Daedong 3A165D Скачать руководство пользователя

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ENGINE

( E ) Idle Gear Oil clearance
1. Measure the idle gear shaft O.D. with an outside

m i c r o m e t e r.

2. Measure the idle gear bushings I.D. with an inside

m i c r o m e t e r.

3. If the clearance exceeds the allowable limit,

replace the bushing.

( F ) Replacing Idle Gear Bushings
1. Press out the bushings using an idle gear bushing

replacing tool.

2. Clean the bushings and the bore, and apply oil to

t h e m .

3. Press in the bushing using the replacing tool.

( G ) Camshaft Oil clearance
1. Measure the I.D. of the camshaft bore on the

crankcase with an inside micrometer.

2. Measure the O.D. of the camshaft journal with an

outside micrometer.

3. If the clearance exceeds the allowable limit,

replace the shaft.

Factory

0.025 to 0.066mm

Oil

spec.

0.00098 to 0.00259in.

Clearance

Allowable

0.1mm

limit

0.004in.

Shaft

Factory

37.959 to 37.975mm

O.D.

spec.

1.4944 to 1.4950in.

Bushing

Factory

38.000 to 38.025mm

I.D.

spec.

1.4961 to 1.4970in.

Factory

0.050 to 0.091mm

Oil

spec.

0.00197 to 0.00358in.

Clearance

Allowable

0.15mm

limit

0.0059in.

Journal

Factory

39.934 to 39.950mm

O.D.

spec.

1.57221 to 1.57284in.

Bore

Factory

40.000 to 40.025mm

I.D.

spec.

1.57480 to 1.57579in.

Содержание 3A165D

Страница 1: ...FUEL CAMSHAFT H ROCKER ARM ASSEMBLY I INLET AND EXHAUST VALVES J TIMING GEARS K FLYWHEEL 2 2 LUBRICATING SYSTEM A FLOW OF LUBRICATING OIL B OIL PUMP C OIL FILTER AND RELIEF VALVE D OIL PRESSURE SWITC...

Страница 2: ...ER 3 DISASSEMBLING AND SERVICING 3 1 TROUBLESHOOTING 3 2 SERVICING SPECIFICATIONS A ENGINE BODY B LUBRICATING SYSTEM C COOLING SYSTEM D FUEL SYSTEM E TIGHTENING TORQUES 3 3 CHECKING DISASSEMBLING AND...

Страница 3: ...nd mechanism of each part with figure and description CHAPTER 3 DISASSEMBLING AND SERVICING DISASSEMBLING AND SERVICING provides information about disassembling and servicing procedures checking servi...

Страница 4: ...rs diesel engines they concentrate DAEDONG s foremost technologies With vortex combustion chamber Bosch K type fuel injection pump well balanced designs they feature greater power low fuel consumption...

Страница 5: ...rpm minimum 800 900 800 900 idling speed rpm Order of firing 1 2 3 1 3 4 2 Direction of rotation Counterclockwise viewed from flywheel side Counterclockwise viewed from flywheel side Injection pump B...

Страница 6: ...ENGINE 1 3 PERFORMANCE CURVE...

Страница 7: ...0 400 0 488 1 25 16 729 9 259 7 240 0 315 0 95 0 in 23 71 28 44 11 02 15 75 19 22 9 91 28 74 10 00 9 45 12 40 3 74 4A200B mm 697 3 817 3 280 0 400 0 488 1 251 6 735 8 259 7 240 0 321 0 92 0 in 27 45 3...

Страница 8: ...a O ring and the oil seal when reassembling When exchanging parts use DAEDONG genuine parts to maintain engine performance and safety To prevent oil and water leakage apply non drying adhesive to the...

Страница 9: ...igned for high combustion efficiency and reducing fuel consumption The glow plug assures easier than ever engine starts even at 15o C 5o F 1 Combustion Chamber 2 Inlet Port 3 Exhaust Port 4 Injection...

Страница 10: ...g fits well to the cylinder wall The second ring 2 is an undercut type which prevents the oil from being carried up The oil ring 3 has chambered contact faces and an expander ring which increase the p...

Страница 11: ...the injection pump and the fuel transfer pump The governor balls are installed on the fuel camshaft to control the engine speed 1 Fuel camshaft 2 Injection pump gear H ROCKER ARM ASSEMBLY The rocker a...

Страница 12: ...aligning the mark on the crankshaft gear 6 with one the idle gear 5 idle gear with camshaft gear idle gear with injection pump gear when assembling 1 Injection Pump Gear 5 Idle Gear 2 Fuel camshaft 6...

Страница 13: ...gears B OIL PUMP The oil pump is a gear pump Whose rotors have trochoid lobes The inner rotor 3 has 4 lobes and the outer rotor 4 has 5 lobes and they are eccentrically engaged with each other The inn...

Страница 14: ...il pressure rises more than 441 kPa 4 5kgf cm2 64psi 1 Bypass Valve 4 Oil Pressure Switch a To Idle Gear Camshaft and Rocker Arm 2 Bypass Adjusting Spring 5 Relief Valve Ball b From Oil Pump 3 Filter...

Страница 15: ...erature When the water temperature is high the thermostat opens to allow the water to flow from the cylinder block to the radiator When the water temperature is low the themostat closes and the flow s...

Страница 16: ...or The radiator core consists of water carrying tubes 2 with fins 3 at a right angle to it The water in the radiator is cooled by the air flowing through between the tube wall and the fin 1 Cooling Ai...

Страница 17: ...ylinders for combustion The exessive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes 6 and returns to the fuel tank B FUEL FILTER The fuel filter removes...

Страница 18: ...CTION PUMP The injection pump is Bosch K type mini injection pump It features a compact and lightweight design a To Injection Pump b Front Fuel Feed Pump 1 Delivery Valve Holder 5 Plunger 2 Delivery V...

Страница 19: ...ole Plunger 2 Relief Plunger 5 Fuel Chamber 3 Control Groove c Amount of fuel delivery A No fuel delivery At the engine stop position of the control rack 3 the lengthwise slot 1 on the plunger 2 align...

Страница 20: ...essure is about 13 7 to 14 7 MPa 140 to 1150kgf cm2 1990 to 2130 psi the pressure overcomes the counterforce of nozzle valve spring and push the valve up instantly the fuel is then injected in a prope...

Страница 21: ...adjusting the amount of fuel supplied to the engine according to changes in the load The engine employs an all speed governor which controls centrifugal force of the steel ball 13 weight produced by r...

Страница 22: ...ernor Spring 2 15 Speed Control lever 4 Fork Lever 1 16 Idling Limiting Spring 12 Governor Sleeve 20 Idling Limiting Screw c At High Speed Running with Overload When an overload is applied to the engi...

Страница 23: ...vacuator 6 where the dust exhaust port The fine dust in the air is filtered with the air cleaner element 4 and the filtered air flows to theoutletport 1 a Inlet Air b To Inlet Manifold c Heavier Dust...

Страница 24: ...AC into DC Direct Current also controls the output voltage for charging current to the battery a Alternator The AC alternator produces higher voltage in slow speed compared with DC dynamo and charge m...

Страница 25: ...nder bore or bearing Compression leak from cylinder Replace head gasket tighten cylinder head screw glow plug and nozzle holder Improper valve seating valve Repair or replace spring broken valve seize...

Страница 26: ...holder Piston ring s gap facing the Shift ring gap direction same direction Excessive Oil ring worn or stuck Replace Lubrication Oil Piston ring groove worn Replace the piston Consumption Valve stem...

Страница 27: ...te corroded Clean or replace Engine Radiator cap defective Overhead Water pipe damaged Replace Thermostat defective Replace Water pump defective Replace Mechanical seal defective Replace Overload runn...

Страница 28: ...0098in EX 0 30mm 0 0118in 1 047rad 60 o Valve Seat Angle IN 0 785rad 45 o Valve Face Angle IN 1 047rad 60 o EX 0 785rad 45 o 0 2 to 0 25mm Valve Recessing 0 0078 to 0 0197in Clearance Between Valve S...

Страница 29: ...pecification Allowable Limit 0 01mm 0 05mm Camshaft Alignment 0 0031in 0 0020in IN 3A165D 4A200B 33 59mm 33 54mm 1 3224in 1 3205in EX 33 69mm 33 64mm 1 3264in 1 3244in Clearance Between Camshaft 0 050...

Страница 30: ...0 014 to 0 30mm 0 15mm 0 00055 to 0 00150in 0 0059in Piston Pin O D 25 002 to 25 011mm 0 068433 to 0 98469in Small End Bushing I D 25 025 to 25 040mm 0 98524 to 0 98583in k Connecting Rod Item Factor...

Страница 31: ...rance between Outer rotor and Pump 0 11 0 19mm 0 2mm 0 0043 0 0078in 0 0098in End Clearance between Inner rotor and Cover 0 015 0 150mm 0 2mm 0 00413 0 00591in 0 00787in Valve Opening Temperature At B...

Страница 32: ...cover nuts M10 1 25 0 7 0 9 6 9 to 8 8 5 1 to 6 5 Bearing case screw 1 M9 1 25 4 7 5 2 46 1 to 51 0 34 0 to 37 6 Bearing case screw 2 M10 1 25 7 0 7 5 69 7 to 73 6 50 6 to 54 2 Flywheel screw M12 1 2...

Страница 33: ...Crankshaft 29 T appet 41 Oil Filter 6 Rocker Arm 18 Bearing Case Cover 30 Push Rod 42 Oil Filter Flange 7 Cylinder Head 19 Flywheel housing 31 Crank Gear 43 Fan Drive Pulley 8 Exhaust manifold 20 Fly...

Страница 34: ...e alternator 5 and the belt 1 5 Remove the hourmeter unit 2 6 Loosen the oil filter cartridge 3 with the filter wrench and remove it and the flange 4 1 Fan Belt 6 Dipstick 2 Hourmeter Unit 7 Exhaust M...

Страница 35: ...ews 1 Screw 5 Stop lever 1 2 Engine stop lever 6 Screw 3 Screw 7 Stop lever 2 4 Screw 8 Solenoid 3 Inlet Manifold and Fuel Pipes 1 Disconnect the fuel pipe 3 2 Loosen the injection pipe fitting with t...

Страница 36: ...re while running serveral times 6 If the pressure does not reach the allowable limit apply a small amount of oil to the cylinder wall through the nozzle holder hole and measure the pressure again 7 If...

Страница 37: ...h a feeler gauge 4 If the clearance is not within the factory specifications turn the adjusting screw to adjust 5 Turn the flywheel just one turn to position the 1st cylinder valves at the top head ce...

Страница 38: ...th the injection nozzle gasket If theheatsealdrops repeattheaboveprocedure 4 Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service 1 Pl...

Страница 39: ...of water flange gasket Replace the head gasket with new one and place on the cylinder block be careful of its direction and side When using head gasket shim assemble the shim first on the cylinder he...

Страница 40: ...1 Remove the injection pump cover 3 with the engine stop lever 2 2 Remove the injection pump When reassembling Apply liquid gasket to the both sides of injection pump cover gasket and install it Inst...

Страница 41: ...from the fork lever 1 2 When reassembling Be careful not to drop the start spring into the gear case Hook the start spring so that the longer hook is on the fork lever side 1 Start Spring 2 Fork leve...

Страница 42: ...he water pump body 1 2 Remove the relief valve cover 2 and take out the ball spring and seat When reassembling Install the relief valve cover 2 with its mark up 1 Water Pump Body 2 Relief Valve Cover...

Страница 43: ...rench 2 Draw out the camshaft 1 3 Remove the cam gear 2 When reassembling Heat the cam gear to approx 80o C 176o F and insert the camshaft 1 1 Camshaft 2 Cam Gear J Fuel Camshaft 1 Remove the fuel cam...

Страница 44: ...iston assembly When reassembling Apply oil to the crankpin bearing cylinder wall and connecting rod cap screw Insert the rod and piston assembly with the mark on the rod facing the injection pump usin...

Страница 45: ...ark on connecting rod to the injection pump Install the piston rings with their manufacture s mark to the top of piston Install the expander in the oil ring with its gap opposite to the gap of oil rin...

Страница 46: ...wing two screws gradually and evenly refering to the photo When reassembling Apply grease to the oil seal lip and take care that it is not rolled when installing 1 Bearing Case cover C Crankshaft 1 Re...

Страница 47: ...Bearing 2 IMPORTANT Mark the location number to the bearing case to prevent interchanging When reassembling Clean the parts and the oil passage of the bearing case Apply oil to the journal bearing ins...

Страница 48: ...ylinder head surface with the detergent B after ten minutes 5 Spray the cylinder head surface with the white developer C 6 If any flaw is found such as a red mark replace the cylinder head A Red perme...

Страница 49: ...flapper 5 Turn and flap the valve back and forth on the valve seat to lap 6 Remove the compound and clean the valve and the seat 7 Apply oil on the valve face and finish to complete fitting 8 Repeat l...

Страница 50: ...eplace the rocker arm shaft 2 Timing Gears and Camshafts A Timing Gear Backlash 1 Set a dial indicator lever type with its tip on the gear tooth 2 Move the gear to measure the backlash holding its mat...

Страница 51: ...nce exceeds the allowable limit replace the camshaft stopper 3 1 Camshaft 3 Stopper 2 Cam Gear D Injection Pump Gear Side Clearance 1 Pull the fuel camshaft and pull the injection pump gear 1 to each...

Страница 52: ...asure the I D of the camshaft bore on the crankcase with an inside micrometer 2 Measure the O D of the camshaft journal with an outside micrometer 3 If the clearance exceeds the allowable limit replac...

Страница 53: ...outside micrometer 2 If the measurement is less than the allowable limit replace the camshaft 3 Connecting Rod and Piston A Piston Pin Bore 1 Measure the I D s of piston pin bore in piston lengthwise...

Страница 54: ...the bushing D Piston ring Gap 1 Push down the ring into the cylinder to the lower limit of ring travel in the assembled engine with a piston 2 Measure the ring gap with a feeler gauge 3 If the gap ex...

Страница 55: ...connecting rod 3 Install the connecting rod on the connecting rod alignment tool 4 Put a gauge over the piston pin and move it against the face plate 5 If the gauge does not fit squarely against the f...

Страница 56: ...lywheel back and forth to each end and measure the end play 6 If the play exceeds the allowable limit replace the side bearing B Crankshaft Alignment 1 Support the crankshaft with V blocks on the surf...

Страница 57: ...rnal and Bearing 2 Oil Clearance 1 Put a stop of Plastigage lengthwise in the center of the journal 2 Install the bearing cap and tighten the screw to the specified torque once and remove the cap agai...

Страница 58: ...If the clearance exceeds the allowable limit replace the bearing 5 Cylinder bore A Cylinder bore diameter 1 Measure the cylinder liner I D at sit positions shown in the figure to find the maximum wea...

Страница 59: ...relief valve for dirt and the seat 2 and ball 1 for damage 3 If damaged replace 4 Check the free length of spring 3 5 If less than the allowable limit replace NOTE Install the relief valve cover with...

Страница 60: ...ge on the rotor and assemble the pump 2 Disassemble the pump and measure the amount of the flattening with the scale to get the clearance 3 If the clearance exceeds the allowable limit replace the pum...

Страница 61: ...water pressure to the specfied pressure 3 Check the radiator for water leaks 4 For water leak from the pin hole repair with the radiator cement and for other leaks replace the radiator C Radiator Cap...

Страница 62: ...mechanical seal 5 When reassembling Replace the mechanical seal 5 with new one 1 Pully Boss 4 Water Pump Body 2 Snap Ring 5 Mechanical Seal 3 Pump Shaft 6 Impeller c Servicing A Thermostat Valve Openi...

Страница 63: ...n of shim and retards by adding one approx 0 26rad 1 5o of crank angle Approx 3 6mm 0 142in of turn at outer rim of flywheel equals 0 26 rad 1 5o of crank angle B Delivery Valve Fuel Tightness 1 Remov...

Страница 64: ...the nozzle holder Reference Pressure variation with 0 1mm 0 004in difference of adjusting washer thickness is approx 10kgf cm2 B Fuel Tightness of Needle Valve Seat Tightness 1 Set the injection nozz...

Страница 65: ...Delivery valve spring 5 Delivery valve 6 Tappet roller 7 Cylinder 8 Plunger 2 Injection nozzle Nozzle holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and take out...

Страница 66: ...ody and C terminal 3 The pinion gear should pop out when a jumper lead is connected between the positive terminal of the battery to the s terminal of the magnet switch 4 The pinion gear should stay ou...

Страница 67: ...replace alternator B Return current Current must not flow from the battery to the alternator when the engine stopped and starter switch is turned ON It means short occured at plus diode if current fl...

Страница 68: ...insulation lamp will be off E Continuity test of coil Test it with DC test lamp or ohm meter If the coil is not connected the test lamp is off and resistance of the ohm meter will be infinite F Short...

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