Doosan DB33A Page 21 Service Manual Download | Manualshive

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17

2. Engine Assembly

2.1. General Description

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Summary of Contents for DB33A

Page 1: ...Service Manual Diesel Engine 3 3 Liter DB33A SB2013E02 May 1998...

Page 2: ...lowing symbol 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...

Page 3: ...ssential In this manual the following symbols are used to indicate the type of service operations to be performed Removal Installation Disassembly Reassembly Align the marks Directional Indication Ins...

Page 4: ...1 General Description 5 3 Injection Nozzle 5 2 Fuel Filter 6 SPECIAL TOOL LIST 74 WORLDWIDE NETWORK CONTENTS 1 GENERAL INFORMATIONS 1 1 1 General Repair Instructions 1 4 Major Parts Fixing Bolts 1 2 E...

Page 5: ...n 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 fun...

Page 6: ...on pump type VE DOOWON Governor type Mechanical governing Injection nozzle type Multi hole type 6 hole VCO nozzle Fuel injection pressure Kg cm2 220 3 128 psi Compression pressure kg cm2 30 at 200 RPM...

Page 7: ...16 2 0 18 1 5 20 1 5 22 1 5 24 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...

Page 8: ...4 1 4 Major Parts Fixing Bolts Cylinder head and block unit kg U m 15 2 lb ft 2 1 10 0 11 5 2 5 5 3 72 32 lb ft 83 17 lb ft 18 0 lb ft 38 33 lb ft...

Page 9: ...5 Intake and exhaust manifold unit kg U m 15 2 lb ft 2 1 2 1 15 2 lb ft...

Page 10: ...6 Cylinder block and others unit kg U m 2 1 2 6 7 9 2 6 2 4 13 7 Lubricate with engine oil Lubricate with engine oil 99 1 lb ft 15 2 lb ft 18 8 lb ft 18 8 lb ft 57 0 lb ft...

Page 11: ...7 Cylinder block and others unit kg U m 2 6 2 6 2 6 5 3 5 3 38 3 lb ft 38 3 lb ft 18 8 lb ft 18 8 lb ft 18 8 lb ft...

Page 12: ...8 Crankshaft and camshaft unit kg U m 44 0 5 5 2 5 16 0 16 0 12 0 25 9 75 0 25 318 lb ft 39 8 lb ft 18 1 lb ft 115 7 lb ft 115 7 lb ft 70 5 1 8 lb ft 86 8 1 8 lb ft...

Page 13: ...9 Thermostat and housing unit kg U m 2 1 5 3 25 1 lb ft 10 5 lb ft...

Page 14: ...t 7 Gasket Oil cooler 8 Gasket Oil pump cover 9 Oil seal Crankshaft RR 10 Gasket Retainer 11 Gasket Case and cylinder block 12 Gasket Cover and case 13 Gasket Oil pan drain plug 14 Gasket Oil pan and...

Page 15: ...the No 1 cylinder or the No 4 cylinder to top dead center on the compression stroke by turning the crankshaft until the TDC notched line on the crankshaft pulley is aligned the timing pointer 2 Check...

Page 16: ...pointer are aligned Remove the inspection hole cover at the front of gear case cover Check the alignment between the notched line on the camshaft gear and the arrow mark of gear case cover Setting Ti...

Page 17: ...er Adjust the timing pointer with the marking on the pulley 2 Remove 2 fixing bolts of timing flange and injection pump Remove bolt located at the center Insert the dial gauge to check the plunger lif...

Page 18: ...sure in each cylinder with a compression gauge by engaging starter kg cm2 200 rpm Compression gauge adapter Standard 30 Limit 22 23 312 327 psi 1 6 5 Air Cleaner Dry type air cleaner Observe the air c...

Page 19: ...store good elements in a clean dry place 1 6 6 Radiator Install the radiator cap tester and pressurize the radiator Inspect the cooling system if there any leak Measuring pressure kg cm2 1 0 14 2 psi...

Page 20: ...the adjusting screw using a nozzle tester Incorrect Incorrect Correct 1 6 9 Fan Belt mm Fan pulley Depress here Generator pulley Crank pulley 1 6 10 Glow Plug Inspection Resistance Check the continuit...

Page 21: ...17 2 Engine Assembly 2 1 General Description...

Page 22: ...embly steps 1 Breather hose 2 Exhaust manifold 3 Oil guide tube and level gauge 4 Starter 5 Cooling fan belt 6 Alternator 7 Oil pan 8 Cylinder head cover 9 Rubber hose 10 Water pump 11 Thermostat hous...

Page 23: ...4 2 7 5 3 1 3 2 Important operations Exhaust manifold assembly 2 Loosen the manifold fixing bolts in sequence of figure s shown Cylinder head cover 8 Loosen the head cover bolts in sequence of figure...

Page 24: ...2 2 2 External Parts B Disassembly steps 1 Fuel injection pipe 2 Injection nozzle 3 Glow plug 4 Intake manifold 5 Oil pipe 6 Oil filter assembly 7 Injection pump 8 Oil cooler assembly 7 8 6 5 2 6 3 8...

Page 25: ...Disassemble the engine control cable Injection nozzle 2 Avoid damaging the nozzle tips or other parts during disassembly Injection pump assembly 7 When disassembving the injection pump cap or tape th...

Page 26: ...Fly wheel housing 7 Rear oil seal assembly 8 Oil pump cover 9 Oil pump assembly 10 Piston and connecting rod assembly 11 Crankshaft front nut and washer 12 Crankshaft pulley 13 Gear case cover 14 Idl...

Page 27: ...the figure Flywheel 5 Loosen the flywheel bolts a little at a time in numerical sequence as shown in the figure Piston assembly 10 Remove any carbon deposits from the upper part of the cylinder bore...

Page 28: ...rd 0 10 0 17 0039 0069 in Limit 0 3 012 in Backlash mm Includes the crankshaft gear camshaft gear and idle gear Crankshaft bearing cap and bearing 17 Measure the crankshaft end play before disassembly...

Page 29: ...t 21 Remove the tappets and mark the cylinder number each tappet Be careful against the damages Wire Intake Exhaust Mark the cylinder No 2 2 4 General Components Rocker arm Bracket and shaft assembly...

Page 30: ...ring compressor Disassembly steps 1 Spring retainer and valve cotter 2 Spring and spring seat 3 Valve 4 Valve stem oil seal Important operations Mark the cylinder No each component when it disassemble...

Page 31: ...g rod assembly Important operations Mark the cylinder No each component when it disassembles Disassembly steps 1 Piston ring 2 Snap ring 3 Piston pin and connecting rod 4 Piston Piston ring Piston Pis...

Page 32: ...e piston pin with brass bar 2 3 Inspection and Repair Make the necessary adjustments repairs and replacements if excessive wear or damage is discovered during inspection 2 3 1 Cylinder Head Lower face...

Page 33: ...n mm Valve seat angle Valve seat angle Valve seat insert replacement Removal Arc weld the entire inside circumference of the valve seat insert Cooling the valve insert for a few minutes and pull out w...

Page 34: ...ter mm Valve guide replacement Remover installer 45 Thickness Measuring point Remover installer Standard 1 5 059 in Limit 1 0 039 in Intake valve Exhaust valve Standard 8 946 8 961 352 353 in 8 921 8...

Page 35: ...tandard less than 1 3 mm 051 in Limit 2 7 mm 106 in 1 0 mm 039 in 1 0 mm 039 in Inner Outer Remark for Industrial for Automotive Valve Spring Tension at 40 mm Set Length 42mm 1 65 in 44mm 1 73 in Rema...

Page 36: ...a smooth flat surface as shown in the figure 2 3 6 Rocker Arm Shaft Assembly Inspect all disassembled parts for wear damage and any abnormalities Rocker arm shaft mm Micrometer Dial indicator Standar...

Page 37: ...any abnormalities End play mm Camshaft journal diameter mm Camshaft Cam gear Thrust plate Camshaft gear Thrust plate Camshaft Feeler gauge Standard 19 01 19 03 748 749 in Limit 19 05 75 in Standard 0...

Page 38: ...camshaft on a measuring stand Use a dial indicator to measure the camshaft run out Note the total indicator reading T I R Camshaft bearing Replace the camshaft gear if any damages or excessive backlas...

Page 39: ...han the specified limit the camshaft must be replaced Camshaft gear Cam lobe height C Cam journal diameter A B 2 3 8 Idle Gear and Idle Gear Shaft Shaft outside diameter mm use a micro Clearance betwe...

Page 40: ...f 2 500kg to fully seat the cylinder liner After installing the liner measure the cylinder liner projection and inner diameter Liner projection For the cast liner removal or installation is done easil...

Page 41: ...015 in 101 963 101 977 4 014 4 015 in 20mm 2 3 10 Piston Piston Pin and Piston Ring Piston outer diameter mm Piston and liner bore clearance Standard mm 0 055 0 075 Piston ring Piston ring and ring gr...

Page 42: ...arallelism Alignment per length of 100mm 3 94 in mm Bushing inside diameter Use a caliper calibrator and micrometer to measure the piston pin and connecting rod small end bushing clearance Piston pin...

Page 43: ...cting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Reassemble the connecting rod and bearing cap Reamer Pin hole grinder 2 3 12 Crankshaft and Bearing C...

Page 44: ...ure the connecting rod inside diameter with an inside dial indicator Crankshaft journal bearing Tension Fit the journal bearing into the journal bearing cap and check the tension with the same method...

Page 45: ...25 2 989 in Torque kg U m 24 173 6 lb ft Journal bearing 76 j nominal diameter mm 2 992 in Crankshaft journal and bearing clearance mm Crankshaft run out mm 1 Mount the crankshaft on a set of v blocks...

Page 46: ...ect the crankshaft gear Before the gear disassembly check the crank gear backlash If excessive wear of any damage is found through the inspection replace the crankshaft gear Refer to Major components...

Page 47: ...e a hammer to install the ring gear when it is sufficiently heated Flywheel housing oil seal replacement Removal Use a pry bar and hammer Installation Use a oil seal installer 2 3 13 Flywheel and Hous...

Page 48: ...ller 2 4 Engine Reassembly 2 4 1 Minor Components Piston and connecting rod assembly Disassembly steps 1 Piston 2 Piston pin 3 Snap ring 4 Piston ring 5 Connecting rod 1 2 3 4 3 5 Important operation...

Page 49: ...t the piston moves smoothly on the piston pin Piston ring 4 1 Use a piston ring installer to install the three piston rings Install the piston rings in the following order oil ring M2nd compression ri...

Page 50: ...e stem oil seal 1 Installer Lubricate the oil seals and valve guides and install the oil seals with an installer Intake and exhaust valves 2 1 Lubricate valve stems with engine oil 2 Install the valve...

Page 51: ...d cotter key 4 Installer Spring compressor Use a spring compressor to push the valve spring into position Install the cotter key Set the cotter key by tapping lightly around the head of the collar wit...

Page 52: ...ase 7 Camshaft assembly 8 Piston and connecting rod assembly 9 Oil pump assembly 10 Oil pump cover 11 Oil cooler 12 Injection pump assembly 13 Idle gear 14 Timing gear case cover 15 Crankshaft pulley...

Page 53: ...rankshaft contact face Crankshaft bearing cap Lubricate the bearing cap bolts with engine oil Install the bearing caps to the crankshaft The arrow mark must be pointing to the front of the engine Tigh...

Page 54: ...me rotate the crankshaft until the crank pin reaches its highest point Set the bearing cap cylinder number marks and the connecting rod cylinder number marks The marks must be facing the exhaust manif...

Page 55: ...en the cooler bolts to the specified torque Start from the middle and work out to either side Injection pump assembly 12 Check the punched line of the injection pump body is aligned to the pump bracke...

Page 56: ...as shown in the figure Crankshaft front nut 16 Wrench 41 mm Flywheel housing 17 Fixing bolts torque 14kg U m 101 25 lb ft Flywheel 19 Crankshaft gear Camshaft gear A mark C mark B mark Idle gaer Inje...

Page 57: ...n the head bolts in the numerical order as shown in the figure Rocker arm shaft assembly 23 Tighten the rocker arm bracket bolts to the specified torque a little at a time in the numerical order shown...

Page 58: ...eps 1 Breather hose 2 Exhaust manifold 3 Oil guide tube and level gauge 4 Starter 5 Cooling fan belt 6 Alternator 7 Oil pan 8 Cylinder head cover 9 Rubber hose 10 Water pump 11 Thermostat housing asse...

Page 59: ...over 2 Tighten the bolts as shown in the figure Water pump assembly 3 Apply liquid gasket belco bond No 4 to the water pump gasket before installing the water pump Thermostat housing assembly 5 Apply...

Page 60: ...gasket with the TOP mark side facing up Install either end of the distance tube in the spot facing Tighten the exhaust manifold and gasket fixing bolts in numerical order as shown in the figure Refer...

Page 61: ...57 2 4 4 Extermal Parts B 6 7 1 3 2 5 4 2 1 3 6 Disassembly steps 1 Oil filter and bracket 2 Oil pipe 3 Intake manifold 4 Glow plug 5 Injection nozzle 6 Injection pipe 7 Engine control lever...

Page 62: ...sting the opening pressure with adjust screw using a nozzle tester Replace the nozzle gasket and dust cover with new one Tighten the injection pipe sleeve nut and flange nut Protruding Part Refer to m...

Page 63: ...on pipe 6 Delivery valve holder must be tightened as specified torque Excessive torque causes leakage at control rack and pipe Torque kg U m 3 0 21 7 lb ft Delivery valve 4 0 4 5 Holder torque kg U m...

Page 64: ...and gear 6 Driven gear shaft 4 6 3 2 5 1 Full flow filter By pass valve O P 1kg cm2 Paper filter O P 8kg cm2 Oil relief valve Oil pump Oil pan Oil strainer By pass valve Oil cooler O P 2kg cm2 O P war...

Page 65: ...wear or damage is found through inspection Visually inspect the disassembled parts for excessive wear and damage Oil pump cover and oil pump drive gear clearance Cover and driven gear clearance Drive...

Page 66: ...ssembly steps 1 Oil filter ass y 2 Head oil filter 3 Element oil fiter 4 Relief valve ass y 5 Gasket 6 Bolt 7 Spring washer 8 Plain washer 9 O Ring 10 Plug screw Inspection and repair Make the necessa...

Page 67: ...63 Reassembly To reassemble follow the disassembly procedures in reverse order Important operation Relief Valve 1 Torque kg U m 2 5 18 1 lb ft...

Page 68: ...lve Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection Reassembly To reassemble follow the disassembly procedure...

Page 69: ...65 4 Cooling System 4 1 General Description 4 2 Water Pump Disassembly Disassembly steps 1 Cover 2 Impeller 3 Center Fan 4 Snap ring 5 Shaft bearing and spacer 6 Seal unit washer and seal...

Page 70: ...g a bench press and a bar Snap ring 4 Remove the snap ring using a snap ring plier Shaft bearing and spacer 5 Remove the shaft and bearings using a bench press and suitable remover Seal unit Washer an...

Page 71: ...earings with a marked side outward Reassembly To assemble follow the disassembly procedures in reverse order Important operation Shaft bearing and spacer 5 Lubricate the bearing with multi purpose gre...

Page 72: ...clearance between the impeller and the pump body 4 3 Thermostat Inspection and repair Make the necessary adjustments pepairs and part replacements if excessive wear or damage is found through inspect...

Page 73: ...69 5 Fuel System 5 1 General Description Injection nozzle Injection pump Fuel filter water separator Fuel tank Fuel return...

Page 74: ...if excessive wear or damage is found through inspection Reassembly To assemble follow the disassembly procedures in reverse order Disassembly steps 1 Plunger 2 Retaining nut 3 Injection nozzle 4 Spac...

Page 75: ...ep the parts separately to maintain the proper needle valve to body combination Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found...

Page 76: ...pin with the dowel hole in the nozzle holder body Retaining nut 2 Adjust shim 7 The injection nozzle injection starting pressure can be adjusted after the adjusting shim is installed Torque kg U m 6 8...

Page 77: ...name Cylinder head bolt wrench Injection pump Compression gauge adapter Valve spring compressor Valve guide remover and installer Camshaft bearing remover and installer Cylinder remover Cylinder line...

Page 78: ...rankshaft gear remover Crankshaft gear installer Crankshaft pilot bearing remover Crankshaft rear oil seal installer Crankshaft front oil seal installer Valve stem oil seal installer Piston ring compr...

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