Daewoo D50S-2 User manual

Service Manual

Diesel Engine

5.8 Liter (DB58)

D50S-2, D60S-2, D70S-2

SB2148E00

Oct. 1998

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety

rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an

accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,

skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,

maintenance and repair on this product.

Basic safety precautions are listed in the ÒSafetyÓ section of the Service or Technical Manual. Additional safety

precautions are listed in the ÒSafetyÓ section of the owner/operation/maintenance publication.

Specific safety warnings for all these publications are provided in the description of operations where hazards

exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.

If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in

this publication and on the product labels are identified by the following symbol.

IImproper operation, lubrication, maintenance or repair of this product can be dangerous and could result

in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and

understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this

publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in

this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating

technique not specifically recommended by DAEWOO 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.

The information, specifications, and illustrations in this publication are on the basis of information available at the

time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other

items can change at any time. These changes can affect the service given to the product. Obtain the complete

and most current information before starting any job. DAEWOO dealers have the most current information

available.

WARNING

TO THE CUSTOMERS

This operation and maintenance manual is designed to serve as a reference for DHI's customers and distributors

who wish to gain basic product knowledge on DHI's DB58 Diesel engine.

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 Liquid gasket application

Disassembly Cleaning

Reassembly Pay close attention-Important

Alignment(Marks) Tighten to specified torque

Directional Indication Use special tools of manufacturer's

Inspection Lubricate with oil

Measurement Lubricate with grease

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.

CONTENTS

1. GENERAL INFORMATION¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥1

1.1. General Repair Instructions 1.4. Major Part Fixing Bolts

1.2. Engine Specifications 1.5. Maintenance

1.3. Torque Specifications 1.6. Engine Repair Parts

2. ENGINE DISASSEMBLY AND ASSEMBLY¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥24

2.1. Engine External Parts 2.3. Inspection and Repair

2.2. Disassembly 2.4. Reassembly

3. SYSTEM OF LUBRICATION¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥73

3.1. General Description 3.3. Oil Cooler

3.2. Oil Pump

4. COOLING SYSTEM¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥78

4.1. General Description 4.2. Coolant pump

5. FUEL SYSTEM¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥83

5.1. General Description 5.3. Injection Nozzle

5.2. Fuel filter 5.4. Injection Pump

6. CAUSE OF TROUBLE, DIAGNOSIS AND TROUBLESHOOTING¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥¥92

1. General Information

1.1. General Repair Instructions

1. For safety, park the truck on even ground or work station and fix the wheels using wedges and hand brake

during operation.

2. Before performing service operations, disconnect the grounding cable from the battery to reduce the chance

of cable damage and burning due to short-circuiting.

3. Before performing service operations release the air pressure in the machine air line system for safety. To not

do so is extremely dangerous.

4. Use covers to prevent the components from damage or pollution.

5. Brake oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.

6. The use of proper tools and special tools where specified is important for efficient and reliable service

operation.

7. Use genuine DAEWOO parts exclusively.

8. Used cotter pins, gaskets, O-rings, oil seals, lock washers 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.

9. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping

bolts and nuts separate is very important as they vary in hardness and design depending on the position of

installation.

10. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make

certain they are free from restrictions.

11. Lubricate rotating and sliding faces of parts with oil or grease before installation.

12. When necessary, use a sealant on gaskets to prevent leakage.

13. Carefully observe all specifications for bolts and nuts torques.

14. When a service operation is completed, make a final check to ensure that the service has been done

properly.

- 1 -

1.2. Engine Specifications

- 2 -

Engine Model

Items

Engine type Water cooled, 4 cycle, vertical in-line, overhead valve

Combustion chamber type Direct injection

Cylinder liner type Dry type

Timing gear system Gear drive type

Number of piston ring Compression ring 2, oil ring 1

No. of cylinder-bore

b

stroke (mm) 6-102

b

118

Total piston displacement (cc) 5,785

Compression ratio 17.5 : 1

Engine dimension(length

b

width

b

height) (mm) 1122

b

648

b

775

Engine weight(dry) (kg) 455

Fuel injection order 1-5-3-6-2-4

Fuel injection timing(B.T.D.C static) 18

û

Type of fuel used High speed diesel fuel (SAE No.2)

Fuel filter type Cartridge type

Injection pump type Bosch in-line A type

Governor type Mechanical governing (RSV type)

Injection nozzle type Multi-hole type

Fuel injection pressure (Kg/cm

2

) 220

Compression pressure (kg/cm

2

) 31 (at 200 RPM)

Low idle speed(R.P.M) 750

L

30

High idle speed(R.P.M) 2370

L 50

Intake and exhaust valve clearance(mm) 0.4 (at cold)

Rated Power 100ps / 2,200rpm

Max torque 35 kg ¥ m / 1,600rpm

Lubrication method Pressurized circulation

Oil pump type Gear type

Oil filter type Full-flow, cartridge

Lubricating oil capacity (

M

) 14.5

Oil cooler type Water cooled

Cooling method Pressurized forced circulation

Cooling water capacity(engine only) (

M

)12

Water pump Belt driven impeller type

Thermostat type Wax pallet type

Battery (V) 24

Alternator (V-A) 24-4.5

Starter (V-KW) 24-4.5

DB 58

- 3 -

1.3. Torque Specifications

Standards bolts

The torque values given in the following table should be applied where a particular torque is not specified.

(Unit : kg¥ m)

Bolt

identification

Bolt

diameter

b

pitch

4T

Low carbon steel

7T

High carbon steel

9T

Alloy steel

6

b

1.0

8

b

1.25

10

b

1.25

8

10

b

1.5

12

b

1.25

8

12

b

1.75

14

b

1.5

8

14

b

2.0

16

b

1.5

8

16

b

2.0

18

b

1.5

20

b

1.5

22

b

1.5

24

b

2.0

0.4-0.8

0.8-1.8

2.1-3.5

2.0-3.4

5.0-7.5

4.6-7.0

7.8-11.7

7.3-10.9

10.6-16.0

10.2-15.2

15.4-23.0

21.0-31.6

25.6-42.2

36.6-55.0

0.5-1.0

1.2-2.3

2.8-4.7

2.8-4.6

6.2-9.3

5.8-8.6

9.5-14.2

9.0-13.4

13.8-20.8

13.2-19.8

19.9-29.9

27.5-41.3

37.0-55.5

43.9-72.5

-

1.7-3.1

3.8-6.4

3.7-6.1

7.7-11.6

7.3-10.9

11.6-17.4

10.9-16.3

16.3-24.5

15.6-23.4

23.4-35.2

32.3-48.5

43.3-64.9

56.5-84.7

The

8

indicates that the bolts are used for female-threaded parts that are made of soft materials such as casting,

etc.

1.4. Major Parts Fixing Bolts

Cylinder Head and Block

(Unit : kg¥ m)

- 4 -

2.7

L

0.25

(19.5

L

1.8)

5.3

L

1

2.1

L

0.5

5.3

L

1

11.5

L

05. (hexagon bolt) : (Torque Control Method)

4 Kg m + 90û+60û(0~30û)

(docoecagon bolt) : (Angle Control Method)

EJM1001S

preheating plug

¥ Intake and Exhaust Manifold(DB58)

(Unit : kg¥ m)

- 5 -

2.9

L

0.3

2.6

L

0.5

EJM1007S

- 6 -

¥ Cylinder Block

(Unit : kg

¥

m)

5.3

L

1

2.6

L

0.5

2.6

L

0.5

2.6

L

0.5

2.1

L

0.5

24.1

L

1

EJM1002S

¥ Oil Pan and Dipstick

(Unit : kg

¥

m)

- 7 -

2.6

L

0.5

8.0

L

1.0

2.9

L

0.3

EJM1003S

¥ Cam Shaft and Rocker Arm

(Unit : kg

¥

m)

- 8 -

16

L

1.5

Engine oil application

5.5

L

1

2.6

L

0.5

2.6

L

0.5

3.1

L

0.5

3.1

L

0.5

EJM1004S

¥ Crankshaft, Piston, and Flywheel

(Unit : kg

¥

m)

- 9 -

22.3

L

2.2

60

L

5

A type : 12

L

0.25

B type : 9.25

L

0.25

B type or

A type

EJM1005S

Mark : ON BOLT HEAD

¥ Thermostat and Thermostat Housing

(Unit : kg

¥

m)

- 10 -

EJM1006S

5.3

L

1

5.3

L

1

2.6

L

0.5

¥ Timing Gear Case and Flywheel Housing

(Unit : kg

¥

m)

- 11 -

EJM1010S

16.0

L

1.0

16.0

L

1.0

Outside

2.6

L

0.5

2.6

L

0.5

¥ Oil Cooler, Oil Filter and Oil Pump

(Unit : kg

¥

m)

- 12 -

2.6

L

0.5

2.6

L

0.5

5.3

L

1.0

EJM1011S

5.3

L

1.0

5.3

L

1.0

¥ Fuel System

(Unit : kg

¥

m)

- 13 -

EJM1013S

1.9

L

0.2

1.3

L

0.2

3.1

L

0.2

4.2

L

0.8

1) Wipe the fuel filter mounting face with clean rag to

install a new filter.

2) Lightly oil the O-ring part.

3) Inject fuel to the new fileter to be easily discharged

an air.

4) Turn the new fuel filter until the sealing face is filted

against the O-ring.

5) Additionally tighten the fuel filter by 3/4 of one turn.

Plug

EJM1022I

- 14 -

¥ Removal

1) Remove filter as turning it counterclock wise.

2) Do not reuse the used filter.

¥ Assembly

1) Wipe the oil filter mounting face with a clean rag to

install a new filter.

2) Lightly oil the O-ring part.

3) Turn the new oil filter until the sealing face is fitted

against the O-ring.

4) Additionally tighten the oil filter by 3/4 of one turn.

5) Check the engine oil level and replenish to the

specified level if necessary.

6) Check the leakage at the replaced filter as

operating the engine.

EJM1019I

1.5. Maintenance

1.5.1. Replacement of Oil Filter

Cartridge (Spin-On) Type

1) Remove the filter as turning it counterclock wise.

2) Do not reuse the used filter.

1.5.2. Replacement of Fuel Filter

Head

Cartridge

- 15 -

1.5.3. Water separator

1) Drain plug should be loosened to remove water in

fuel filter if necessary.

2) When assembling plug, make to surely keep the

forque to be 1.2

L

0.3 kg ¥ m

• Disassembly Procedure

1) Fix the injection nozzle with a vise.

2) Release nozzle holder cap with a wrench.

3) Disassemble the injection nozzle holder from a

vise.

¥ Adjusting Procedure

Injection Opening Pressure Check.

1) Assemble nozzle holder at nozzle tester.

2) Release adjustment screw (1), As shown in fig.

3) Check injection opening pressure.

4) Adjust injection nozzle opening pressure if

necessary with nozzle tester.

EJM1023S

EIO3008S

1.5.4. Injection Nozzle

DB58

Injection Opening Pressure 220 kg/cm

2

EJM1024S

1

Injection Condition Check (Operating the Nozzle

Tester)

1) Tighten cap nut (1)

2) Check injection nozzle opening pressure

3) Check the injection nozzle sparay condition

Prior to injecting the fuel completely, compress 4~6

times and finally inject.

See figure for injection condition.

1) Good

2) Inferiority (orifice)

3) Inferiority (dripping)

EJM1027S

EJM1028S

- 16 -

Carefully keep away from skin

and keep off from tester because pressure of

nozzle tester is very high when inject.

EJM1025S

EJM1026S

1

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