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Doosan D50S-5 - Service Manual
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Service Manual
Diesel Engine
5.8
Liter (DB
58
S)
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)
SB41
18E01
May
. 2007
2
Table of Contents
Main Page
Default Chapter
3
Important Safety Information
3
Table of Contents
7
1 General Information
9
Engine Specifications
9
D50/60/70/80/90S-5 (3 Speed)
9
Performance Curve
10
Performance Curve (ECRFD), D35/40/45S-5, D50/55C-5
11
Performance Curve (ECRFE), D50/60/70S-5 (2 Speed)
12
Engine Assembly
13
Engine Assembly View (ECRFA), D50/60/70/80/90S-5 (3 Speed)
13
Engine Assembly View (ECRFD), D35/40/45S-5, D50/55C-5
14
Engine Assembly Views (ECRFE), D50/60/70S-5 (2 Speed)
15
Safety Regulations
16
General Notes
16
Regulations Designed to Prevent Accidents
16
Regulations Designed to Prevent Damage to Engine and Premature Wear
17
Regulations Designed to Prevent Pollution
18
General Repair Instructions
19
2 Technical Information
20
Engine Model and Serial Number
20
Engine Type
21
Cylinder Block
21
Piston Con-Rod / Crankshaft
21
Engine Timing
21
Valves
22
Lubrication System
22
Recommend of Lubricating Oil
23
Oil Cooler
24
Oil Filter
24
Air Cleaner
25
Fuel System
25
Injection Pump
26
Fuel Filter
26
Fuel Requirements
26
How to Select Fuel Oil
27
Cooling System
28
Anti-Freeze
29
Cooling Water
29
V-Belt Tension Check and Adjust
31
Valve Clearance and Adjustment
32
Cylinder Compression Pressure
33
Injection Nozzle
34
Battery
34
Starting Motor
34
Diagnosis and Remedy
35
Engine Inspection
44
Stopping Engine
44
General Engine Inspection Cycle36
44
Use of Original Parts for Repair and Replacement
45
3 Maintenance
46
Engine Disassembly
46
Major Part Fixing Nuts and Bolts
46
Main Structure Parts (1)
57
Main Structure Parts (2)
59
Rocker Arm Disassembly
61
Cylinder Head Disassembly
62
Piston and Connecting Rod Disassembly
63
Engine Inspection
65
Cylinder Block
65
Cylinder Head
65
Valve Stem and Valve Guide Clearance
66
Valve Spring
70
Tappet
71
Push Rod
71
Rocker Arm Correction
72
Idler Gear and Shaft
73
Camshaft
73
Cylinder Liner
75
Cylinder Block
76
Piston
79
Maintenance of Cylinder Block, Cylinder Liner and Piston
82
Connecting Rod
83
Crankshaft
85
Flywheel and Flywheel Housing
89
Engine Reassembly
90
Piston and Connecting Rod Assembly
90
Cylinder Head Assembly Parts
92
Rocker Arm and Shaft Assembly
95
Main Components
96
Major Component Assembly
102
External Parts
106
4 Commissioning and Operation
111
Preparation
111
Starting
111
Starting and Operation
112
Operation of a New Engine (Break-In)
112
Check Points for Break-In
112
Inspections after Starting
114
Operation in Winter Time
114
Prevention against the Freeze of Cooling Water
114
Prevention against Excessive Cooling
114
Lubricating Oil
115
Starting of Engine in Winter
115
Tuning the Engine
115
Maintenance and Care
116
Periodical Inspection and Maintenance
116
Exchanging of Lubrication Oil
116
Oil Level
116
Oil Exchange Procedure
116
Replacement of Oil Filter Cartridge109
117
Cooling System
118
Coolant Draining
118
Cleaning of the Cooling Inside System Circuit
119
Valve Clearance and Adjustment
119
Injection Timing
121
Tightening the Cylinder Head Bolts
124
Fuel Injection Pump
124
Feed Pump Strainer
125
Separator (Add if Necessary)
125
Air Bleeding
125
Belts
126
5 Maintenance of Major Components
129
Lubrication System
129
Oil Pump
129
Oil Cooler
131
Cooling System
132
Water Pump
132
Thermostat
136
Fuel System
137
Fuel Filter
137
Injection Nozzle
138
Injection Pump Calibration
142
Precautions for Operation
145
Walk-Around Check and Servicing
146
Diagnostics and Troubleshooting139
147
6 Special Tool List
148
Appendix
150
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