Service Manual - Doosan Infracore
Contents
1. 2 3 9 Cylinder Block and Liner ei Fe el Cylinder bore measurement Measuring point Approx 20mm bellow from upper face Maximum wear portion mm Standard Limit Forseliner BO LS np AAS 9818 Cylinder liner replacement Disassembly Removeer Angle for steel liner only Installation Installer i Use abench press to apply an initial seating force of 500kg to the cylinder liner And then apply a final seating force of 2 500kg to fully seat the cylinder liner 0 001 0 019 0004 0007 in 0 005 0 026 Steel liner Tight fit standard mm Castliner Loose fit mm 0002 0010 in After installing the liner measure the cylinder liner projection and inner diameter Liner projection Standard mm 0 03 0 010 0011 0004 in For the cast liner removal or installation is done easily 36 Remover Installer Cylinder liner inner diameter mm Liner Grade Standard 102 021 102 040 A D For steel liner 4 016 4 017 in 102 041 102 060 G 4 017 4 018 in A 102 021 102 030 For cast liner 4 016 4 017 in B 102 031 102 042 4 017 in 2 3 10 Piston Piston Pin and Piston Ring Piston outer diameter mm Piston grade Standard For steel liner 101 955 101 975 4 014 4 015 in 1012. clearance Piston pin and connecting rod small end bushing mm Standard Limit 0 01 0 03 0 05 0004 0012 in 002 in 38 Bushing replacement Removal Use a brass bar and a bench press m Installation Use a brass bar and a bench press The connecting rod busing oil port must be aligned with the connecting rod oil port After new bushing installation ream the bushing inside diameter with a pin hole grinder or a reamer to fit the piston pin Connecting rod bearing Bearing spread Bench press Brass bar 68 00 68 01 Standard mm 2 677 2 678 in Bearing tension 1 Fit the connecting rod bearing lower half into the connecting rod bearing cap 2 Check the connecting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Reassemble the connecting rod and bearing cap 2 3 12 Crankshaft and Bearing i Crankshaft and bearing inspection 1 2 3 Inspect the crankshaft journal and pin surfaces for excessive wear and damage Inspect the oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and damage Replace or repair the crankshatt if any excessive wear or damage is found Inspect the crankshaft oil ports for obstructions Use high pressure air to clean the oil ports if necessary 39 z Crankshaft pin outside diameter sandera am
3. Crankshaft bearing lower 5 Center lower half bearing has no oil groove and oil hole while others all have oil groove and oil hole i Crank shaft 3 Install the crankshaft so that the crank gear assembled part is directed to the front of the engine i Thrust bearing 4 Install the thrust bearings with the oil groove side facing the crankshaft contact face i 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 Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order shown in the figure With oil hole and groove I Fit correctly No oil groove and hole center lower Oil groove side 24 Torque kgfm 173 6 Ib At Check that the crankshaft turns smoothly by manually rotating it 49 Lubricate with enging oil i Timing gear case 6 Torque kgfm 2 6 18 8 Ib At i Camshaft 7 Tighten the thrust plate bolts through the camshaft gear hole i Torque kgf un Thrust plate bolt Camshaft gear bolt 2 1 15 2 ib ft 16 115 7 Ib ft i Piston and connecting rod assembly 8 Position the piston ring gaps as shown in the figure engine Use a hammer grip to push the piston in until Q Position the piston front ma
4. 23 Apply engine oil Crankshaft front nut and washer 11 Wrench 41 mm Idle gear 14 Measure the following points before disassembly Idle gear end play mm Standard Limit 0 058 0 115 0 2 002 0 0045 in 0078 in Backlash mm Standard Limit 0 10 0 17 0 3 0039 0069 in 012 in Includes the crankshaft gear camshaft gear and idle gear i Crankshaft bearing cap and bearing 17 Measure the crankshaft end play before disassembly Crankshaft end play mm Standard Limit 0 10 0 17 0 3 0039 0067 in 012 in Includes the crankshaft gear camshaft gear and idle gear Loosen the crankshaft bearing cap bolts in numerical sequence as shown in the figure 24 a PG re en a H i Thrust bearing 18 Remove the thrust bearing with steel wire i Tappet 21 Remove the tappets and mark the cylinder number each tappet Be careful against the damages Exhaust 2 2 4 General Components i Rocker arm Bracket and shaft assembly Disassembly steps 1 Bracket 3 Spring 2 Rocker arm 4 Rocker arm shaft 25 Cylinder head assembly Disassembly steps 1 Spring retainer and valve cotter 3 Valve 2 Spring and spring seat 4 Valve stem oil seal V Important operati
5. V 4 Install the No 1 injection pipe and tighten to specified torque 3 3 5 21 7 25 3 Ib Aft Do not overtighten the delivery valve holder It will distort the injection pump body shape and adversery affect control rack operation Injection pipe nut torque kgf un 1 6 4 Compression Pressure Remove the glow plugs from all cylinders then check the compression pressure in each cylinder with a compression gauge by engaging starter kg cm 200 rpm Standard Limit 22 23 30 812 327 psi Compression gauge adapter 1 6 5 Air Cleaner Dry type air cleaner Observe the air cleaner service indicator Clean the air cleaner element and dust pan when the RED band in the service indicator looks in the visible position Cleaning primary filter element Direct air inside of the element and blow out dusts from the pleats completely Maximum air pressure does not excess 2 1kg cm Always replace the secondary element Do not attempt to reuse it by cleaning 14 Compression gauge adapter ka Mao Air cleaner Naj q service s i indicator D T Dans ge D r o E Detergent Wash the element in warm water and nonsudsing household detergent Rinse the element with clean water Dry it thoroughly with natural air or electric fan Don t use a flame or compressed air for drying It damages the element Checking element Insert
6. 63 932 63 944 2 517 2 517 in Use a micrometer to measure the crankshaft pin outside diameter across points x and srat the two points xgand x Connecting rod bearing cap reassembly 12 0 25 9 75 0 25 867 1 81 lb 4 70 51 1 81 b 4 Connecting rod bolt torque kgf m Bolt type A B A Bolt head A Ms Inside diameter Apply engine oil to bearing surface Measure the connecting rod inside diameter with an inside dial indicator Connecting rod bearing 645 j nominal diameter mm 2 52 in Crankshaft pin and bearing clearance mm Standard Limit 0 03 0 07 0 10 001 003 in 004 in mm Under size 0 25 0 50 Bearing specifications 010 020 in Crankshaft journal bearing Tension Fit the journal bearing into the journal bearing cap and check the tension with the same method of connecting rod cap bearing 40 Crankshaft journal outside diameter Standard mm 75 913 75 925 2 989 in Use a micrometer to measure the crankshaft journal outside diameter across points and atthe two points amp and amp 3 Journal bearing cap reassembly 24 Torque kgfm 173 6 Ib At i Inside diameter Apply engine oil to bearing surface Measure the journal bearing cap inside diameter with an inside dial indicator Journal bearing 76Sj nominal dia
7. Length 1 93 in 1 85 in Industrial Inner 52 4mm 50 0 mm EE 2 06in 197i fr length Outer 53 6 mm 50 6 mm Automotive 2 11 in 1 99 in Valve Spring Inclenation Use a surface plate and a square to measure the valve spring inclination If the measured value exceeds the specified limit the valve spring must be replaced Standard Limit Remark Valve spring Med 2 7 mm for Inclination 051 in 106 in Industrial Inner 1 0 mm Free 039 in for l length Outer 1 0 mm Automotive 039 in Inclination Free length Valve Spring Tension Use a spring tester to measure the valve spring tension if the measured value is less than the specified limit the valve spring must be replaced Standard Limit Remark Valve Sprin 145kg 11 5kg for Se enak Oam 32 tbs 25 4 Ibs Industrial inner 42mm 10 9 kg 9 9 kg k 1 65in 24lbs 21 8 Ibs BH Bu 44mm 23 0 kg 20 0 kg Automotive 1 73 in 50 7 Ibs 44 1 Ibs 2 3 4 Tappet Inspect the tappets for excessive wear damage and any abnormalities 31 Spring tester Pitted Crack normal contact Abnormal contact Diameter mm Standard Limit 27 97 27 98 0 2 1 10 in 1 09 in Clearance between the tappet and cylinder body 2 3 5 Push Rod 2 3 6 Rocker Arm Shaft Assem
8. 975 101 994 e 4 015 4 016 in A 101 953 101 967 For cast liner 4 014 4 015 in B 101 963 101 977 4 014 4 015 in Piston and liner bore clearance Standard mm 0 055 0 075 Piston ring Piston ring and ring groove clearance mm Standard Limit e 5 0 085 0 11 0 2 st compression ring 053 699 in 008 in 0 035 0 055 0 15 2nd no compression NY 001 002 in 006 in 0 03 0 07 0 15 Alang 001 003 in 006 in Piston ring gap mm Standard Limit s 0 25 0 45 1 5 tst compression ring 040 ou jl 006 in e 0 2 0 4 1 5 2nd compression ring 008 016 in 006 in 0 2 0 4 1 5 l Ong 008 016 in 006 in 37 Piston pin outside diameter mm Standard Limit 35 000 35 005 34 95 1 377 1 378 in 1 376 in Piston pin and piston clearance mm 0 005 Limit mm 0002 in 2 3 11 Connecting Rod and Bearing Connecting rod aligmment parallelism Alignment per length of 100mm 3 94 in mm Standard Limit 0 05 0 2 002 in 009 in Bushing inside diameter 35 017 35 025 Standard 1 379 1 380 in Use a caliper calibrator and micrometer to measure the piston pin and connecting rod small end bushing
9. Important operation i Injection nozzle 3 Remove the nozzle assembly from the nozzle body Keep 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 through inspection Reassembly To assemble follow the disassembly procedures in reverse order 71 V Important operation i Injection nozzle 3 X Align the nozzle dowel pin with the dowel hole in the nozzle holder body Torque kgfm 43 4 57 9 Ib At Retaining nut 2 6 8 i Adjust shim 7 SL The injection nozzle injection starting pressure can be adjusted after the adjusting shim is installed Injection starting pressure kg cm 220 3 128 psi 72 6 Special Tool List Tool 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 liner remover angle Cylinder liner installer 73 Figure Tool name Crankshaft 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 compressor Water
10. Oil filter ass y 2 Head oil filter 3 Element oil fiter 4 Relief valve ass y 5 Gasket e Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection 62 6 Bolt 7 Spring washer 8 Plain washer 9 O Ring 10 Plug screw V Reassembly To reassemble follow the disassembly procedures in reverse order Important operation Relief Valve 1 2 5 Torque kgf 18 1 Ib At 63 ato WI 3 4 Oil Cooler el Disassembly Disassembly steps 1 Element 3 Spring 2 Bolt 4 By pass valve 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 procedures in reverse order Important operation Element 1 2 6 Torque kgfm 18 8 Ib At i 64 4 Cooling System 4 1 General Description 4 2 Water Pump s Disassembly Disassembly steps 1 Cover 3 Center Fan 5 Shaft bearing and spacer 2 Impeller 4 Snap ring 6 Seal unit washer and seal 65 V Important operation Impeller 2 Q Removal Remover i Pulley center 3 Remove the pulley center using a bench press and a bar i Snap ring 4 Remove the snap ring using a snap ring plier i Shaft bear
11. Valve depression mm Standard Limit 1 0 2 5 039 in 098 in Valve seat angle Valve seat angle Valve seat insert replacement Removal Arc weld the entire inside circumference of the valve seat insert i Cooling the valve insert for a few minutes and pull out with a screw driver Installation Use a bench press to smoothly press the valve seat insert 29 M Depression Valve seat insert Cylinder head Welding bead Valve seat angle Thickness Intake valve seat angle 451 Exhaust valve seat angle 451 Valve seat angle mm Standard Limit 1 5 1 0 059 in 039 in Valve stem outer diameter mm Standard Standard intake valve 8 946 8 961 8 88 352 353 in 350 in Exhaust valve 8 921 8 936 8 88 351 352 in 350 in Valve stem outer diameter mm Standard Standard 002 003 in 008 in Exhaust 0 06 0 09 0 25 002 009 in 010 in Valve guide replacement Remover installer 30 Measuring point Remover installer 2 3 3 Valve Spring Valve Spring Free Length Use a vernier caliper to measure the valve spring free length If the measured value is less than the specified limit the valve spring must be replaced Standard Limit Remark Exhaust and Intake Valve Spring Free 49 0 mm 47 0 mm G
12. distance tube in the spot facing Tighten the exhaust manifold and gasket fixing bolts in numerical order as shown in the figure Torque kgf 18 8 Ib At 56 TOP mark Distance tube 2 6 2 4 4 Extermal Parts B Disassembly steps 1 Oil filter and bracket 5 Injection nozzle 2 Oil pipe 6 Injection pipe 3 Intake manifold 7 Engine control lever 4 Glow plug 57 V Important operation i Main oil filter and bracket 1 Kg f um 5 3 A bolt torgue 38 3 Ib ft i Intake manifold assembly 3 Install the gasket with its protruding part facing up Protruding Part of Jes se Glow plug 4 5 3 Torgue kgrm 38 3 Ib At i Injection nozzle 5 SL Adjusting 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 Refer to maintenance for the injection nozzle opening pressure adjustment 2 6 Torque kgfm 18 8 Ib At 58 Dust cover SO Nozzle gasket Fuel injection pipe 6 3 0 Torque kgf 21 7 Ib A Delivery valve holder must be tightened as specified torque Excessive torque causes leakage at control rack and pipe Delivery valve 4 0 4 5 Holder torq
13. in the figure Idle gear bolt 2 6 E Torque kgf un 18 8 Ib At i Crankshaft front nut 16 Wrench 41 mm Injection pump gear Idle gaer n 3 o Gemar 2 M Crankshaft Torque kgf 18 B At l i Flywheel housing 17 14kgfm 101 25 Ib At Fixing bolts torque Flywheel 19 16 0 Torque kgfm 115 7 Ib Ai s 52 Lubricate with engine oil i Cylinder head gasket 20 The gasket TOP mark must be facing up and FRONT mark is towards the front of the engine i Cylinder head assembly 21 Carefully place the cylinder head on the cylinder body Lubricate the head bolts and contact face of the cylinder head D Tighten the head bolts in the numerical order as shown in the figure 1st step 2nd step 7 0 11 5 50 6 Ib At 83 2 Ib ft i 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 in the figure 3 1 Torque kgfm 22 4 lb At Adjust the valve clearance 53 Front top mark SEEN S a AN SS in K E PA ee zi SG Gs C x UA k SA ZRNA SAN x A A i Shorter head bolts are used for injection pump side 3 zx Pr i Refer to MAINTENANCE for the valve clearance adjustment procedure 2 4 3 External p
14. pump 18 Gasket Oil jet pipe 6 Gasket Tappet chamber and bolt 19 Gasket Water pump 7 Gasket Oil cooler 20 Gasket Outlet pipe 8 Gasket Oil pump cover 21 Gasket Thermostat housing 9 Oil seal Crankshaft RR 22 Gasket Nozzle gasket 10 Gasket Retainer 23 Oil seal Crank gear case 11 Gasket Case and cylinder block 24 Gasket Exhaust manifold 12 Gasket Cover and case 25 Gasket Injection nozzle 13 Gasket Oil pan drain plug 10 1 6 Repair 1 61 Cylinder Head Bolt Tighten the cylinder head bolts in seguence as shown in the figure Torgue kgf um 11 5 83 2 Ib At 1 6 2 Valve Clearance ch N Adjust the valve clearance in the following manner using a feeler gauge Standard in cold Intake and exhaust mm 0 4 016 in Bring the piston in either 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 Check to see if there is play in the No 1 intake and exhaust valve rocker arms If the No 1 cylinder intake and exhaust valve rocker arms are depressed the No 4 piston is at TDC on the compression stroke The same results can be obtained by using the TDC line on flywheel and pointer 11 TDC line Timing pointer arrow Adjust the clearances of valves ma
15. the cylinder body oil ports The oil holes of No 1 camshaft bearing front side are two otherwise is one Camshaft run out T I R mm G Camshaft bearing MR ADD Align the oil c he 0 1 Standard 004 in i Place the camshaft on a measuring stand i Use a dial indicator to measure the camshaft run out i Note the total indicator reading T I R Camshaft bearing Replace the camshaft gear if any damages or excessive backlash are found 14 0 Gear bolt torque kgf un 101 3 lb Al 34 i Refer to the standard backlash table at Major components disassembly Cam gear and thrust plate replacement Disassembly Gear puller Install Use a bench press and a hammer Torque kgfm 16 0 115 7 lb At Cam lobe height mm Standard Limit Cam lobe height C 1 88 in 1 83 in Cam journal diameter A B e 2n 218 in Use a micrometer to measure the cam lobe height and journal diameter If the measured number is less than the specified limit the camshaft must be replaced 2 3 8 Idle Gear and Idle Gear Shaft Shaft outside diameter mm Standard Limit 44 94 44 97 44 84 1 76 1 77 in 1 765 in use a micro Clearance between shaft and gear mm Standard Limit 0 009 0 060 0 2 0004 0023 in 008 in 35 pre Camshaft gear
16. Ring gear replacement Removal Use a brass bar and hammer Strike around the edges of the ring gear with a hammer and brass bar to remove it Installation Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the ring gear to exceed 200 390 Use a hammer to install the ring gear when it is sufficiently heated Q Flywheel housing oil seal replacement Removal Use a pry bar and hammer Installation Use a oil seal installer move the contact area with a oil seal spacer Install V If the crankshaft contact area wears excessively new oil seal and discard the used one 43 Crankshaft assembly face Friction face Installer Cil seal Spacer 2 3 14 Timing Gear Case Cover Oil seal replacement Installation Installer Installer 2 4 Engine Reassembly 2 4 1 Minor Components i Piston and connecting rod assembly Disassembly steps 3 Snap ring 1 Piston 4 Piston ring 2 Piston pin 5 Connecting rod Important operation Piston heater i Piston 1 Use a piston heater to heat the piston approximately 60 140 IO Piston pin and connecting rod 2 Install the connecting rod to the piston with setting the marks as illustrated Install the piston pin into the piston and the connecting rod bushing Snap ring 3 Use a pai
17. Service Manual Diesel Engine 3 3 Liter DB33A 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 train ing 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 A 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 produ
18. T 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 Installation Disassembly Reassembly Align the marks Directional Indication Inspection Measurement Ee Fs 4 Z P E 3 8 2 SI Fe 9 lt BE Adjustment Cleaning Pay close attention Important Tighten to specified torque Use special tools of manufacturer s Lubricate with oil 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 INFORMATIONS 1 1 1 General Repair Instructions 1 4 Major Parts Fixing Bolts 1 2 Engine Specifications 1 5 Engine Repair Kit 1 3 Torgue Specifications 1 6 Repair 2 ENGINE ASSEMBLY un au au ne RE APA HA ER 19 2 1 General Description 2 3 Inspection and Repair 2 2 Disassembly 2 4 Reassembly 3 LUBRICATING SYSTEM mm nun nn oii te ES HE HEISE PER RAN 61 3 1 General Description 3 3 Oil Filter 3 2 Oil Pump 3 4 Oil Cooler 4 COOLING SYSTEM 66 4 1 General Description 4 3 Thermostat 4 2 Water Pump 5 FUEL SYSTEM 70 5 1 General Description 5 8 Injection Nozzle 5 2 Fuel Filte
19. a light inside the clean and dry element and examine it Discard the element if tears rips or damages are found Wrap and 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 i 1 0 Measuring pressure kg cm gi Mg 14 2 psi Radiator cap Pressure valve opening pressure kg cm a 5 m i 0 05 V ka cm accum valve opening pressure kg cm 71 pel 1 6 7 Lubricating System E Cil filter replacement Before installing a new filter element apply a small amount of clean engine oil to the element gasket Install the new element When the gasket contacts the base tighten it 3 4 of a turn more Do not overtighten 15 Element 6 8 Fuel System Injection nozzle Check the spraying condition and injection starting pressure zu 220 Injection starting pressure kg cm amp gP glo 3 128 psi Adjustment Adjust the injection starting pressure with the adjusting screw using a nozzle tester oo LA 1 6 9 Fan Belt mm Correct Incorrect Incorrect AM e e e o Specified belt deflection T in 1 6 10 Glow Plug Inspection Resistance Fan pulley Silver color 4 5 S Black color 1 65 Check the continuity across the
20. arts A 11 4 8 2 2 3 Ki s 9 s Se 6 6 10 UT Co e en 5 TRANS I S SY 9 4 7 gt lt Disassembly steps gt 1 Breather hose 7 Oil pan 2 Exhaust manifold 8 Cylinder head cover 3 Oil guide tube and level gauge 9 Rubber hose 4 Starter 10 Water pump 5 Cooling fan belt 11 Thermostat housing assembly 6 Alternator 54 V Important operation i Oil pan 1 A Apply liguid gasket to the cylinder block and oil pan Install oil pan gasket and oil pan 1 6 Bolt torque kg f un 11 6 Ib 4t Cylinder head cover 2 Bolt torque kg f un Sal 15 2 Ib At Tighten the bolts as shown in the figure i Water pump assembly 3 Apply liguid gasket belco bond No 4 to the water pump gasket before installing the water pump i Thermostat housing assembly 5 Bolt torque kg f un 2 38 3 Ib At 55 Apply liquid gasket to the cylinder block side i Cooling fan belt 13 Adjust the cooling fan belt tension i Starter motor 9 Refer to Maintenance for the fan bolt tension adjustment 8 6 Torque kgfm 62 2 Ib At l i Exhaust manifold 11 Carefully install the gasket with the TOP mark side facing up Install either end of the
21. bly mm Standard Limit 0 02 0 054 0 1 0008 002 in 004 in Run out T 0 03 Him mm 0012 in i Use a feeler gauge to measure the push rod run out i Roll the push rod along a smooth flat surface as shown in the figure Inspect all disassembled parts for wear damage and any abnormalities Rocker arm shaft mm Standard Limit 18 98 19 00 18 85 747 748 in 742 in 32 Rocker arm bushing mm Standard Limit 19 01 19 03 19 05 748 749 in 75 in Clearance between rocker arm shaft and bushing mm Standard Limit 0 01 0 05 0 2 0004 0020 in 0079 in 2 3 7 Camshaft Assembly Inspect all disassembled parts for wear damage and any abnormalities Camshaft Cam gear Thrust plate hs Camshaft gear QNOD Thrust plate End play mm Standard Limit 0 050 0 114 0 2 0020 0045 in 0079 in Camshaft journal diameter mm Standard Limit 55 94 55 97 55 60 2 202 2 204 in 2 189 in 33 A Fs Run out mm 56 00 56 03 2 205 2 206 in Standard Clearance between camshaft journal and body mm Standard Limit 0 03 0 09 0 15 001 004 in 006 in Camshaft bearing replacement Remover installer Align the camshaft oil holes with
22. ct 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 publica tion 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 lubri cation 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 avail able 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 DB33 Diesel engine To maintain the engine in optimum condition and retain maximum performance for a long time CORREC
23. ing etc 1 4 Major Parts Fixing Bolts i Cylinder head and block unit kgf s eb 18 0 Ib At 72 32 b dt New bolts 10 0 a Reused bolts 11 5 L 38 33 Ib At i Intake and exhaust manifold unit kgf 15 2 bb At 15 2 bb At Cylinder block and others unit kgf 197 99 1 Ib ft 26 Lubricate with engine oil 18 810 4 NIS2Ib At pO 57 0 Ib dt 18 8 Ib At i 2 4 Lubricate with engine oil Cylinder block and others unit kgf 2 6 18 8 Ib At amp te o co 38 3 Ib ft FE 9 AML 0 ol d 0 5 OF pr AA 3 NER FR qg 9 e ae P 2 5 3 38 3 Ib At Crankshaft and camshaft unit kgf 318 Ib ft CD CD pesta 70 5 i 18 lb At L CG O me 868 18b4t Lubicate with oil 39 8 Ib ft 18 1 Ib At Thermostat and housing unit kgf 10 5 Ib At 53 25 1 Ib At 1 5 Engine Repair Kit Part No 1 25 Engine disassembly components Part No 1 3 21 22 25 Engine top disassembly components 1 Gasket Cylinder head 14 Gasket Oil pan and body 2 Gasket Cylinder head cover and bolt 15 Gasket Oil filter 3 Gasket Head cover 16 Gasket Oil pump and pipe 4 Gasket Relief valve 17 Gasket Oil filter pipe 5 Gasket Injection
24. ing and spacer 5 Remove the shaft and bearings using a bench press and suitable remover i Seal unit Washer and seal 6 Remove the seal unit using a bench press and suitable remover 66 Bench press ill Bil E Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection Bearing replacement Removal Use a bench press Assembly Use a bench press to install two bearings with a marked side outward Reassembly To assemble follow the disassembly procedures in reverse order Important operation i Shaft bearing and spacer 5 Lubricate the bearing with multi purpose grease i Washer seal and seal unit 6 Apply a thin coat of liquid gasket Belco bond No 4 to the seal unit outer periphery before installation 67 Marked side outward Lubricate with multi purpose grease Marked side outward Apply liquid gasket i Snap ring 4 Install the snap ring using a snap ring plier i Pulley center 5 Install the pulley center using a bench press i Impeller 2 fUnstall the impeller to the shaft using a bench press fWse a feeler gauge to measure the clearance between the impeller and the pump body 0 3 0 8 Standard mm 012 031 Ib At 4 3 Thermostat Inspection and repair Make the necessary adjustment
25. meter mm 2 992 in Crankshaft journal and bearing clearance mm Refer to Major components disassembly Crankshaft bearing cap Bearing specifications mm Standard Limit nass 0 065 0 116 0 15 enter bearing 003 006 in 006 in l 0 025 0 076 0 11 Other bearings 001 003 in 004 in Under size 0 25 0 50 010 020 in Crankshaft run out mm Standard Limit 0 05 0 40 002 in 016 in 1 Mount the crankshaft on a set of v blocks 2 Set a dial indicator to the center of the crankshaft journal 3 Gently turn the crankshaft in the normal direction of engine rotation 4 Read the dial indicator TIR as you turn the crankshaft 41 Crankshaft gear Inspect 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 Crankshaft gear replacement Removal Remover Installation Installer Pilot bearing replacement Removal remover Installation Use a brass bar and hammer 42 Refer to Major components disassembly Gear backlash Remover p Installer 2 3 13 Flywheel and Housing Rear Oil Seal i Flywheel thickness Friction face mm Standard Limit 33 4 33 6 32 5 1 315 1 323 in 1 280 in
26. ons Mark the cylinder No each component when it disassembles Valve spring Valve Valve seat Retainer and valve cotter 1 Spring compressor Valve spring compressor 26 i Piston and connecting rod assembly Disassembly steps 1 Piston ring 3 Piston pin and connecting rod 2 Snap ring 4 Piston V Important operations Mark the cylinder No each component when it disassembles Piston ring Piston Piston pin Connecting rod 27 Piston ring 1 Remove the piston rings Snap ring 2 Remove the piston pin snap ring i Piston pin and connecting rod 3 Pull out the 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 warpage i Use a straight edge and a feeler guage to measure the four sides and the two diagonals of the cylinder head lower face 28 Piston ring remover Piston pin Lower face warpage and height mm Standard Limit Warpage 0 05 or less 0 2 002 in 008 in Thickness 89 95 90 05 89 75 reference 3 54 3 55 in 3 53 in 2 3 2 Valve Valve Guide and Valve Seat Insert Contact width Valve contact width mm Standard Limit 1 5 2 0 059 in 079 in
27. plug terminals and body 16 2 Engine Assembly 2 1 General Description 2 2 Disassembly 2 21 External Parts A 11 1 BT 8 9 gr 2 3 9 gra s 10 zaz Jr If 0 JL e oya 7 gt Disassembly 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 Oylinder head cover 9 Rubber hose 10 Water pump 11 Thermostat housing assembly Important operations V Exhaust manifold assembly 2 Loosen the manifold fixing bolts in sequence of figure s shown Oylinder head cover 8 Loosen the head cover bolts in sequence of figure s shown 19 2 2 2 External Parts B Disassembly steps 1 Fuel injection pipe 2 Injection nozzle 3 Glow plug 4 Intake manifold 20 5 Oil pipe 6 Oil filter assembly 7 Injection pump 8 Oil cooler assembly Important operations Engine control cable 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 the delivery valve holder to avoid di
28. pressed air to make certain they are free from restrictions Lubricate rotating and sliding faces of parts with oil or grease before installation When necessary use a sealant on gaskets to prevent leakage Carefully observe all specifications for bolts and nuts torques When a service operation is completed make a final check to ensure that the service has been done properly 1 2 Engine Specifications es Engine Model DB 33A Engine type Water cooled 4 cycle in line overhead valve type Combustion chamber type Direct injection type Cylinder liner type Dry type casting liner Timing gear system Gear drive type No of piston ring Compression ring 2 oil ring 1 No of cylinder bore stroke mm 4 102 100 Total piston displacement cc 3 268 199 cu in Compression ratio 17 5 1 Engine dimension length width height mm 795 2701 2720 31 28 28 in Engine weight dry kg 340 750 lbs Fuel injection order 1 3 4 2 Fuel injection timing B T D C static 13 Type of fuel used High speed diesel fuel SAE No 2 Injection pump type VE DOOWON Governor type Mechanical governing Injection nozzle type Multi hole type 6 hole VCO nozzle Fuel injection pressure Kg cm 220 3 128 psi Compression pressure kg cm 30 at 200 RPM 426 psi Low idle speed R P M 775 825 High idle speed R P M 2400 2500 Intake and exhaust
29. pump impeller remover 74
30. r 6 SPECIAL TOOL LIST emen 74 WORLDWIDE NETWORK 1 GENERAL INFORMATION 1 1 General Repair Instructions 10 11 12 13 14 For safety park the truck on even ground or work station and fix the wheels using wedges and hand brake during operation Before performing service operations disconnect the grounding cable from the battery to reduce the chance of cable damage and burning due to short circuiting Before performing service operations release the air pressure in the machine air line system for safety To not do so is extremely dangerous Use covers to prevent the components from damage or pollution Brake oil and anti freeze solution must be handled with reasonable care as they cause paint damage The use of proper tools and special tools where specified is important for efficient and reliable service operation Use genuine DAEWOO parts exclusively 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 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 Clean the parts before inspection or reassembly Also clean oil ports etc using com
31. r of snap ring pliers to install the piston pin snap ring Check that the piston moves smoothly on the piston pin Piston ring 4 Use a piston ring installer to install the three piston rings Install the piston rings in the following order oil ring aM2nd compression ring M1st compression ring The marked side of the two compression rings must be facing up The undercut side of the 2nd compression ring will be facing down As the oil ring has no any facing mark it may face in either direction Lubricate the piston ring surfaces with engine oil Check the piston ring rotate smoothly in the piston ring grooves Use Cr coating piston ring for cast liner and normal piston ring for steel liner 45 Piston head Front mark O IN Cylinder numder marked side FOR STEEL LINER AO Marked side X Oil ring a FOR CAST LINER 2nd ring Oil ring i Cylinder head assembly Disassembly steps 1 Valve stem oil seal 3 Spring seat and spring 2 Valve 4 Spring retainer and cotter key Important operation Valve stem oil seal 1 Installer HES e i Installer Lubricate the oil seals and valve guides and install the oil seals with an installer i Intake and exhaust valves 2 1 Lubricate valve stems with engine oil Intake valve Exhaust valve 2 Install
32. rk towards the front of the it makes contact with the crank pin At the same time 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 manifold i Connecting rod cap bolt 2nd compression ring Oil ring y SE ring L Piston ring compressor Eccl Hammer grip NE TI Bolt head BB Torque kgf m 12 0 25 868 18 bb 4 9 75 0 25 705 1 8 lb At Lubricate the connecting rod cap bolt threads and setting faces with MoS grease 50 Cylinder No i Oil pump assembly 9 Full up the oil pump with engine oil and install the pump to the cylinder body i Oil pump mounting bolts 3 8 Torque kgrm 27 5 Ib At i Oil pump i Oil cooler 11 Tighten the cooler bolts to the specified torque Start from the middle and work out to either side i Injection pump assembly 12 2 6 Torque kgfun 18 8 Ib ft Check the punched line of the injection pump body is aligned to the pump bracket line 51 Notched line Notched line i Idle gear 13 Use the thrust collar fixing bolt as a guide to install the idler gear shaft The oil port must be facing the camshaft Set the timing marks A B C as shown
33. rked with an Rocker arm screw lock nut torque kgf un ERI 2 5 18 1 Ib At After adjusting the valve clearances referring to the drawing turn the crankshaft one full turn in the rotative direction and align the TDC mark with the pointer then adjust the remaining valve clearances 1 6 3 Injection Timing Inspection Check the notched line on the crankshaft pulley and timing pointer are aligned Setting Timing BTDC Engine 13 BTDC UP Plunger Lift 0 3mm 0118 in e 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 F Check the notched line on the injection pump is in alignment with the notched line on the timing gear cover Check the alignment of the notched lines injection pump and bracket 12 Notched line Notched line Injection timing adjustment SL 1 Adjust fuel injection timing with crank pulley notched line and timing pointer Adjust the timing pointer with the marking on the pulley 9 Disconnect the inj pipes 4pieces from I P 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 lift 3 Turn the timing flange to adjust the plunger lift to 0 3mm 13
34. rt entry Ds 1 21 2 2 3 Internal Parts i Major Components Disassembly steps 1 1 1 2 3 4 5 6 7 8 9 0 1 Rocker arm shaft assembly Push rod Cylinder head assembly Cylinder head gasket Fly wheel Fly wheel housing Rear oil seal assembly Oil pump cover Oil pump assembly Piston and connecting rod assembly Crankshaft front nut and washer 22 12 13 14 15 16 17 18 19 20 21 Crankshaft pulley Gear case cover Idle gear Camshaft assembly Timing gear case Crankshaft bearing cap and bearing Thrust bearing Crankshaft assembly Crankshaft bearing Tappet V Important operations Rocker arm shaft assembly 1 Loosen the rocker arm shaft assembly bolts a little at a time in numerical sequence as shown in the figure Cylinder head assembly 3 Loosen the cylinder head bolts a little at a time in the numerical sequence as shown in 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 using a scraper This will prevent damage to the piston and the piston rings when they are removed from the cylinder bore Position the piston to the top by turning the crankshaft remove the piston assembly from cylinder using a wooden bar or hammer
35. s pepairs and part replacements if excessive wear or damage is found through inspection Valve opening temperature 80 84 Standard 176 183 Valve lift at testing temperature approx 10 mm at 95 Standard 393 in at 2036 68 Feeler gauge Agitating rod Thermometer Wood piece 5 Fuel System 5 1 General Description gt gt gt gt gt gt gt gt gt gt lt lt gt gt gt gt gt gt Injection nozzle a a T Qo o gt gt Tea 3 9 2 eH r D a Injection pump gt gt gt gt Fuel filter El Water separator a Y A V Fuel tank Fuel return 69 5 2 Fuel Filter Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection Reassembly To assemble follow the disassembly procedures in reverse order 5 3 Injection Nozzle Disassembly Disassembly steps 1 Plunger 4 Spacer 7 Adjust shim 2 Retaining nut 5 Spring seat 8 Nozzle holder body 3 Injection nozzle 6 Nozzle spring 70
36. the valves to the intake and exhaust guides Install the valves to their original lapped valve seats Valve face 46 i Spring seat and spring 3 Install the valve springs with their painted end the close pitched end facing down Painted portion Pa 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 with a rubber hammer Q i Spring retainer and cotter key 4 Spring compressor lt Disassembly steps gt 1 Bracket 3 Spring 2 Rocker arm 4 Rocker arm shaft 47 2 4 2 Internal Parts i Major components N EA SE EM uf N erem bg DIS 9 Le d 1 Disassembly steps 1 Tappet 13 Idle gear 2 Crankshaft bearing upper 14 Timing gear case cover 3 Crankshaft 15 Crankshaft pulley 4 Thrust bearing 16 Crankshaft front nut and washer 5 Crankshaft bearing cap and bearing lower 17 Flywheel housing 6 Timing gear case 18 Rear oil seal assembly 7 Camshaft assembly 19 Flywheel 8 Piston and connecting rod assembly 20 Oylinder head gasket 9 Oil pump assembly 21 Cylinder head assembly 10 Oil pump cover 22 Push rod 11 Oil cooler 23 Rocker arm shaft assembly 12 Injection pump assembly 48 t Es lt t Es e Important operation i Crankshaft bearing upper 2
37. ue kgf un 28 9 32 5 Ib ft 59 3 Lubricating System 3 1 General Description O P Opening pressure Full flow filter O P warning Base Ananas E lamp Start H J il filter e iR d Es warning lamp res L l Op 1kglcm By pass j Oilpress S W I Oylinder body main oil gallery Paper Oil filter cooler rm E ae PE ett c A 2 O P 8kg cm O P 2kg cm Injection Oil relief pe valve Oil pump Oil pan 3 2 Oil Pump Disassembly Disassembly steps 1 Strainer 3 Cover and dowel 5 Drive shaft and gear 2 Suction pipe 4 Drive gear 6 Driven gear shaft Inspection and repair Make the necessary adjustments repairs and part replacements if excessive wear or damage is found through inspection Visually inspect the disassembled parts for excessive wear and damage Limit mm 007 in Oil pump cover and oil pump drive gear clearance 0 18 Cover and driven gear clearance 0 12 Limit mm 005 in Drive gear shaft diameter mm Standard Limit 15 9 16 0 626 in 61 Reassembly To Assemble follow the disassembly procedures in reverse order Important operation i Strainer 1 P lt E 1 0 1 8 Torque Rem 7 233 13 0 Ib At 3 3 Oil Filter Disassembly Si Disassembly steps 1
38. valve clearance at cold mm 0 4 Open at 28 B T D C Intake valve Close at 62 A B D C ass Open at 70 B B D C Close at 28 A T D C Lubrication method Pressurized circulation Oil pump type Gear type Oil filter type Full flow type Lubricating oil capacity S 7 5 Oil pan 1 97 gal Oil cooler type Water cooled Cooling method Pressurized circulation Cooling water capacity engine only S 7 5 1 97 gal Thermostat type Wax pallet type with jiggle valve Generator voltage capacity V A 12 61 Starter Voltage output V KW 12 2 5 1 3 Torgue Specifications i Standards bolts The torgue values given in the following table should be applied where a particular torgue is not specified Unit kgfm Bolt identification en pitch ar T at Low carbon steel High carbon steel Alloy steel 6 21 0 0 4 0 8 0 5 1 0 8 1 25 0 8 1 8 1 2 2 3 1 7 3 1 10 21 25 2 1 3 5 2 8 4 7 3 8 6 4 10115 2 0 3 4 2 8 4 6 3 7 6 1 12 21 25 5 0 7 5 6 2 9 3 7 7 11 6 12 1 75 4 6 7 0 5 8 8 6 7 3 10 9 14 1 5 7 8 11 7 9 5 14 2 11 6 17 4 14 2 0 7 3 10 9 9 0 13 4 10 9 16 3 16 1 5 10 6 16 0 13 8 20 8 16 3 24 5 16 2 0 10 2 15 2 13 2 19 8 15 6 23 4 18 21 5 15 4 23 0 19 9 29 9 23 4 35 2 20 1 5 21 0 31 6 27 5 41 3 32 3 48 5 22 1 5 25 6 42 2 37 0 55 5 43 3 64 9 24 22 0 36 6 55 0 43 9 72 5 56 5 84 7 The i indicates that the bolts are used for female threaded parts that are made of soft materials such as cast
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