doosan D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 D50S-5 Service Manual

Service Manual

SB4118E01
May. 2007

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
D50S-5, D60S-5, D70S-5

(2 speed)

(3 speed)

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 “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” 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.

WARNING

Improper 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.

DOOSAN 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 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.

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. DOOSAN dealers have the most current information available.

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. 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 15

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.

1. GENERAL INFORMATION

1.1. Engine specifications..................................1

1.2. Performance curve.....................................2

1.2.1. Performance curve (ECRFA),

D50/60/70/80/90S-5 (3 speed) .... 2

1.2.2. Performance curve (ECRFD),

D35/40/45S-5, D50/55C-5 ..........3

1.2.3. Performance curve (ECRFE),

D50/60/70S-5 (2 speed).............. 4

1.3. Engine assembly........................................5

1.3.1. Engine assembly view (ECRFA),

D50/60/70/80/90S-5 (3 speed) .... 5

1.3.2. Engine assembly view (ECRFD),

D35/40/45S-5, D50/55C-5 ..........6

1.3.3. Engine assembly views (ECRFE),

D50/60/70S-5 (2 speed).............. 7

1.4. Safety regulations.......................................8

1.4.1. General notes ............................. 8

1.4.2. Regulations designed to prevent

accidents .................................... 8

1.4.3. Regulations designed to prevent
damage to engine and premature

wear........................................... 9

1.4.4. Regulations designed to prevent

pollution.................................... 10

1.4.5. General repair instructions ........ 11

2. TECHNICAL INFORMATION

2.1. Engine model and serial number..............12

2.2. Engine type ..............................................13

2.2.1. Cylinder block ........................... 13

2.2.2. Piston con-rod / crankshaft........ 13

2.3. Engine timing............................................13

2.4. Valves.......................................................14

2.5. Lubrication system ...................................14

2.5.1. Recommend of lubricating oil .... 15

2.5.2. Oil cooler .................................. 16

2.5.3. Oil filter..................................... 16

2.6. Air cleaner ................................................17

2.7. Fuel system..............................................17

2.7.1. Injection pump .......................... 18

2.7.2. Fuel filter................................... 18

2.7.3. Fuel requirements ..................... 18

2.7.4. How to select fuel oil................. 19

CONTENTS

2.8. Cooling system ........................................ 20

2.8.1. Anti-freeze.................................21

2.8.2. Cooling water............................21

2.9. V-belt tension check and adjust............... 23

2.10. Valve clearance and adjustment............ 24

2.11. Cylinder compression pressure ............. 25

2.12. Injection nozzle...................................... 26

2.13. Battery ................................................... 26

2.14. Starting motor ........................................ 26

2.15. Diagnosis and remedy........................... 27

2.16. Engine inspection .................................. 36

2.16.1. Stopping engine ......................36

2.16.2. General engine inspection cycle36

2.17. Use of original parts for repair and

replacement.................................................... 37

3. Maintenance

3.1. Engine Disassembly ................................ 38

3.1.1. Major part fixing nuts and bolts ..38

3.1.2. Main structure parts (1) .............49

3.1.3. Main structure parts (2) .............51

3.1.4. Rocker arm disassembly...........53

3.1.5. Cylinder head disassembly........54

3.1.6. Piston and connecting rod

disassembly.............................. 55

3.2. Engine Inspection .................................... 57

3.2.1. Cylinder block............................57

3.2.2. Cylinder head ............................57

3.2.3. Valve stem and valve guide

clearance..................................58

3.2.4. Valve spring .............................. 62

3.2.5. Tappet ......................................63

3.2.6. Push rod ...................................63

3.2.7. Rocker arm correction...............64

3.2.8. Idler gear and shaft ...................65

3.2.9. Camshaft ..................................65

3.2.10. Cylinder liner ...........................67

3.2.11. Cylinder block..........................68

3.2.12. Piston......................................71

3.2.13. Maintenance of cylinder block,

cylinder liner and piston ...........74

3.2.14. Connecting rod........................75

3.2.15. Crankshaft...............................77

3.2.16. Flywheel and flywheel housing 81

3.3. Engine Reassembly .................................82

3.3.1. Piston and connecting rod assembly

................................................. 82

3.3.2. Cylinder head assembly parts ... 84

3.3.3. Rocker arm and shaft assembly 87

3.3.4. Main components ..................... 88

3.3.5. Major component assembly ...... 94

3.3.6. External parts ........................... 98

4. Commissioning and Operation

4.1. Preparation.............................................103

4.1.1. Starting................................... 103

4.2. Starting and operation ............................104

4.2.1. Operation of a new engine (Break-

In)........................................... 104

4.2.2. Check points for break-in ........ 104

4.3. Inspections after starting ........................106

4.4. Operation in winter time .........................106

4.4.1. Prevention against the freeze of

cooling water .......................... 106

4.4.2. Prevention against excessive

cooling.................................... 106

4.4.3. Lubricating oil ......................... 107

4.4.4. Starting of engine in winter...... 107

4.4.5. Tuning the engine ................... 107

4.5. Maintenance and care............................108

4.5.1. Periodical inspection and

maintenance........................... 108

4.5.2. Exchanging of lubrication oil.... 108

4.5.3. Oil level................................... 108

4.5.4. Oil exchange procedure .......... 108

4.5.5. Replacement of oil filter cartridge109

4.6. Cooling system.......................................110

4.6.1. Coolant draining...................... 110

4.6.2. Cleaning of the cooling inside

system circuit.......................... 111

4.7. Valve clearance and adjustment ............111

4.8. Injection timing .......................................113

4.9. Tightening the cylinder head bolts..........116

4.10. Fuel injection pump ..............................116

4.11. Feed pump strainer ..............................117

4.12. Separator (Add if necessary)................117

4.13. Air bleeding ..........................................117

4.14. Belts .....................................................118

5. Maintenance of Major Components

5.1. Lubrication system................................. 121

5.1.1. Oil pump .................................121

5.1.2. Oil cooler.................................123

5.2. Cooling system ...................................... 124

5.2.1. Water pump ............................124

5.2.2. Thermostat.............................. 128

5.3. Fuel system ........................................... 129

5.3.1. Fuel filter.................................129

5.3.2. Injection nozzle ....................... 130

5.3.3. Injection Pump Calibration.......134

5.3.4. Precautions for operation......... 137

5.3.5. Walk-around check and servicing

...............................................138

5.3.6. Diagnostics and troubleshooting139

6. Special Tool List ......................... 140

• Appendix ...............................................142

1. GENERAL INFORMATION

1.1. Engine specifications

Engine Model
Items

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. 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 : 1

Engine dimension
(length X width X height)
(mm)

Engine weight (kg) 450

Rotating direction (from fly wheel) counter clockwise

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

Fuel injection timing (B.T.D.C static) 15°

Injection pump type Bosch in-line A type

Governor type Mechanical governor RSV type

Injection nozzle type Multi-hole type (5 hole)

Fuel injection pressure (kg/cm²) 220

Compression pressure (kg/cm²) 28 (at 200 rpm)

Intake & exhaust valve clearance (mm)
(at cold)

Intake valve

Exhaust valve

Lubrication method Pressurized circulation

Oil pump type Gear type

Oil filter type Full-flow, cartridge type

Lubricating oil capacity (oil pan) (lit) 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 (82 ∼95°C)

Cooling fan 10- Ø 520.7 blower 7 – Ø 457 blower 10- Ø 520.7 blower

Starting Motor
(voltage – output) (V - kW)

Open at 17° B.T.D.C

Close at 51° A.B.D.C

Open at 60° B.B.D.C

Close at 18° A.T.D.C

DB58S ECRFA

D50/60/70/80/90S-5

(3 speed)

DB58S ECRFD

D35/40/45S-5,

D50/55C-5

1,173 x 666 x 793

0.4

24 – 4.5

DB58S ECRFE

D50/60/70S-5

(2 speed)

General information - 1 -

1. 2. Performance curve

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

General information - 2 -

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

General information - 3 -

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

General information - 4 -

1.3. Engine assembly

1.3.1. Engine assembly view (ECRFA), D50/60/70/80/90S-5 (3 speed)

10

4

5

2

3

1

14

15

24

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

6

11

17 26

18

12

22

28

8

19

9

13

7

21

23

25

20

16

27

General information - 5 -

1.3.2. Engine assembly view (ECRFD), D35/40/45S-5, D50/55C-5

10

2

4

5

6

9

28

8

3

19

1

14

15

11

17 26

7

13

21

12

22

24

18

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

25

23

20

16

27

General information - 6 -

1.3.3. Engine assembly views (ECRFE), D50/60/70S-5 (2 speed)

10

4

5

6

9

28

8

2

3

19

15

1

14

11

17

7

26

13

21

12

22

24

18

25

23

1 Oil filter 11 C.C.V 21 Push rod chamber cover
2 Lifting hook 12 Crank shaft pulley 22 Flywheel housing
3 Oil cooler 13 Vibration damper 23 Fly wheel
4 Intake manifold 14 Oil drain plug 24 Oil pan

5 Priming pump 15 water pump 25 Starter

6 Fuel injection pump 16 Alternator 26 Cylinder head cover

7 Fuel injection pipe 17 Oil level gauge 27 Fuel injection nozzle
8 Water outlet 18 Exhaust manifold 28 Fuel filter

9 Cooling fan 19 Water pump pulley
10 Oil filler cap 20 Thermostat housing

20

16

27

General information - 7 -

1.4. Safety regulations

1.4.1. 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.

1.4.2. 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 DOOSAN 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 DOOSAN

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.

CAUTION
There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare hands.

Safety regulations - 8 -

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.
z 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.

1.4.3. 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 DOOSAN.

(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of

damage.

(3) Use only genuine DOOSAN spare parts. DOOSAN 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 DOOSAN-approved

service products. (engine oil, anti-freeze and anticorrosion 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".

Safety regulations - 9 -

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.

1.4.4. 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.

1.4.5. 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.
z Wash thoroughly with soap and water, A nailbrush is an effective aid.
z Certain products make it easier to clean your hands.
z 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.

Safety regulations - 10 -

1.4.5. 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 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.

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.

Safety regulations - 11 -

2. TECHNICAL INFORMATION

2.1. Engine model and serial number

The engine model and serial number is located on the
engine as illustrated. These numbers are required
when requesting warranty and ordering parts. They

are also referred to as engine model and serial
number because of their location.

Engine serial No. (example : DB58)
DB58S 3 00001 FA

Engine suffix (ECRFA)
Serial no.
Production year (2003)
Engine model

ENGINE SERIAL NO.

EC90M011

Technical information - 12 -

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. 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.

Injection pump gear

(Z = 50)

Idle gear

(Z = 51)

Camshaft gear

(Z = 50)

Oil pump drive gear

(Z = 12)

P.T.O Drive gear

(Z=24)

Crankshaft gear

(Z = 25)

Oil pump gear

(Z = 9)

P.T.O gear (Option)

(Z = 25)

EC90M013

Technical information - 13 -

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 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.

EC90M014

Technical information - 14 -

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 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

- After 50hr operation ; 250

z The following oils are also recommended

Engine oil capacity Recommend oil

Max.

(liter)

Oil pan

(liter)

Min.

Total

(liter)

SAE No. API No.

SAE10W40
SAE15W40

ACEA-E2 or ACEA-E3

(API CH-4)

Engine model

DB58S 19 14 20.5

Technical information - 15 -

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

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

• Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.

• Change the oil filter cartridge
simultaneously at every replacement of
engine oil.

EA4M1008

Technical information - 16 -

EDM3001I

<ECRFD>

Cartridge,
Oil filter

<ECRFA, ECRFE>

Head, 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.

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.

EC9OM015

EFM1002I

EC9OM065

Technical information - 17 -

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.

2.7.2. Fuel filter

This fuel filter has two functions not only oil
filtering but
also water separating
Before entering the suction chamber of the
injection pump, the fuel is cleaned in a
strainer of fuel feed pump and a fuel filter.
Drain water in filter with loosening the drain
plug under filter manually from time to time.
The fuel filter element should be replaced at
every 200 hours.

Air bleeding plug

Seal ring

Head, fuel filter

Cartridge, fuel filter

Water drain plug

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. Once kerosene has been added,
the engine should be run for several minutes to mix the fuel.

EC9OM016

EC9OM017

Technical information - 18 -

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. 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.
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.

Fuel Oil Selection Chart

General Fuel

Classification

Gravity, °API #) D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855

ASTM

Test

No. 1

ASTM 1-D

No. 2

ASTM 2-D

DIN 51601

Flash Point

Min. °F (°C)

Viscosity, Kinematic

CST 100 °F (40 °C )

Cloud Point °F #) D 2500 See Note 1) See Note 1) See Note 1)

Sulfur Content

wt%, Max.

Carbon Residue

on 10%, wt%, Max.

Accelerated Stability
Total Insolubles

mg/100 ml, Max. #)

Ash, wt%, Max. D 482 0.01 0.01

Cetane Number, Min. +) D 613 45 45 > 45

Distillation
Temperature, ℉(℃)

IMP, Typican #)
10% Typical #)
50% Typical #)
90% +)
End Point #)

D 93 100 (38) 125 (52) 131 (55)

D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10

D 129 0.5 0.5 0.15

D 524 0.15 0.35 0.1

D 2274 1.5 1.5

D 86

350(177)
385(196)

45(218)

500 (260) Max.

550(288) Max.

625(329) Max.
675(357) Max.

375(191)
430(221)
510(256)

680(360)

Water & Sediment

%, 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.

D 1796 0.05 0.05 0.05

Technical information - 19 -

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.

Technical information - 20 -

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.

Temperature (°C)

Ambient

Cooling water (%) Anti-freeze (%)

Over -10

-10

-15

-20

-25

-30

-40

85
80
73
67
60
56
50

15
20
27
33
40
44
50

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.
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.

2.8.2. 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.

Technical information - 21 -

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) (7) locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.

(8) 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.

Technical information - 22 -