6M33 Training Document

Date ： 2021-01-
10
目录
CONTENTS

1 Engine basic knowledge

发动机基础知识
2 Key points for assembly and disassembly
装配与拆装要点
3 Troubleshooting
故障处理
P 01
ART

Engine basic knowledge

CONTENTS

• Engine Summary………………………………………..…………………………………………...5
• Major Components…………………………………………………………………………………..6
• Cooling System………………………………………………………. ……………………………..8
• Lubrication System…………………………………………………... …………………………….9
• Fuel System………………………………………………………….. …………………………….10
• Cylinder Designation………………………………………..……………………………………...11
• Engine Name Plate………………………………………………….. …………………………….12
• Technical Data………………………………………………………. …………………………….13
• Special Tools………………………………………………………….. ...………………………….14

OASC PAGE 4
Engine Summary
6M33 series diesel engine is a new product developed independently on the basis of M26 series products
of French engine manufacturer Moteurs Baudouin. This product inherits as well as improves the Baudouin
M26 advanced platform, targeting international advanced engine applications and continuing this brand-
new design philosophy to each engine system and the structure.
6M33 系列柴油机是在法国发动机制造商博杜安公司 M26 系列产品的基础上自主开发的新产品。本产品继承
并改进了博杜安 M26 先进平台，面向国际市场

OASC PAGE 5
Major Components
1-Fan 风扇
2-Water outlet pipe 出水管
3-Turbocharger 进气管
4-Exhaust manifold 排气管
5-Flywheel housing 飞轮壳
6-Starter 起动机
7-Oil sump 油底壳
8-Oil-gas Separator 油气分离器

OASC PAGE 6
Major Components
9 10 9-Air Filter 空滤
11 12 13
10-High Pressure Pipe 高压油管
11-Intake Manifold 进气管
12-Oil cooler 机油冷却器
13-Thermostat 节温器
14-Water pump 水泵
15-Alternator 发电机
16-Oil Filter 机油滤清器
24 14 17-Oil sump 油底壳
18-Centrifuge Filter 离心过滤器
19-Handhole Cover 加油管
15 20-Electromagnetic Actuator 电磁执行器
21-Pre-fuel Filter 燃油粗滤
22-Fuel filter 燃油精滤
23-Pre-fuel pump 预供油泵
24-Fuel pump 高压油泵

23 22 21 20 19 18 17 16 PAGE 7
OASC
Cooling System
1-Thermostat assembly 节温器总成
21 22 23 24
2-Water-outlet pipe 出水管
3-Radiator 散热器
4-Fan 风扇
5- Water inlet pipe 进水管
6-Water pump 水泵
7-Water gallery 水道
8-Oil Cooler 机油冷却器
9-Cylinder block cooling circuit 发动机机体冷却

10-Cylinder head cooling circuit 缸盖冷却

11-Outlet pipe 出水管

211210 29 28 27 26 25

OASC PAGE 8
Lubrication System
1-Oil Sump 油底壳
2- Suction strainer 吸滤器
3- Oil pump 油泵
4a-Centrifuge filter 离心式滤清器
4b-Oil Filter 机油滤清器
5-Oil Cooler 机油冷却器
5a-Bypass Valve 旁通阀
5b-Pressure Relief Valve 安全阀
6-Main Oil Gallery 主油道
7a-Piston Spray nozzle 机油喷嘴
8a-Piston 活塞
9a-Connecting rod; 连杆
10a-Connecting rod bearings 连杆衬套
7b-Camshaft bearings 凸轮轴衬套
7c- Cylinder head lubricating oil pipe 气缸盖机油管
8c-Tappet; 挺柱
9c-Pushrod 推杆
10c-Rocker arm shaft and rocker arm 摇臂组
7d-Main bearing 主轴瓦
11-Turbocharger 涡轮增压器
12- Lubricating oil pipe of fuel injection pump 高压油泵机油管

OASC PAGE 9
Fuel System
1-Pre-fuel filter 粗滤
2-Fuel filter 燃油滤清器
7
3-Low Pressure Fuel Pipe 低压油管
9
8 4- Injection pump 喷油泵
5-Shut-down 停车电磁阀
electromagnetic Valve
6-Electronic governor 电磁执行器
4
2 7-High Pressure Fuel Pipe 高压油管

3 8-Injector 喷油器
9-Fuel Return Pipe 回油管
5

1 2

OASC PAGE 10
Cylinder Designation

11 22 33 45 5
111111122 6

ERC-Engine Reference Cylinder PRC-Pump Reference Cylinder

 Cylinder No. 1 is on the flywheel side.
 Single cylinder heads with 4 valves per cylinder.
 Engine firing order : 1-5-3-6-2-4

OASC PAGE 11
Engine name plate

Model:
XM33 D XXX EX XX
Product series
Application code Power code Emission level Variant code
code
系列产品代号 用途代号 功率代号 排放水平 变型代号

Order No.:
DH XXX X XXXX
The first letter of “DING
The diesel engine series Product usage Sequence No.
HUO”
订货 产品系列 产品用途 序列号

OASC PAGE 12
Technical data
Item 6M33
Aspiration Method Turbocharged and intercooled
Bore / Stroke (mm) 150/185
Displacement (L) 19.6
Compression Ratio 15:1
Firing Order 1-5-3-6-2-4
Fuel System Electric pump
Intake valve: 0.3±0.03
Cold Valve Clearance (mm)
Exhaust valve: 0.6±0.03
Intake valve open before TDC: (34±5)°
Intake valve close after BDC: (40±5)°
Valve Timing
Exhaust valve open before BDC: (61±5)°
Exhaust valve close after TDC: (27±5)°
Thermostat Opening Temperature (°C) 77
Starting Method Electric starter motor
Lubrication Method Forced lubrication
Oil Capacity (L) 60.5
Cooling Method Water cooling forced circulation
Oil Pressure (kPa) 400~650
Crankshaft Rotation Direction (view from belt pulley side) Clockwise
Length 1820
Overall dimensions (mm) Width 1036
Height 1406
Weight (kg) 2090

OASC PAGE 13
Special Tools

Rear Oil Seal Installer Front Oil Seal Installer Tappet Removal Tool Injector Bushing Piston Grasping Tool
Removal Tool

Piston Guide Cylinder Cylinder Liner Installer Valve Collet Engine Block Cylinder Liner Puller
Assembling Tool Expansion Tool

OASC PAGE 14
Special Tools

Barring Tool Flywheel Position Tool Flywheel Guide Rod Vibration Damper 21# Socket Wrench
Guide Rod

30# Socket Wrench Flywheel Hoisting Tool Camshaft Installment Camshaft Copper
Tool Installer

OASC PAGE 15
P 02
ART

Key points for assembly

and disassembly
装配与拆装要点
CONTENTS

• 6M33 Dismantling the ECU and engine harness………………………………………………………..19

• 6M33 Dismantling the fuel pipes and fuel
pump………………………………………………………..20
• 6M33 Dismantling fuel high pressure pipe and common rail………………………………………….21
• 6M33 Dismantling a cylinder head………………………………………………………………………22
• 6M33 Dismantling a piston……………………………………………………………………………….24
• 6M33 Dismantling cylinder liner………………………………………………………………………...25
• 6M33 Dismantling the valve……………………………………………………………………………...26
• 6M33 Dismantling the flywheel………………………………………………………………………….28
• 6M33 Dismantling the flywheel housing………………………………………………………………...29
• 6M33 Dismantling the tappet…………………………………………………………………………….30
• 6M33 Assemble the piston cooling nozzle……………………………………………………………….31
• 6M33 Assemble the camshaft…………………………………………………………………………….32
• 6M33 Assemble the crankshaft…………………………………………………………………………..33

OASC PAGE 17
CONTENTS

• 6M33 Assembling the cylinder liner……………………………………………………………………..35

• 6M33 Assembling the piston and connecting-rod………………………………………………………36
• 6M33 Assembling the cylinder head…………………………………………………………………......42
• 6M33 Assembling the valve bridge………………………………………………………………………45
• 6M33 Assembling the rocker arm………………………………………………………………………..46
• 6M33 Assembling the fuel injector………………………………………………………………………47
• 6M33 Assembling the timing gear groups………………………………………………………………48
• 6M33 Assembling the flywheel housing and rear oil seal……………………………………………....52
• 6M33 Assembling the flywheel…………………………………………………………………………...54
• 6M33 Adjusting the valve clearance…………………………………………………………………...56
• 6M33 Assembling the common rail high-pressure pipe and fuel pump……………………………....57
• 6M33 Assembling the fuel pump………………………………………………………………………...58
• 6M33 Assembling the ECU and engine harness………………………………………………………...59

OASC PAGE 18
6M33 Dismantling a Cylinder Head

1) Remove the fuel return pipe hollow screw

2) Remove the Water outlet pipe
3) Remove the intake air pipe
4) Remove the exhaust pipe
1 2 5) Remove the oil pipe
6) Remove the rocker arms cover
7) Remove the injector and connection pipe

3 4

5 6

OASC PAGE 19
6M33 Dismantling a Cylinder Head

7) Remove the rocker arms

8) Loosen and remove the cylinder head mounting screws
9) Remove the cylinder head

8a 8b 9

OASC PAGE 20
6M33 Dismantling a Piston Assembly

1 2 3

1) Remove the handhole cover

2) Turn the engine to be able to loosen the connecting-
rod cap screw and remove the connecting-rod screw
3) Remove the connecting-rod cap
4) Fit the piston handle tool
5) Remove the connecting-rod/piston assembly,
carefully not hurt the cooling jet
4 5

OASC PAGE 21
6M33 Dismantling Cylinder Liner

1) Assemble the liner removal tool

2) Insert the liner removal tool inside the cylinder
liner ,being careful to not damage the cooling jet and
crankshaft during installation
3) Use appropriate wrench and turn clockwise until the
liner moves freely inside cylinder block housing
4) Pull the liner and tool together out.
1 2a

2b 3 4

OASC PAGE 22
6M33 Dismantling the valve

1) Prepare the valve removal tool

2) Remove the valve bridge seat

3) Take the valve bridge seat out

1 2 4) Assemble the pedestal of the tool, assemble the

screw

3 4

OASC PAGE 23
6M33 Dismantling the valve
5) Add the plate and the nut of the tool

6) Turn the nut clockwise

7) Until the plate exposes the valve collets, take the

valve collets out, and screw the nut back, then you can
5 6 take the valve spring and the valve out.

OASC PAGE 24
6M33 Dismantling the flywheel

1 2 3 4

1) Remove the flywheel bolts

2) Before you remove the last flywheel bolt, install the guide bars sufficiently
3) Remove the flywheel out a bit along the guide bars
4) Screw the lifting bolts in the top hole of the flywheel, and take the flywheel out, the flywheel is
heavy and should be handled carefully.

OASC PAGE 25
6M33 Dismantling the flywheel housing

1 2a 2b 3

1) Use the guide bars

2) Screw the top bolts of the fly wheel housing out, and install the guide bars sufficiently
3) Screw the other bolts out, use the copper bar to tap the flywheel housing lightly, and then remove
flywheel housing.

OASC PAGE 26
6M33 Dismantling the tappet

1) Use the tappet removal tool

2) Insert the tool in the tappet, take the tappet

out slowly, being careful not to drop it

1 2

OASC PAGE 27
6M33 Assembling the piston cooling nozzle

1) Blow the cooling nozzle with

compressed shop air in order to
ensure that there are no internal
Piston cooling nozzle blockages
1 positioning pin.
2) Tighten the locking bolt of the
nozzle.
The locking bolt of
the cooling nozzle is a
pressure valve
structure with an
opening pressure of
277 kpa.
2

OASC PAGE 28
6M33 Assembling the camshaft

1) coat camshaft Bearings with assembly oil , then insert the

camshaft, and assemble the camshaft thrust plate , The specifications
of fastening bolts for camshaft thrust plate are M8*20 (no locking
gasket), tightening torque is 35 N.m, and use of Loctite Blue 242
thread glue or similar thread locker is recommended.

2) The axial clearance of camshaft is 0.15-0.35 mm.

OASC PAGE 29
6M33 Assembling the crankshaft

1 2

1) Make sure the crankshaft is clean , and coat assembly oil on main
bearing and crankshaft journal, then install crankshaft
2) Assemble the thrust bearing, There are four pieces of crankshaft
thrust vanes in the upper and lower parts. The thrust's oil groove
should toward crankshaft side when assembling the thrust
3) Insert the main bearing cover, When assembling the main bearing
cover , it may necessary to use the expansion tooling to expand the
cylinder block slightly.
3 Note:
1. The seven main bearing covers have corresponding marks with the cylinder
block, hence one cover can be not be exchanged for another.
OASC PAGE 30
 6M33 Assembling the crankshaft
4) Tighten the main bearing bolts the order A-to-N (4-2-6-3-5-1-7) as shown
in the figure below.
coat oil on threads and shoulders of the bolts before mounting them,
Step 1: pre-tighten the main bearing bolts in the order of A-to-N , and the
pre-tightening torque is 180±10 N·m;
Step 2: tighten the main bearing bolts in the order of A-to-N , rotate the bolts
by 60 degrees;
4 Step 3: tighten the main bearing bolts in the order of A-to-N , rotate the bolts
by 60 degrees.

Note:
1. Check whether the crankshaft is flexible to rotate after
Fan installation;
side 2. The axial clearance of the crankshaft is 0.15-0.35mm;
3. Main bearing clearance is 0.102-0.182mm
4. The main bearing bolts can only be used 3 times.
5. The final torque of the main bearing bolt is ~750 N·m, and
the bolt torque is only for reference. The final tightening
method shall be subject to the 60 degree rotation method.
OASC PAGE 31
 6M33 Assembling the cylinder liner

1 2 3 4

1) Prepare the cylinder liner assembling tool

2) Ensure no O-ring distortion or damage is present during assembly. When assembling O-ring of cylinder liner, it is
recommended to coat Mobil Vactra No.2 slideway oil or other coolant compatible oil which will not cause O-ring failure.
3) Insert the cylinder liner into the cylinder slowly and vertically, being careful not to damage the O-rings, assemble the
cylinder liner assembling tool
4) Tight the bolts to press down the cylinder liner, the top surface should protrude 0.07-0.13mm from the surface the cylinder
block.
OASC PAGE 32
6M33 Assembling the piston and connecting-rod

1) Connecting rod are grouped

according to weight and the weight
sign is marked on the connecting rod
body.

2) An engine is assembled with the

connecting rods of the same weight.

3) The connecting rod body and the

Match marker Connecting rod body connecting rod cover should be paired
and connecting rod with like markers and are not
cover are positioned interchangeable with different
by cylindrical pin markers.

OASC PAGE 33
6M33 Assembling the piston and connecting-rod
Keystone Barrel Ring
same weight mark 1) Pistons are grouped
Twist Taper Ring according to weigh, The
weight of each group's
pistons is not more than
12g, and the weight mark
of each group is marked
on the piston.

2) The piston of the same

group weight is used in
the same engine and
Coil Spring Loaded should not be exchanged.
Oil-control Ring

OASC PAGE 34
6M33 Assembling the piston and connecting-rod

1)  When assembling the piston ring, The piston rings are marked with letters facing
up.
 The first gas ring's opening is located at the position of 30 degrees offset of the
piston pin center line; the second gas ring's opening is 120 degrees offset from the
first gas ring's opening; the oil ring opening is 120 degrees offset from the first and
second gas ring opening respectively
1  Piston rings shall be assembled in parallel in the ring groove, and no distortion
shall be allowed.
 After the piston ring is assembled on the piston, the piston ring is not allowed to
collide with other objects.

2) Make sure that the connecting rod body and the connecting rod cover have
matching marks

OASC PAGE 35
6M33 Assembling the piston and connecting-rod
3) ensure connecting-rod bearing surface is
clean and free of contaminates

4) Assemble the tool-piston guide cylinder

5) Clean the cylinder liner, add the piston

3 4 extraction tool

Add some oil for pre-

lubrication

OASC PAGE 36
6M33 Assembling the piston and connecting-rod
6) Lift the piston to prevent the piston from
falling suddenly and breaking the crankshaft, and
insert the piston into the cylinder liner slowly
7) Tighten connecting rod bolt: Use new
connecting-rod bolts if needed, Lubricating Oil
on Thread and Support Surface before installation
8) Assemble the cover.

6 7

Manual tightening:
first step: tighten both bolts to 200N·m,
Tightening second step: turn both bolts 60 degrees,
M16×1.5
torque of third step: turn two bolts 45 degrees;
(10.9
connecting rod Automatic wrench tightening:
level)
bolt first step: tighten two bolts to 200 N·m,
second step: turn two bolts 105 degrees
8
Notice: Connecting rod bolts can be used three times at most, while the bolts
have been used twice during connecting rod production,So new connecting rod
bolts must be used during re-installation such as repairing.
OASC PAGE 37
6M33 Assembling the piston and connecting-rod
After assembling the piston and connecting-rod, Please check these two points:

After the piston is assembled, it is necessary to

Connecting rod bearing clearance: 0.08-0.15 mm
Connecting rod axial clearance: 0.17-0.48 mm
OASC
check whether the nozzle interferes with the
piston. When the piston is at the bottom dead
center, ensure the nozzle is in the piston
cooling oil duct.
PAGE 38
6M33 Assembling the cylinder head

1 2 3

1) Properly position the cylinder head gasket

2) Properly position the cylinder head
3) Apply lube oil on Thread and Support Surface of the
cylinder head main bolts, then insert the cylinder head main
bolt
4) Lubricating Oil on Thread and Support Surface of the
4 cylinder head secondary bolts, then insert the secondary bolts

OASC PAGE 39
6M33 Assembling the cylinder head

5a
The main bolts of cylinder head are to be tightened in sequence numbered
from 1 to 24

5b
The secondary bolts of cylinder head are to be tightened in sequence from A
to N

OASC PAGE 40
6M33 Assembling the cylinder head

5) The cylinder head bolts tightening method

Final Torque Down:

Before tightening, paint the bolt thread and support surface with
lubricant, then do the steps as follows:
 First step: Pre-tighten the main bolts in sequence, the pre-
tightening torque is 80N·m, and then pre-tighten the secondary
bolts in sequence, the pre-tightening torque is 80N·m.
 Second step: Turn the main bolts by 60±5 degrees , then turn
the secondary bolts by 60±5 degrees.
 Third step: Turn the main bolts by 60±5 degrees , then turn the
secondary bolts by 60±5 degrees.
 Fourth step: Turn the secondary bolts by 60±5 degrees, then
turn the main bolts by 45±5 degrees.

Notice:The main bolt can be re-used a maximum of three times,

and the secondary bolts can be re-used a maximum of six times.

OASC PAGE 41
6M33 Assemble the valve bridge

1 2

1) Assemble the valve bridge

2) To make sure the two intake valve or two exhaust valve open at the same
time, there should be 0.02mm clearance between valve bridge and the top of the
valve. Insert 0.02mm gauge between the valve bridge and the top of the valve.

3 3) Adjust the adjusting screw on the valve bridge, then tighten the nut.

OASC PAGE 42
6M33 Assemble the rocker arm

There should be 0.4-

0.6mm clearance
between rocker arm and
the sleeve

1) Insert the rocker arm assemblies

2) Insert 0.4-0.6mm gauge between the rocker arm and the sleeve.
3) While leaving the gauge in and tighten the bolts, after tightening, check
3 if the clearance is 0.4-0.6mm, if not, loosen the bolts and try again.

OASC PAGE 43
 6M33 Assemble the timing gear groups
In the gear chamber, the engagement of gears are shown by marks on the gear teeth. When assembling timing gears
and various transmitting gears, the markings on the gears must be aligned. As shown in the figure, the gears of
6M33 are assembled in the correct meshing position.

mark mark

mark
Fuel pump
Camshaft gear
Timing Gear
Fuel pump
Idler Gear

Crankshaft
Timing
OASCGear PAGE 44
6M33 Assemble the timing gear groups

1) Assemble camshaft
Camshaft lock gear, small idler gear,
bolt M10, fuel pump idler gear, the
tightening mark should be aligned
torque is (65±5) as pictures 1a,1b.
N m,
Lubricating oil
on bolt
shoulder,bolts
thread coated
with 242
thread-locking 1a Note the marks of
1b
glue. fuel pump idler
gear and small
Note the marks of idler gear
camshaft gear and
small idler gear

OASC PAGE 45
6M33 Assemble the timing gear groups

2) Check the clearance

of each gear

3)Turn crankshaft until

2 cylinder piston one is
at top dead center

The clearance of each

gear is between 0.11 and
0.285 mm. 3

OASC PAGE 46
6M33 Assemble the timing gear groups
4) Assemble the big idler gear, mark
aligned(ə'laɪnd) with crankshaft gear,
when assembling every bolts, please
lubricate oil on bolt shoulder and coat
threads with 242 thread-locking glue,
after assembling. Check the gear
clearance.
Small idler gear bolt M10, tightening
torque is (70±5) N m

fuel pump middle gear bolt M10,

tightening torque is (95±5) N m

4 big idler gear bolt M8,

tightening torque is (30±5) N
m,
crankshaft gear mark should be aligned
with the big idler gear mark
OASC PAGE 47
6M33 Assemble the flywheel housing and rear oil seal
1) Flywheel housing and gear chamber are
sealed with 5900 silica  /'sɪlɪkə/ gel /dʒel/
. Flywheel housing bolts are coated with
242 thread locking glue.
1 2) Tighten the fly housing bolts M12, The
order is shown in the picture 2a.:
 Hexagonal  /hek'sæɡənəl/ Flange
Bolts: (120±5) N·m
First time: (65 ±5) N·m
Second time: (120± 5) N m
 Hexagonal Head Bolts: (105±5) N·m
First time: (65±5) N·m
Second time: (105±5) N·m

2a
2

OASC PAGE 48
6M33 Assemble the flywheel housing and rear oil seal

3) Prepare the Rear Oil Seal Installer tool

3
4) Press the rear oil seal into the flywheel housing

OASC PAGE 49
6M33 Assemble the flywheel

1) Position the flywheel for installation

and push it into the flywheel housing

2) Paint the flywheel bolt’ thread and

the supporting surface with lubricant
oil, and insert the bolts

1 2 3) pre-tighten the flywheel bolts

4) Tighten the flywheel bolts :

 First step: tighten all flywheel bolts, the
torque is (180 ± 10) N·m.
 The second step: turn all flywheel bolts
by angel (90±5) degree.
3 4

OASC PAGE 50
6M33 Adjust the valve clearance

1) Turn the crankshaft until the flywheel

position indicator is on the zero mark, then
install a flywheel lock bar into the flywheel
from the flywheel housing.

2)  Check if this point is on cylinder

1a 1b 1's top dead center, if it is , adjust
the valves in table 1, if it is
cylinder 6's top dead center,
adjust the valves in table 2;
 then turn the crankshaft by 360
degree, then adjust the other
valves. the intake valve
clearance is 0.3±0.03mm, the
exhaust valve clearance is
2a 0.6±0.03
2b

OASC PAGE 51
 6M33 Adjust the valve clearance
when cylinder 1's piston is at top dead center, adjust these valves ：
cylinder 1 2 3 4 5 6
valve intake intake exhaust intake exhaust
cylinder 6 cylinder 1 and
exhaust

table 1

when cylinder 6's piston is at top dead center, adjust these valves ：
cylinder 1 2 3 4 5 6
valve exhaust intake exhaust intake intake
flywheel and
exhaust

table 2
OASC PAGE 52
6M33 Assemble fuel pump
1. Turn the flywheel so that the first cylinder of the engine(flywheel end) reaches
the degree before compression TDC.
2. Install the fuel injection pump hub, drive gear and pressure plate. Make sure
that the mark on the drive gear aligns with the groove mark in the pressure
plate and the hub. Install the four bolts
3. Fit the assembled hub with the injection pump shaft, tighten the locking nut
M24×1.5 with a torque of 300-340 N·m.
4. Two bolts are installed on the gear chamber as guides to assemble the fuel
injection pump assembly. Prevent gear rotation of fuel injection pump during
installation.
5. Tighten the fuel injection pump flange and fuel injection pump bracket.
Tighten the bolts in the order shown.
6. Turn the engine, check the engine fuel supply angle, If adjustment is needed,
loosen the press plate fixing bolt, fine-tune the flywheel, and then check the fuel
supply advance angle until the requirements are met.

OASC PAGE 53
P 03
ART

Troubleshooting
CONTENTS

• Engine fails to start…….……………………………………………………………………………...

…..62
• Engine stops shortly after starting…………….…………………………………………………………63
• Low power………………..
……………………………………………………………………………......64
• Excessive fuel consumption………………………………………………………………………………66
• Black exhaust smoke………………………………………………………………………………….…..67
• White or blue exhaust smoke………………………………………………………………………….…68
• Deposit of engine oil at turbocharger inlet...……………………………………………………………69
• Unstable speed…………………………………………………………………………………….……....70
• Engine oil pressure too low……………………………………………………………..
………………...71
• High coolant
temperature………………………………………………………………………………...72
• Excessive component wear…………………..…………………………………...……………………....73
OASC • Excessive noise…………………………………………………………………..………………………...74 PAGE 55
Engine Fails to Start
Cause
Working failure of starter motor
Low air temperature
Air content in fuel system
Blockage of fuel delivery pump inlet filter screen or fuel Check and remove dirt and check fuel cleanliness.
lines (such as hoses)
Malfunction of fuel injection pump
Damage or leakage of valve or fuel supply pipes
Damage and leakage of high pressure fuel pipes
Malfunction of fuel injector
Insufficient compression pressure of cylinder
OASC
Troubleshooting
If the starter motor failure is suspected, first exclude the
malfunctions of electric circuits.
Implement auxiliary /ɔːɡˈzɪljərɪ/ starter.
Bleed the air, check sealing performance of connectors,
and repair accordingly.
Investigate cause and origin of blockage.
Check plunger and fuel outlet valve and repair or replace
damaged parts.
Check and adjust
Repair and replace
Check atomization state of fuel injector. Clean, repair, or
replace as needed.
Check sealing performance of valves and cylinder gasket,
check wear of piston rings, and repair or replace.
PAGE 56
Engine stops shortly after starting
Cause
Air content in fuel system
Blockage of fuel filter
Poor fuel quality and high water content
Failure of fuel delivery pump
Low regulated idling speed
OASC
Troubleshooting
Check the sealing performance of fuel pipes and
connectors, check and ensure the tightening of bleeder
screw, and bleed the remained air.
Disassemble the filter body, remove internal contaminant
and water, and when necessary replace filter element.
Clean filter and replace fuel
Check piston and valve of fuel delivery pump, clean, and
repair
Readjust
PAGE 57
Low power
Cause
Intake blockage (blockage of air filter)
Excessively high exhaust back pressure
Insufficient turbocharger performance
Abnormal performance of turbocharger
Blockage of air compressor or turbine runner by dirt
Failure of floating bearing
Carbon deposit and oil sludge at back gap of turbine and
Clean
compressor
Damage and air leakage of intercooler Replace or repair
Leakage or blockage of fuel pipe line
Poor fuel quality
Excessive wear of fuel injection pump or speed regulator
OASC
Troubleshooting
Check air filter and intake pipe and clean or replace filter
element. Investigate origin and cause of blockage
Check valve timing, check exhaust pipeline for blockage,
adjust and repair.
Check and solve leaks at pipeline connections. Investigate
turbocharger system condition.
Replace assembly.
Clean or replace
Replace
Check sealing performance of fuel pipes and connectors,
check condition of filter, repair the fuel pipeline and replace
filter element.
Clean fuel tank, filtration parts and fuel pipes, and replace
fuel. Be mindful of fuel quality from suppliers
Repair or replace
PAGE 58
Low power
Cause Troubleshooting

Damaged fuel injection pump smoking limiter diaphragm Replace or repair

Air leakage from damaged smoking limiter air pipe Replace

Check fuel injection pressure and carbon deposit of fuel
Poor atomization of fuel injector nozzle
injector nozzle and adjust and repair.
Incorrect valve or fuel supply timing Check and adjust
Check speed regulation characteristic and adjust
Excessively low high-speed adjustment of speed regulator
accordingly
Check oil dipstick and drain excessive engine oil,
Excessive engine oil level
investigate cause of excessive oil level
Check compression pressure during warm-up and replace
Air leakage of cylinder gasket
damaged cylinder gasket
Wear and breakage of piston rings and excessive gap of
Replace worn parts or overhaul the engine
bearing shells
Wear or scuffing of cylinder sleeve or piston Repair or replace, investigate cause of excessive

OASC PAGE 59
Excessive fuel consumption
Cause Troubleshooting
Check the air filter and intake pipeline and clean
Blockage of intake pipe
accordingly. Investigate cause of blockage.
Excessively-high exhaust backpressure Check exhaust pipeline and clean accordingly
Poor fuel quality Replace with specified fuel.
Blockage of fuel pipeline Check and repair. Investigate cause of blockage.
Leakage of fuel pipeline Check and repair.
Poor atomization of fuel injector Check and adjust or repair
Adjust valve clearance and fuel supply advance angle as
Incorrect valve or fuel supply timing
per specification
Poor compression due to gasket leakage Check compression pressure
Excessive wear of bearing shells to point outside of service
Check and overhaul
life acceptance.
Expanding of piston (do you mean excessive
piston/cylinder wear or carbon deposits or do you actually Replace cylinder sleeve, piston, and piston rings.
mean piston expansion from excessive heat?)
Check and solve leaks at pipeline connections. Check
Insufficient pressure of turbocharger system
turbocharger condition.

Abnormal working of turbocharger Check and replace

OASC PAGE 60
Damage and air leakage of inter-cooler Replace or repair
Black exhaust smoke
Cause Troubleshooting
Blockage of intake pipe or excessive exhaust Clear blockage and clean intake pathway and investigate
backpressure origin of blockage.
Poor fuel quality Clean and replace fuel, be more mindful of fuel quality
Incorrect valve or fuel supply timing Adjust as per specification
Poor atomization of fuel injector nozzle Check, repair, or replace
Excessive fuel volume from fuel injection pump Check and adjust
Check and solve leaks at pipeline connections. Check
Insufficient pressure of turbocharger system
Turbocharger condition.
Abnormal working of turbocharger Check and replace assembly
Damage and air leakage of inter-cooler Replace or repair
Incorrect application point of smoking limiter Re-adjust

OASC PAGE 61
White or blue exhaust smoke
Cause Troubleshooting
Poor fuel quality and high water content Replace fuel. Be mindful of fuel quality moving forward
Check operation of thermostat and replace when
excessively-low coolant temperature
necessary.
Wear of turbocharger seal rings Check and replace
Wear of turbocharger thrust bearing Check and replace
Blockage of turbocharger oil return pipe Clean or repair. Investigate cause of blockage
Poor atomization of fuel injector nozzle Check and repair.
Incorrect valve or fuel supply timing Check and adjust
Low compression pressure, incomplete combustion, and Check piston rings, cylinder sleeve, cylinder gasket and
piston expanding(?) repair accordingly
Improper run-in of piston rings and cylinder sleeves Complete proper the run-in procedure
Non-staggered openings of piston rings Adjust and reassemble
Failure of piston oil rings Replace
Large fit clearance between piston and cylinder sleeve Repair and replace

OASC PAGE 62
Deposit of engine oil at turbocharger inlet
Cause
Turbocharger sealing failure
Failure of fuel-air separator
Excessively high oil sump level due to too
much engine oil being added
OASC
Troubleshooting
Repair or replace turbocharger
Replace
Check and drain engine oil as appropriate to meet the required level.
Investigate cause of excessive oil.
PAGE 63
Unstable speed
Cause Troubleshooting
Poor fuel quality, with water or paraffin content Replace fuel. Be mindful of fuel quality moving forward
Check sealing performance of fuel pipes and connectors
Air ingress of fuel suction pipe
and bleed air
Abnormal operation of speed regulator (mechanical pump)
Check and adjust
counterweight and speed regulation spring
Non-uniform fuel supply Check and adjust
Unstable atomization of fuel injector nozzle Check and repair
Check and clean air compressor runner, dredge blockage,
Vibration of turbocharger and remove carbon deposit from exhaust passage
Damaged turbocharger bearing Replace

OASC PAGE 64
Engine oil pressure too low
Cause
low oil sump level or oil shortage
Inappropriate engine oil brand, rating, or viscosity
High Cooling system and engine oil temperature
Excessive oil flow resistance from engine oil filter
Blockage of oil cooler
Check strainer, engine oil pipeline, and connector gaskets
for presence of blockage and cracking
Leakage of oil pump inlet pipe
Malfunction of main oil-way pressure regulator valve
Blockage of main oil-way
Excessive gap of bearing shells or damage of bearing shell
Excessive wear of parts to the point that an overhaul is
required.
Leakage of diesel into engine oil
OASC
Troubleshooting
Add oil to the specified level on oil dipstick.
Replace with specified engine oil and choose an
application appropriate oil brand, rating and viscosity
Check the cooling system for normal operation.
Replace with new filter element
Check and clean
Check and clean air compressor runner, dredge blockage,
and remove carbon deposit from exhaust passage
Check oil pipes and connectors and repair or replace.
Check valve, clean and repair
Check and clean. Investigate origin of blockage
Check and replace
Check the working condition of engine and overhaul
Shut engine off and wait until engine has cooled sufficiently
before continuing work. Drain and properly dispose of oil
and investigate cause of diesel leakage. Repair as needed
PAGE 65
High coolant temperature
Cause Troubleshooting
Low level in Coolant reservoir Check for coolant leaks and add as needed
Blockage of radiator fins Clean radiator fins
Loose water pump belt Adjust tension as per specification
Damage of water pump gasket and wear of water pump
Check and repair or replace
impellor
Check water pipes, connectors, and gaskets and replace
Damage of water pipe and ingress of air
damaged parts
Thermostat malfunction Replace
Check radiator, clean, repair and replace as needed.
Blockage in radiator
Investigate origin of blockage
low oil sump level or oil shortage Check oil level and for oil leaks, repair, and add oil

OASC PAGE 66
Excessive wear of parts
Cause
Worn, clogged or damaged air filter element
Air leak into air intake system.
Failure to adhere to timely replacement of oil filter element
low oil sump level or oil shortage
Inappropriate engine oil brand, rating, or viscosity
Continued use of dirty engine oil
Blockage of oil-way
Breakage or wear of piston ring
Wear or scuffing of cylinder sleeve or piston
Non-coaxiality between crankshaft and driven shaft
Excessive wear of parts an overhaul maybe required.
Troubleshooting
Check and replace with new filter element.
Check intake pipe, gasket, and conecting pipe sleeve and
repair or replace
Replace as per specification
Check oil level and for oil leaks, repair, and add oil
Replace with specified engine oil and choose an
application appropriate oil brand, rating and viscosity
Use clean oil
Clean oil-way
Replace damaged parts
Disassemble and check piston and cylinder sleeve and
repair or replace
Check mounting bracket and repair
Check hour count and determine need for overhaul.

OASC PAGE 67
Excessive noise
Cause Troubleshooting
Poor fuel quality Replace fuel
low coolant temperature Check thermostat and replace when necessary.
Incorrect valve or fuel supply timing Check, repair, and adjust
Poor atomization of fuel injector nozzle Check, repair, and adjust
Excessive fuel volume from fuel injection pump Check and adjust
Check for damage, check state of connecting bolts, and
Wear of engine damper
replace damaged parts
Air leakage or improper adjustment of valve Disassemble and check valves and adjust
Excessive gear backlash or broken tooth Check and replace damaged parts
Wear or scuffing of cylinder sleeve or piston Check and repair or replace
Bending or breakage of push rod and breakage of rocker
Replace
arm
Breakage or wear of piston ring Check and replace damaged parts

OASC PAGE 68
Failure of starter motor
Cause
Burnt fuse
Poor contact of connecting wires
Insufficiently charged battery
Shortcircuit of starter motor
Poor contact of electric brush
OASC
Troubleshooting
Replace fuse
Clean circuits and tighten wiring posts
Check and charge or replace battery
Check and repair motor or replace assembly
Clean electric brush surfaces or replace electric brush
PAGE 69
Weak starter motor
Cause
Insufficiently charged battery
Wear of motor bearing bushing
Poor contact of electric brush
Dirty or burnt commutator
Loose weld of wire ends
Poor contact of switch
Slip of friction clutch
OASC
Troubleshooting
Charge or replace battery.
Replace assembly
Clean electric brush surfaces or replace electric brush
Remove oil and dirt and polish with sand paper or replace
assembly
Reweld
Check and repair switch
Adjust clutch or replace assembly
PAGE 70
 谢谢
THANK YOU