6M33 Training Document EPA - FA R01
6M33 Training Document EPA - FA R01
6M33 Training Document EPA - FA R01
Date : 2021-01-
10
目录
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
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
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
OASC PAGE 17
CONTENTS
OASC PAGE 18
6M33 Dismantling a Cylinder Head
3 4
5 6
OASC PAGE 19
6M33 Dismantling a Cylinder Head
8a 8b 9
OASC PAGE 20
6M33 Dismantling a Piston Assembly
1 2 3
OASC PAGE 21
6M33 Dismantling Cylinder Liner
2b 3 4
OASC PAGE 22
6M33 Dismantling the valve
3 4
OASC PAGE 23
6M33 Dismantling the valve
5) Add the plate and the nut of the tool
OASC PAGE 24
6M33 Dismantling the flywheel
1 2 3 4
OASC PAGE 25
6M33 Dismantling the flywheel housing
1 2a 2b 3
OASC PAGE 26
6M33 Dismantling the tappet
1 2
OASC PAGE 27
6M33 Assembling the piston cooling nozzle
OASC PAGE 28
6M33 Assembling the camshaft
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
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.
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
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:
1 2 3
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
OASC PAGE 41
6M33 Assemble the valve bridge
1 2
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
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
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
2a
2
OASC PAGE 48
6M33 Assemble the flywheel housing and rear oil seal
OASC PAGE 49
6M33 Assemble the flywheel
OASC PAGE 50
6M33 Adjust the valve clearance
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
Damage and leakage of high pressure fuel pipes Repair and replace
Check atomization state of fuel injector. Clean, repair, or
Malfunction of fuel injector
replace as needed.
Check sealing performance of valves and cylinder gasket,
Insufficient compression pressure of cylinder
check wear of piston rings, and repair or replace.
OASC PAGE 56
Engine stops shortly after starting
Cause Troubleshooting
Poor fuel quality and high water content Clean filter and replace fuel
OASC PAGE 57
Low power
Cause Troubleshooting
Check air filter and intake pipe and clean or replace filter
Intake blockage (blockage of air filter)
element. Investigate origin and cause of blockage
Check valve timing, check exhaust pipeline for blockage,
Excessively high exhaust back pressure
adjust and repair.
Check and solve leaks at pipeline connections. Investigate
Insufficient turbocharger performance
turbocharger system condition.
Abnormal performance of turbocharger Replace assembly.
Blockage of air compressor or turbine runner by dirt Clean or replace
Failure of floating bearing Replace
Carbon deposit and oil sludge at back gap of turbine and
Clean
compressor
Damage and air leakage of intercooler Replace or repair
Check sealing performance of fuel pipes and connectors,
Leakage or blockage of fuel pipe line check condition of filter, repair the fuel pipeline and replace
filter element.
Clean fuel tank, filtration parts and fuel pipes, and replace
Poor fuel quality
fuel. Be mindful of fuel quality from suppliers
Excessive wear of fuel injection pump or speed regulator Repair or replace
OASC PAGE 58
Low power
Cause Troubleshooting
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.
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 Troubleshooting
Turbocharger sealing failure Repair or replace turbocharger
Failure of fuel-air separator Replace
Excessively high oil sump level due to too Check and drain engine oil as appropriate to meet the required level.
much engine oil being added Investigate cause of excessive oil.
OASC 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 Troubleshooting
low oil sump level or oil shortage Add oil to the specified level on oil dipstick.
Replace with specified engine oil and choose an
Inappropriate engine oil brand, rating, or viscosity
application appropriate oil brand, rating and viscosity
High Cooling system and engine oil temperature Check the cooling system for normal operation.
Excessive oil flow resistance from engine oil filter Replace with new filter element
Blockage of oil cooler Check and clean
Check strainer, engine oil pipeline, and connector gaskets Check and clean air compressor runner, dredge blockage,
for presence of blockage and cracking and remove carbon deposit from exhaust passage
Leakage of oil pump inlet pipe Check oil pipes and connectors and repair or replace.
Malfunction of main oil-way pressure regulator valve Check valve, clean and repair
Blockage of main oil-way Check and clean. Investigate origin of blockage
Excessive gap of bearing shells or damage of bearing shell Check and replace
Excessive wear of parts to the point that an overhaul is
Check the working condition of engine and overhaul
required.
Leakage of diesel into engine oil 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
OASC 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 Troubleshooting
Worn, clogged or damaged air filter element Check and replace with new filter element.
Check intake pipe, gasket, and conecting pipe sleeve and
Air leak into air intake system.
repair or replace
Failure to adhere to timely replacement of oil filter element Replace as per specification
low oil sump level or oil shortage Check oil level and for oil leaks, repair, and add oil
Replace with specified engine oil and choose an
Inappropriate engine oil brand, rating, or viscosity
application appropriate oil brand, rating and viscosity
Continued use of dirty engine oil Use clean oil
Blockage of oil-way Clean oil-way
Breakage or wear of piston ring Replace damaged parts
Disassemble and check piston and cylinder sleeve and
Wear or scuffing of cylinder sleeve or piston
repair or replace
Non-coaxiality between crankshaft and driven shaft Check mounting bracket and repair
Excessive wear of parts an overhaul maybe required. 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 Troubleshooting
Burnt fuse Replace fuse
Poor contact of connecting wires Clean circuits and tighten wiring posts
Insufficiently charged battery Check and charge or replace battery
Shortcircuit of starter motor Check and repair motor or replace assembly
Poor contact of electric brush Clean electric brush surfaces or replace electric brush
OASC PAGE 69
Weak starter motor
Cause Troubleshooting
Insufficiently charged battery Charge or replace battery.
Wear of motor bearing bushing Replace assembly
Poor contact of electric brush Clean electric brush surfaces or replace electric brush
Remove oil and dirt and polish with sand paper or replace
Dirty or burnt commutator
assembly
Loose weld of wire ends Reweld
Poor contact of switch Check and repair switch
Slip of friction clutch Adjust clutch or replace assembly
OASC PAGE 70
谢谢
THANK YOU