2,200 DV15TIS 309(420)/2,100 L086TIH 210(285)/2,100 V180TIM 478(650)/2,100
DC23 37(50)/3,000 D1146 115(156)/2,200 L086TIM 232(315)/2,300 V222TIH 530(720)/1,800
DC24 41(56)/3,000 D1146T 140(190)/2,200 MD196T 206(280)/2,000 V222TIM 588(800)/2,100
DC24T 41(55)/2,600 D1146TI 162(220)/2,200 MD196TI 235(320)/2,000
DB33 53(72)/3,000 DE08TIS 151(205)/1,900
For
DB33A 46(63)/2,300 DE12T 188(255)/2,000
Industrial
DB58 96(130)/2,800 DE12TI 213(290)/2,000
DB58S 75(102)/2,200 DE12TIS 238(323)/2,000
DB58T 104(142)/2,500 DV15T 238(324)/2,300
DB58TI 112(152)/2,200
Generator Set Engines (G-Drive & G-Pac)

Power (Output ISO 3046) Power(Output ISO 3046)
@ 1,800rpm @ 1,500rpm @ 1,800rpm @ 1,500rpm

Model Model
Power (Stand-by) Power (Prime) Power (Stand-by) Power (Prime) Power (Stand-by) Power (Prime) Power (Stand-by) Power (Prime)
kW(PS) kW(PS) kW(PS) kW(PS) kW(PS) kW(PS) kW(PS) kW(PS)

DC23-2 13(17) 11(15) 15(11) 14(10) P086TI 223(260) 205(237) 199(223) 177(203)
DC23-1 18(25) 17(23) 16(22) 15(20) P126TI-1 288(392) 262(356) - -
DC23 24(33) 22(30) 19(26) 18(24) P126TI 298(405) 278(378) 272(370) 241328)
DC24 25(34) 23(31) 21(28) 18(25) P126TI-2 342(465) - - -
DC24T 32(43) 29(39) 26(36) 24(32) P158LE-2 361(491) 329(447) 321(437) 293(399)
DB33 35(47) 32(43) 29(39) 26(35) P158LE-1 402(546) 366(498) 362(492) 327(444)
P034TI 60(82) 55(75) 48(65) 42(57) P158LE 443(602) 402(547) 414(563) 363(494)
DB58 70(95) 64(87) 59(80) 54(73) P180LE-1 498(677) 454(617) 442(601) 403(548)
D1146 105(143) 96(130) 85(116) 77(105) P180LE 540(734) 497(676) 496(674) 443(602)
D1146T 138(187) 125(170) 118(160) 107(145) P222LE-1 625(850) 563(765) 552(750) 496(675)
P086TI-1 191(303) 174(279) 164(270) 149(420) P222LE 649(883) 591(803) 574(781) 532(723)
DE12T 199(270) 180(245) 166(226) 151(205)
Marine Auxiliary Engines

Power Power Power Power
Model (Output ISO 3046) Model (Output ISO 3046) Model (Output ISO 3046) Model (Output ISO 3046)
kW(PS) @ 1,500rpm kW(PS) @ 1,500rpm kW(PS) @ 1,800rpm kW(PS) @ 1,800rpm
AD034F 26(35) AD034TIF 42(57) AD034S 32(43) AD034TIS 55(75)
AD136F 77(105) AD136TF 107(145) AD136S 93(126) AD136TS 125(170)
AD136TIF 121(165) AD086TIF 151(205) AD136TIS 143(195) AD086TIS 186(253)
AD196TF 155(210) AD196TIF 173(235) AD196TS 181(246) AD196TIS 199(270)
Generator Sets Marine Generator Sets
Generator Set Model Power (kW/kVA) Power (kW/kVA)
Engine 1800rpm(60Hz) 1500rpm(60Hz) Engine 1800rpm(60Hz) 1500rpm(60Hz)
Generator Set
Power Power Model Power Power Power Power Model
Suffix (Stand-by) (Prime) (Stand-by) (Prime) Power (Prime) Power (Prime)
(Stand-by) (Prime)
kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA
PNM DB33 24/30 20/25
DW10E DW10 PIG DC23-2 10/13 9/11 9/11 8/10 PNB AD034TI 50/63 36/45
PNJ AD136 80/100 68/85
DW15E DW15 PIH DC23-1 15/19 14/17 13/17 12/15
PNK AD136T 104/130 96/120
DW20E DW20 PIF DC23 20/25 18/23 16/20 14/18
PND AD136TI 132/165 108/135
PJF DC24 20/25 18/23 16/20 14/18
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
DW200E DW200 PIL P086TI 200/250 182/228 176/220 160/200
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 Power Units
DW360E DW360 PIS P158LE-1 360/450 327/409 320/400 288/360 Power Power
Model Model
DW400E DW400 PIY P158LE 400/500 364/455 370/463 320/400 kW(PS)/rpm kW(PS)/rpm
DW450E DW450 PIO P180LE-1 450/563 409/511 396/495 360/450 PU024 32(44)/2,800 PU086 116(160)/2,200
DW500E DW500 PIM P180LE 500/625 445/556 440/550 400/500 PU024T 40(55)/2,600 PU086T 151(205)/2,200
DW600E DW600 PIN P222LE 600/750 541/676 528/660 480/600 PU034 50(68)/3,000 PU086TI 213(290)/2,200
PU066 85(116)/2,800

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65.

Printed in Jan. 2003 PS-MMA0300-E1A

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

During engine maintenance, please observe following instructions to prevent environmental

z Take old oil to an old oil disposal point only.

DAEWOO Heavy Industries & Machinery LTD.

Printed in Jan. 2003 PS-MMA0300-E1A

4. Commissioning and Operation

Printed in Jan. 2003 PS-MMA0300-E1A

4.12. Fuel injection pump 129

5. Maintenance of Major Components

6. Special Tool List 183

Printed in Jan. 2003 PS-MMA0300-E1A

Engine model Performance

Performance DIN 6270B DIN 6270A

Torque (min) 370 N.m (38.0 kg.m) / 1,600 rpm

1. 3.2. Performance curve (DB58T)

Performance DIN 6270B DIN 6270A

104 kW (142PS) / 90 kW (122PS) /

Torque (min) 450 N.m (46.0 kg.m) / 1,600 rpm

1. 3.3. Performance curve (DB58TI)

Performance DIN 6270B DIN 6270A

112 kW (152PS) / 102 kW (138PS) /

Torque (min) 539 N.m (55.0 kg.m) / 1,600 rpm

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

1.4. Engine assembly

1.4.1. Engine sectional view (DB58TI/TIS : air to water type)

1. Oil spray nozzle 18. Piston pin

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

1. Oil spray nozzle 17. Cooling water pump pulley

1.4.3. Engine assembly views

1 Oil filter 10 Cooling fan idler 19 Push rod chamber cover

1 Engine pick-up sensor 11 Vibration damper 20 Oil filler cap

1 Fuel filter 10 Oil filter 19 Flywheel housing

8 Crank shaft pulley 17 Oil filler cap 25 Fuel injection nozzle

1 Flywheel housing 10 Oil pan 20 Water outlet

1.5. Safety regulations

1.5.1. General notes

1.5.2. Regulations designed to prevent accidents

b) During maintenance and care

c) When carrying out checking, setting and repair work

1.5.3. Regulations designed to prevent damage to engine and premature wear

1.5.4. Regulations designed to prevent pollution

1.5.5. Notes on safety in handling used engine oil

Ensure that used engine oil is disposed of properly.

1.5.6. General repair instructions

z Engine serial No. (example 1 : DB58) Engine number

z Engine serial No. (example 2 : DB58)

z Engine serial No. (example 3 : DB58T)

z Engine serial No. (example 4 : DB58TI)

z Engine serial No. (example 5 : DB58TIS)

2.2. Engine type

2.2.1. Cylinder block

2.2.2. Piston con-rod / crankshaft

2.3. Engine timing

Oil pump drive gear