Doosan D35S-5 Service Manual
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Doosan D35S-5 Service Manual

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Service Manual
Diesel Engine 5.8 Liter (DB58S)
D35S-5, D40S-5, D45S-5, D50C-5, D55C-5
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 (3 speed)
D50S-5, D60S-5, D70S-5 (2 speed)
SB4118E01
May. 2007

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  • Page 1 SB4118E01 May. 2007 Service Manual Diesel Engine 5.8 Liter (DB58S) D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 (3 speed) D50S-5, D60S-5, D70S-5 (2 speed)

  • Page 3: Important Safety Information

    If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
  • Page 5 FOREWORD This maintenance manual is designed to serve as a reference for DOOSAN Infracore Ltd's (here after DOOSAN’s) customers and distributors who wish to gain basic product knowledge on DOOSAN's DB58S 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.

  • Page 7: Table Of Contents

    CONTENTS 1. GENERAL INFORMATION 2.8. Cooling system ........20 2.8.1. Anti-freeze.........21 1.1. Engine specifications........1 2.8.2. Cooling water ......21 1.2. Performance curve........2 1.2.1. Performance curve (ECRFA), 2.9. V-belt tension check and adjust....23 D50/60/70/80/90S-5 (3 speed)..2 2.10. Valve clearance and adjustment.... 24 1.2.2.
  • Page 8 5. Maintenance of Major Components 3.3. Engine Reassembly .........82 3.3.1. Piston and connecting rod assembly 5.1. Lubrication system......... 121 ..........82 5.1.1. Oil pump ......... 121 3.3.2. Cylinder head assembly parts ... 84 5.1.2. Oil cooler......... 123 3.3.3. Rocker arm and shaft assembly 87 5.2.

  • Page 9: General Information

    1. GENERAL INFORMATION 1.1. Engine specifications DB58S ECRFA DB58S ECRFD DB58S ECRFE Engine Model D50/60/70/80/90S-5 D35/40/45S-5, D50/60/70S-5 Items (3 speed) D50/55C-5 (2 speed) Engine type 4 cycle in-line Naturally aspirated Combustion chamber type Direct injection type Cylinder liner type Dry type Timing gear system Gear driven type No.

  • Page 10: Performance Curve

    1. 2. Performance curve 1. 2.1. Performance curve (ECRFA), D50/60/70/80/90S-5 (3 speed) General information - 2 -...

  • Page 11: Performance Curve (Ecrfd), D35/40/45S-5, D50/55C-5

    1. 2.2. Performance curve (ECRFD), D35/40/45S-5, D50/55C-5 - 3 - General information...

  • Page 12: Performance Curve (Ecrfe), D50/60/70S-5 (2 Speed)

    1. 2.3. Performance curve (ECRFE), D50/60/70S-5 (2 speed) General information - 4 -...

  • Page 13: Engine Assembly

    1.3. Engine assembly 1.3.1. Engine assembly view (ECRFA), D50/60/70/80/90S-5 (3 speed) Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan Priming pump water pump Starter Fuel injection pump...

  • Page 14: Engine Assembly View (Ecrfd), D35/40/45S-5, D50/55C-5

    1.3.2. Engine assembly view (ECRFD), D35/40/45S-5, D50/55C-5 Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan Priming pump water pump Starter Fuel injection pump Alternator Cylinder head cover Fuel injection pipe...

  • Page 15: Engine Assembly Views (Ecrfe), D50/60/70S-5 (2 Speed)

    1.3.3. Engine assembly views (ECRFE), D50/60/70S-5 (2 speed) Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan Priming pump water pump Starter Fuel injection pump Alternator Cylinder head cover...

  • Page 16: Safety Regulations

    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 DOOSAN representative. For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting the access of unauthorized persons and that you draw the attention of the operating personal to the fact that they are responsible for the safety of persons who enter the engine room.

  • Page 17: Regulations Designed To Prevent Damage To Engine And Premature Wear

    "just as good". (4) In addition to the above, note the following points. Never let the engine run when dry, i.e. without lube oil or coolant. Use only DOOSAN-approved service products. (engine oil, anti-freeze and anticorrosion agent) Pay attention to cleanliness.

  • Page 18: Regulations Designed To Prevent Pollution

    Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if these instructions are not adhered to. Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and coolant temperature) function satisfactorily.

  • Page 19: General Repair Instructions

    4. The use of proper tools and special tools where specified is important to efficient and reliable service operation. 5. Use genuine DOOSAN 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.

  • Page 20: Technical Information

    2. TECHNICAL INFORMATION 2.1. Engine model and serial number The engine model and serial number is located on the ENGINE SERIAL NO. 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.

  • Page 21: Engine Type

    2.2. Engine type The Engines DB58S are in-line vertical, water-cooled, 6-cylinder four stroke diesel engines with direct injection. DB58S is natural aspiration. 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.

  • Page 22: Valves

    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.

  • Page 23: Recommend Of Lubricating Oil

    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.

  • Page 24: Oil Cooler

    * If long oil change intervals are to be used, ACEA-E3 oil must be used. EA4M1008 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.

  • Page 25: Air Cleaner

    Head, oil filter Cartridge, Oil filter EC9OM015 <ECRFA, ECRFE> 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. EFM1002I 2.7.

  • Page 26: Injection Pump

    EC9OM017 2.7.3. Fuel requirements DOOSAN 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.

  • Page 27: How To Select Fuel Oil

    Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and acceptable exhaust emission levels. DOOSAN 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.

  • Page 28: Cooling System

    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.

  • Page 29: Anti-Freeze

    2.8.1. 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. Ambient Cooling water (%) Anti-freeze (%)
  • Page 30 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.

  • Page 31: V-Belt Tension Check And Adjust

    2.9. V-belt tension check and adjust 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.

  • Page 32: Valve Clearance And Adjustment

    2.10. 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 EAOO4014 After letting the #1 cylinder's piston come at the compression top dead center by...

  • Page 33: Cylinder Compression Pressure

    • No. 1 cylinder is located at the side where flywheel was installed. Cooling fan Cylinder no. Exhaust valve Intake valve Fly wheel EC9OM020 2.11. Cylinder compression pressure Stop the engine after warming up, and take out preheating plug and injection pipe. Install the special tool (compression gauge adapter) at the preheating plug hole, and connect the compression pressure gauge...

  • Page 34: Injection Nozzle

    2.12. Injection nozzle EFM1006I Install a nozzle on the nozzle tester. If the inspected injection pressure is less than the specified value, adjust using the adjusting shims. Engine model Injection nozzle pressure DB58S 220 kg/cm² Check the atomizing state and replace it if abnormal. 2.13.

  • Page 35: Diagnosis And Remedy

    2.15. Diagnosis and remedy The following description summarizes the probable cause of and remedy for general failure by item. Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected. 1. Engine Starting Impossible Starting motor does not turn Starting motor turns but engine does not revolution Inspection of battery electrolytic...
  • Page 36 2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged 3. Continuous over-run Cooling system Fule system Check coolant level Inspect fule quality Fuel excessive supply Poor Check injection nozzle Normal Too low Clean and replace Normal Abnormal with specified fule Check fan belt tension, wear or damage etc.
  • Page 37 3. Output insufficient Engine Chassis Check for clutch silp Adjust or replace clutch Fule system Others Inspect air cleaner Check for air maxing In fule Inspect fule supply pump Normal Clean. Replace Normal Clean. Inspect engine control Inspect air leakage Replace rod, link, cable, ect of air piping line...
  • Page 38 4. Oil Pressure Iowered Check if pressure Check oil amount gauge indicates wrongly Normal To Iow Check cooling Use recommened oil temperature (replenish) Too high Normal Refer to engine overheat Inspect oil quality Normal Improper Check oil Water and fule relief valve mixed in oil Disassemble engine...
  • Page 39 5. Fule Consumption Excessive Cause according to use conditions 1. Overlow 2. Frequent use of low gear position 3. Frequent use of high gear position at low speed Inspect fule Ieakage 4. Clutch slip 5. Too low tire inflation pressure Normal Fule leakage Inspect injection nozzle...
  • Page 40 6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low speed or extremely cold state Inspect oil leakage Inspect air cleaner Clean Replace Normal Oil leakage Check oil quality Extermal Internal Replace with Retighten.
  • Page 41 8. Battery Discharge Battery Wiring, Switch Altemator Inspect cut wire Check fan belt Check electrolytic shorts and loose tension & damage liquid amount connections, etc. Repair. Replace Normal Damaged Battery self Battery over battery case dischage charging Electrolytic Replace Charging Inspect altemator liquid’s standard and voltage regulator...
  • Page 42 Condition Causes Remedies 1) Starting difficult Repair or replace (1) Compression pressure Valve's poor shut, stem distortion Replace valve spring Valve spring damage Replace gasket Cylinder head gasket's leak Adjust Wear of piston, piston ring or liner 2) Idle operation abnormal Adjust Injection timing incorrect Remove air...
  • Page 43 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 Replace bearing & grind As the wear of bearing or crankshaft crankshaft progress, the oil clearances increase.

  • Page 44: Engine Inspection

    2.16. Engine inspection 2.16.1. Stopping engine After checking the engine for any unusual condition at the idling speed, then turn the key switch to the stop the engine. 2.16.2. General engine inspection cycle In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital.

  • Page 45: Use Of Original Parts For Repair And Replacement

    2.17. 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.

  • Page 46: Maintenance

    3. Maintenance 3.1. Engine Disassembly 3.1.1. Major part fixing nuts and bolts 1) Cylinder head cover (Unit : kg.m) EJM1001S Engine disassembly - 38 -...
  • Page 47 2) Cylinder block (Unit : kg.m) EJM1002S - 39 - Engine disassembly...
  • Page 48 3) Oil pan and level gauge (Unit : kg.m) EJM1003S Engine disassembly - 40 -...
  • Page 49 4) Camshaft and rocker arm (Unit : kg.m) EJM1004S - 41 - Engine disassembly...
  • Page 50 5) Crankshaft, piston and flywheel (Unit : kg.m) EJM1005S Engine disassembly - 42 -...
  • Page 51 6) Thermostat and housing (Unit : kg.m) EJM1006S - 43 - Engine disassembly...
  • Page 52 7) Intake and exhaust manifold (Unit : kg.m) EJM1009S Engine disassembly - 44 -...
  • Page 53 8) Timing gear case and flywheel housing (Unit : kg.m) EFM1010S - 45 - Engine disassembly...
  • Page 54 9) Oil cooler, oil filter and oil pump (Unit : kg.m) EFM1011S Engine disassembly - 46 -...
  • Page 55 10) Fuel system (Unit : kg.m) EFM1012S - 47 - Engine disassembly...
  • Page 56 11) Engine repair parts EC9OM064 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.

  • Page 57: Main Structure Parts (1)

    3.1.2. Main structure parts (1) EJM2010S 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 ▲...
  • Page 58 5) Cylinder head Loosen the cylinder head bolts a little in the numerical order shown in the figure. EJM2014S 11) Crankshaft pulley Use an appropriate wrench (54 mm) to remove the crankshaft pulley nut. EJM2015S 12) Taper bushing Use the taper bushing remover to remove the crankshaft end taper bushing.

  • Page 59: Main Structure Parts (2)

    3.1.3. Main structure parts (2) EJM2018S 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.
  • Page 60 6) Idler gear Measure following points before disassembly. <Idler gear end play> Standard Limit 0.058 ∼ 0.115 mm 0.2 mm EJM2022S <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 EJM2019S 7) Camshaft Measure...

  • Page 61: Rocker Arm Disassembly

    3.1.4. Rocker arm disassembly EJM2023S 1. Bracket 3. Spring 2. Rocker arm 4. Rocker arm shaft - 53 - Engine disassembly...

  • Page 62: Cylinder Head Disassembly

    3.1.5. Cylinder head disassembly EJM2024S 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 ▲...

  • Page 63: Piston And Connecting Rod Disassembly

    Importance 6) Valve cotter Use the valve spring compressor to remove the valve cotter. EJM2027S 3.1.6. Piston and connecting rod disassembly EJM2028I 4. Piston ▲ 1. Piston rings ▲ 2. Snap ring 5. Connecting rod bearing ▲ 3. Piston pin and connecting rod - 55 - Engine disassembly...
  • Page 64 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. EDM1011I 1) Piston rings Use a piston ring remover to remove the piston rings.

  • Page 65: Engine Inspection

    3.2. Engine Inspection 3.2.1. Cylinder block Clean the cylinder block thoroughly and make a visual inspection for cracks or damage. Replace if cracked or severely damaged, and correct if slightly damaged. Check oil and water flow lines for restriction or corrosion. Make a hydraulic test to check for any cracks or air leaks.

  • Page 66: Valve Stem And Valve Guide Clearance

    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. EJM2036S 3.2.3.
  • Page 67 2) Measuring method – II Measure valve stem outside diameter. Measure valve guide inside diameter by using of caliper calibrator of telescoping gauge. The difference between the valve stem outside diameter and the valve guide inside diameter is the valve stem clearance.
  • Page 68 Standard Limit Intake and exhaust 1.0 mm 2.5mm valve depression 5) Valve contact width Inspect the valve contact faces for the roughness and unevenness. Make valve contact surfaces smooth. Measure the width of valve contact. Standard Valve contact width, Intake 2.4mm Valve contact width, Exhaust 1.6mm...
  • Page 69 8) Valve seat correction Remove the carbon deposits from the valve seat surface. 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° 90°...

  • Page 70: Valve Spring

    3.2.4. Valve spring 1) Valve spring free length Measure the valve spring with the vernier caliper. 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 EJM2049I 2) Valve spring inclination...

  • Page 71: Tappet

    3.2.5. Tappet Check the valve tappets for excessive wear, damage or abnormalities. EA0M4070 Measure the outside diameter of tappet with the micrometer. Standard Limit Tappet ∅27.96 ∼ ∅27.92 outside ∅27.98mm diameter EJM2052S Measure the clearance between tappets and cylinder motion parts by the using dial indicator.

  • Page 72: Rocker Arm Correction

    3.2.7. Rocker arm correction Check the valve stem contact part of rocker arm. Grind contact surface with an oil stone if it is irregularly contacted. Replace the rocker arm if it is extremely damaged. EJM2055S 1) Rocker arm and shaft Check the disassembled parts for wear, damage and abnormalities.

  • Page 73: Idler Gear And Shaft

    Limit Standard Rocker arm 0.02 ∼ 0.07 bushing and 0.2 mm rocker arm shaft clearance Check the rocker arm oil port whether alien substance is in it or not. Clean the rocker arm oil port with compressed air if necessary. EJM2059I 3.2.8.
  • Page 74 Limit Standard Clearance of 0.03 ∼ 0.09 0.15 cam journal and cam bearing EJM2063S Align the camshaft bearing oil port with the mating oil port (machined on the cylinder block). EJM2064S Measure the cam lobe with the micrometer. Replace the camshaft if the measured values exceed the specified limit.

  • Page 75: Cylinder Liner

    3.2.10. Cylinder liner 1) Cylinder liner bore measurement Measure the bore at measuring position ① in line with the crankshaft③ and across the crankshaft②. EJM2067I Measured position: 20 mm from the top of liner. (max. wear portion) Replace the cylinder liner if the measured value exceeds specified limit.

  • Page 76: Cylinder Block

    3) Cylinder liner replacement Set the cylinder liner remover to the cylinder liner. Check that cylinder liner remover shaft ankle is firmly gripping the cylinder liner bottom edge. Slowly turn the remover shaft handle counter-clockwise to pull the cylinder liner free.
  • Page 77 Grade Cylinder block bore diameter marking ∅105.090 ∼ ∅106.000 mm ∅106.000 ∼ ∅106.010 mm EJM2073S 3) Cylinder liner outside diameter Measure the liner outside diameter at ①, ② and ③measuring point across X-X, Y-Y. Measuring Points : ① 20.0 mm ②...
  • Page 78 Cylinder liner Marking Part no of diameter cylinder liner grade Outer Inner 65.01201- 0068 65.01201- 0069 65.01201- 0070 EJM2074S 65.01201- 0071 4) Cylinder liner assembly Carefully wipe away any foreign material from the cylinder liner inside and outside surfaces and the cylinder bore. Cleanly wash cylinder liner and bore surfaces with new kerosene or diesel oil.

  • Page 79: Piston

    6) Cylinder liner bore measurement Loacte the two measuring points. Cylinder liner measuring point - ① : 20mm - ② : 105mm Measure cylinder liner bore at measuring points ① and ② in four different directions (X-X, Y-Y, W-W and Z-Z). Calculate the average value of the 8 measurements.
  • Page 80 <Cylinder liner bore and piston> Clearance 0.053 ~ 0.077 mm CAUTION: The cylinder liner-piston kit clearances are preset. However, cylinder liner installation procedure may result in slight decreases cylinder liner bore EJM2079S clearances. Always measure the cylinder liner bore clearance after installation to be sure that it is correct.
  • Page 81 Measure piston ring gap with a feeler gauge. 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...

  • Page 82: Maintenance Of Cylinder Block, Cylinder Liner And Piston

    If an inside dial indicator is not available, use the following procedure to check the piston pin fit. (1) Heat piston to approximately 60°C with the piston heater. (2) Push strongly against the piston pin with your thumb. The piston pin fitting should feel tight.

  • Page 83: Connecting Rod

    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.
  • Page 84 (2) Use a piston pin hole grinder① fitted with a reamer② or an adjustable pilot reamer to ream the piston pin hole. Standard Ø35.017 ∼ Connecting rod bush inside diameter Ø35.030 mm EJM2090S 4) Connecting rod bearing Inspection Fit the connecting bearing lower half into the connecting rod bearing cap.

  • Page 85: Crankshaft

    3.2.15. Crankshaft 1) Crankshaft and bearing inspection Check the crankshaft journal surfaces and pin surfaces for excessive wear and damage. Check oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and damage. Replace or repair the crankshaft if any excessive wear or damage is discovered. Check the crankshaft oil ports for obstructions.
  • Page 86 Standard Limit Rod bearing 0.03 ∼ 0.073 mm 0.10 mm clearance 4) Crankshaft bearing diameter 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.
  • Page 87 6) Main bearing and con-rod bearing tension Check to see if the bearing has enough tension, and set bearing into its regular position with the finger pressure. EAMD056S 7) Crankshaft regrinding Pay close attention to the following steps in order to ensure the reground-crankshaft reliability. Undersize bearing 0.25 mm 0.50 mm...
  • Page 88 Standard Limit 0.039 ∼ Main bearing 0.11 mm clearance 0.098 mm Standard Limit 0.03 ∼ Connecting 0.10 mm rod bearing 0.073 mm 9) Crankshaft gear replacement Visually inspect the crankshaft gear. Replace the crankshaft gear as following steps if excessive wear or damage is discovered.

  • Page 89: Flywheel And Flywheel Housing

    3.2.16. Flywheel and flywheel housing 1) Ring gear inspection Inspect the ring gear. If the ring gear teeth are broken or excessively worn the ring gear must be replaced. EJM2099S 2) Ring gear replacement Strike around the edges of the ring gear with a hammer and chisel to remove it.

  • Page 90: Engine Reassembly

    3.3. Engine Reassembly 3.3.1. Piston and connecting rod assembly EJM2103I ▲ 4. Piston ring ▲ 1. Piston ▲ 2. Piston Pin and connecting rod ▲ 5. Connecting rod ▲ 3. Snap ring 6. Connecting rod bolt 1) Piston Use a piston heater to heat piston to approximately 60°C.
  • Page 91 2) Connecting rod Install the piston and connecting rod with setting the marks as illustrated. Assemble the piston pin into the piston and connecting rod bushing. EJM2105S 3) Snap ring Assemble the snap rings by using snap ring flyer. Check that the piston moves smoothly on the piston pin.

  • Page 92: Cylinder Head Assembly Parts

    3.3.2. Cylinder head assembly parts EJM2107S 7. Thermostat housing and gasket ▲ 1. Valve stem oil seal ▲ 2. Intake and exhaust valve 8. Thermostat 3. Spring seat (lower) 9. Cooling water outlet ▲ 4. Intake and exhaust valve spring ▲...
  • Page 93 2) Intake and exhaust valves Place the cylinder head on a flat wooden surface. Lubricate valve stem with the engine oil. Assemble the valves to the intake or exhaust valve guides. EJM2110S 4) Intake and exhaust valve springs Assemble the valve spring with their painted end facing top.
  • Page 94 10) Intake manifold and gasket 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. EJM2114S Assemble the intake manifold. Tighten the intake manifold bolts to the specified torque a little at a time in the numerical order.

  • Page 95: Rocker Arm And Shaft Assembly

    3.3.3. Rocker arm and shaft assembly EJM2119S ▲1. Rocker arm shaft 2. Spring 3. Rocker arm 4. Bracket 1) Rocker arm shaft The rocker arm shaft must be installed with the oil holes facing up. - 87 - Engine reassembly...

  • Page 96: Main Components

    3.3.4. Main components EJM2120S Crankshaft bearing (lower) ▲ 9. Idler gear shaft ▲2. Crank shaft Idler gear ▲3. ▲10. Thrust washer Piston and connection rod ▲4. ▲11. Crank shaft bearing (upper) and cap Oil pump and coupling ▲5. ▲12. Timing gear case Flywheel housing ▲6.
  • Page 97 2) Crankshaft bearing (lower) There is no oil hole and oil groove on the lower bearing. opposite upper bearing has oil hole and oil groove. EJM2122S 3) Crankshaft 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.
  • Page 98 Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order. (see figure) Crankshaft bearing 24.0±1kg.m cap bolt torque Check that the crankshaft turns smoothly by manually rotating it. EJM2126S 6) Timing gear case Tighten timing gear case bolt to the specified torque.
  • Page 99 10) Idler gear Assemble the idle gear. Set the timing marks “A”, ”B”, and ”C” as shown in the figure. Tighten the idle gear bolts seating the thrust collar to the specified torque. The thrust collar must be installed with the chamfered side facing the front of the engine.
  • Page 100 12± 9.75± Torque 0.25kg.m 0.25kg.m Bolt head EJM2134S 12) Oil pump assembled Lubricate the oil pump with the specified engine oil. Install the oil pump with the coupling. Tighten the oil pump bolts to the specified torque. Oil pump bolt torque 5.0 kg.m EJM2135S 13) Flywheel housing...
  • Page 101 15) Oil cooler Assemble the oil cooler with gasket after applying sealant to the oil cooler gasket. Tighten the oil cooler bolts to the specified torque. in the numerical order (see figure) Oil Cooler Torque 2.2 kg m EJM2138S - 93 - Engine reassembly...

  • Page 102: Major Component Assembly

    3.3.5. Major component assembly EJM2139S ▲ 1. Flywheel Oil pump driving pinion ▲ 2. Crankshaft pulley nut Push rod ▲ 3. Tappet chamber cover Taper bushing ▲ 4. Water pump Crankshaft pulley and dust cover ▲ 5. Cylinder head gasket Timing gear cover ▲...
  • Page 103 1) Flywheel Lubricate the flywheel bolt with engine oil. Install the flywheel. Tighten the flywheel bolts to the specified torque in the numerical order. (see figure) Flywheel Bolt torque 18 kg.m EJM2142S 2) Injection pump Align the injection pump gear "C" timing mark with the idler gear “C”...
  • Page 104 3) Tappet chamber cover Apply silicon to the tappet chamber cover gasket. Assemble the tappet chamber cover and tighten the bolts to the specified torque. Tappet chamber cover 2.2 kg.m bolt torque EJM2145S 4) Water pump Apply silicon to the pump gasket before installing the water pump.
  • Page 105 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) 116.2 103.2 Apply engine oil to the cylinder head bolts threads and setting faces. 8) Rocker arm shaft assembly Tighten the rocker arm bolts to the specified torque a little at a time in the...

  • Page 106: External Parts

    3.3.6. External parts Engine assembly view (ECRFA), D50/60/70/80/90S-5(3 speed) Water Water drain valve drain valve Oil drain Oil drain valve valve Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan...
  • Page 107 Engine assembly view (ECRFD), D35/40/45S-5, D50/55C-5 Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan Priming pump water pump Starter Fuel injection pump Alternator Cylinder head cover Fuel injection pipe...
  • Page 108 Engine assembly views (ECRFE), D50/60/70S-5 (2speed) Oil filter C.C.V Push rod chamber cover Lifting hook Crank shaft pulley Flywheel housing Oil cooler Vibration damper Fly wheel Intake manifold Oil drain plug Oil pan Priming pump water pump Starter Fuel injection pump Alternator Cylinder head cover Fuel injection pipe...
  • Page 109 1) Cylinder head cover Tighten the cylinder head cover bolts to the specified torque a little at a time in the sequence. (see figure) Cylinder head cover bolt 2.2 kg.m torque Fan belt Adjust the fan belt tension. EJM2154S 2) Starter Tighten the starter bolts to the specified torque after install the starter to the flywheel housing.
  • Page 110 An improperly positioned clip will result in objectionable fuel pulsing noise and injection pipe breakage. Install the fuel return pipes③. 5) Oil filter Install filter assembly with tightening the bolts securely. Oil filter assembly 5.0 kg.m mounting bolts torque EJM2175I <ECRFD>...

  • Page 111: Commissioning And Operation

    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 DB58S engine". 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.

  • Page 112: Starting And Operation

    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.
  • Page 113 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.

  • Page 114: Inspections After Starting

    4.3. Inspections after starting It is advisable to operate an engine at idling until the engine reaches up to normal operating temperature. Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal. Confirm the following things through warning lamps and gauge panel.

  • Page 115: Lubricating Oil

    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. 4.4.4. Starting of engine in winter It is necessary to preheat engine satisfactorily under 10 °C (50 °F) in winter.

  • Page 116: Maintenance And Care

    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. Daily inspections in below figure should be checked every day. The maintenance should be executed thoroughly at regular internals. 4.5.2.

  • Page 117: Replacement Of Oil Filter Cartridge109

    O- ring. Turn 1-1/4 turns further with the filter Head, oil filter wrench. IMPORTANT: It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement. Cartridge, Oil filter EC9OM015 < ECRFA, ECRFE >...

  • Page 118: Cooling System

    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.

  • Page 119: Cleaning Of The Cooling Inside System Circuit

    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 agents and corrosion inhibitor or defect, not early enough replaced covers for filler neck and working valves.
  • Page 120 After letting the #1 cylinder's piston come at the compression top dead center by turning the crankshaft, adjust the valve clearances. 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...

  • Page 121: Injection Timing

    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> Align the crankshaft pulley TDC mark with the pointer. Remove the inspection hole cover at the front of the injection pump on the timing gear case cover.
  • Page 122 <Check procedure> Turn the crankshaft pulley counterclockwise about 30° crank angle. 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. EC9OM033 Remove the delivery valve holder①, the valve seat②, valve spring③, and the delivery valve④...
  • Page 123 Remove the delivery valve holder from the No.1 plunger Reassemble the delivery valve internal parts to the delivery valve holder. 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 EJM1041S Assemble the No.1 cylinder injection pipe and tighten it to the specified torque.

  • Page 124: Tightening The Cylinder Head Bolts

    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. Tighten the four injection pump fixing nuts. Once remove the No.

  • Page 125: Feed Pump Strainer

    4.11. Feed pump strainer Release joint bolt A. Remove the strainer with a screwdriver and wash the strainer with clean diesel fuel. EJM1029S EJM1030S 4.12. Separator (Add if necessary) Check water level of the separator. Release the plug at the bottom to eliminate water when water level (floating) reaches the warning point.

  • Page 126: Belts

    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.
  • Page 127 4) Measuring tension ① Lower indicator arm (1) into the scale. Apply tester to belt at a point midway between two pulleys so that edge of contact surface (2) is flush with the V- belt. Slowly depress pad (3) until the spring can be heard to disengage.
  • Page 128 5) Tensioning and changing belts Loosen fixing bolts and nuts. Adjust the alternator until belts have correct tensions. Retighten fixing bolts and nuts. To change the belts loosen fixing bolts and nuts. Then push the alternator toward water pump pulley by hand. EC9OM034 Commissioning &...

  • Page 129: Maintenance Of Major Components

    5. Maintenance of Major Components 5.1. Lubrication system 5.1.1. Oil pump 1) Disassembly EC9OM034 1. Oil suction pipe 4. Pinion Gear 2. Cover and dowel 5. Pinion gear shaft 3. Drive shaft and gear - 121 - Maintenance of major components...
  • Page 130 2) Inspection Visually inspect the disassembled parts for the excessive wear and damage. Correct or replace the parts if the wear or damage is discovered during inspection. EC9OM060 3) Oil Pump Drive Gear Use a feeler gauge to measure the clearance between the oil pump cover (oil pump case) inside surface and the drive gear.

  • Page 131: Oil Cooler

    5.1.2. Oil cooler 1) Disassembly EJM3008S 1. Oil cooler element 4. O-ring 2. Gasket 5. By-pass valve spring 3. By-pass plug 6. By-pass valve 2) Inspection Correct or replace the part if the wear or damage is discovered during inspection. 3) Oil cooler element Install the oil cooler element to the oil cooler, then tighten the oil cooler element...

  • Page 132: Cooling System

    5.2. Cooling system 5.2.1. Water pump 1) Disassembly EC9OM061 1. Pulley flange ▲ 5. Impeller ▲ 2. Snap ring 6. Pump housing ▲ 3. Unit bearing 7. Cover 4. Mechanical seal 8. Gasket (1) Impeller Remove the impeller by using the jig. EJM4008I Maintenance of major components - 124 -...
  • Page 133 (2) Unit bearing Remove the unit bearing by using a bench press and a suitable remover. EJM4008I (3) Mechanical seal Remove the mechanical seal by using a suitable remover. EJM4009S (4) Hub Remove the hub by using a bench press and a suitable rod.
  • Page 134 2) Inspection (1) Unit bearing Correct or replace the part if the wear, defect or other damage is discovered during inspection. EJM4011I 3) Water pump reassembly (1) Unit bearing Lubricate the bearing with multipurpose grease. Use a bench press to assemble the unit bearing at the pump.
  • Page 135 (4) Mechanical seal Apply sealant to the seal unit outer periphery before installation. EJM4016S Use a bench press and a bar to install the seal unit into the pump body. EJM4017S (5) Impeller Use a bench press to install the impeller to the shaft.

  • Page 136: Thermostat

    5.2.2. Thermostat Correct or replace thermostat if the wear, defect or other damage is discovered during inspection. EFM2055I Maintenance of major components - 128 -...

  • Page 137: Fuel System

    5.3. Fuel system 5.3.1. Fuel filter 1) Cartridge type Air vent plug Fuel filter head Cartridge, fuel filter Water drain plug EC9OM063 2) Inspection Make the necessary adjustments, repairs and part replacements if excessive wear or damage is discovered during inspection. 3) Fuel filter reassembly To reassemble the fuel filter, follow the disassembly procedure in the reverse order.

  • Page 138: Injection Nozzle

    5.3.2. Injection nozzle 1) Disassembly EJM5008S 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 11. Nozzle holder cap nut 5. Retaining nut 6.
  • Page 139 (1) Push rod spring Check the push rod spring for wear, weakness and corrosion. EJM5005S (2) Nozzle holder push rod Check the nozzle holder push rod curvature. Check the nozzle holder push rod and needle valve contact surface excessive wear and poor contact. EJM5006S (3) Injection nozzle Check the injection nozzle needle valve,...
  • Page 140 4) Reassembly (1) Injection pipe connector Injection pipe 5.5 kg.m connector torque EJM5009S (2) Injection nozzle 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.
  • Page 141 (5) Nozzle adjusting screw (injection starting pressure check) Attach the injection nozzle holder to the injection nozzle tester. EA0M3033 Loosen the adjustment screw①. EJM5024S Check 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...

  • Page 142: Injection Pump Calibration

    5.3.3. Injection Pump Calibration 1) DB58S engine (ECRFD) D.H.I 65.11101-7404 INJ.PUMP CALIBRATION DATA MAKER 101605- 996H(DOOWON) DATE 2003. 11. 04 DB58S SUFFIX ECRFD D35/40/45S,D50C-2 F/L MODEL INJ.PUMP BODY :101062-830A GOVERNOR :105419-1340 TIMING DEVICE : LESS (KP-PES6A95C410RS2000) (KP-EP/RSV200-1450AQ43A311) NOZZLE & HOLDER ASS'Y 105780-8140 (FOR E/G : 105160-465B) NOZZLE...
  • Page 143 2) Injection pump EJM5018S 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.
  • Page 144 3) Governor EJM5019S 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.

  • Page 145: Precautions For Operation

    5.3.4. 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 1) Check oil level When starting the engine 2) Crank the engine with starter to check 2) Abrupt starting of the engine causes the increase in oil pressure(until the the engine to rotate with oil not being...

  • Page 146: Walk-Around Check And Servicing

    5.3.5. 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;...

  • Page 147: Diagnostics And Troubleshooting139

    5.3.6. 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 or 4) Turbocharger seized up and not rotating replace Disassemble/repair or 5) Turbine blades and compressor blades coming in...

  • Page 148: Special Tool List

    6. Special Tool List Remark Part No. Figure Tool Name EU.2-0529 Compression gauge adapter EF122-249 Valve spring compressor EF.122-265 Crankshaft gear punch EF.122-253 Crankshaft pilot bearing remover EF.122-251 Pilot bearing punch EF.122-262A Crankshaft rear oil seal installer EF.122-255 Crankshaft front oil seal installer EF.122-289 Valve stem oil seal installer Special tool list...
  • Page 149 Part No. Figure Tool Name Remark E1.03901-0124 Piston insert sleeve EF.122-281 Cylinder liner remover EF122-261 Cylinder liner installer EU.1-0022 Pulley bush puncher EU.2-0328 Pulley bush puller 60.99901-0027 Feeler gauge T7610001E Snap ring plier T7621010E Piston ring plier - 141 - Special tool list...

  • Page 150: Appendix

    • Appendix 1) Tightening torque for major parts Screw Strength Major Parts Tightening Torque Remarks (Diameter x pitch) (grade) 1st : 4.4 kg.m Cylinder head bolt M12 x 1.5 10.9T 2nd : 150° (Angle method) Connecting rod bearing cap bolt M12 x 1.5 12.9T 9.75 kg.m...
  • Page 151 16.0 20.0 35.0 ★SUM22L STS304 11.0 16.0 20.0 35.0 ★ : Adopted in DOOSAN engine 4) Standard bolt tightening torque table Refer to the following table for bolts other then described above Degree of strength 10.9 12.9 Diameter (4A) (4D)

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