Maintenance Manual of 6M33 Series Industrial Diesel Engine

Maintenance Manual of 6M33 Series Industrial

Diesel Engine

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Foreword
6M33 series diesel engine is of high speed diesel engine independently developed by Weichai

Power Co., Ltd and manufactured by Baudouin (Weifang) Power Co., Ltd. This series diesel engine

features the advantages of compact structure, high reliability,excellent power, economy and

emissionindicators.The series is also quick to start, simple to operate and easy to maintain.And

especially the emission indicator meets the international advanced emission standard.

This maintenance manual describes the safety precautions, maintenance methods, common

inspection and adjustment and troubleshooting of 6M33 series diesel engine. We have expended

every effort to make the contents of this manual systematic, simple and practical. But judging the

malfunction cause of diesel engine is a really precise work. Before the cause is basically identified,

do not disassemble the diesel engine casually, or it will not only eliminate the malfunction, but also

lead to more serious malfunction due to improper assembly after disassembly. The inspection and

maintenance of critical components particularly the electronic control system and the turbocharger

shall be performed by experienced personnel using dedicated instruments. Persons who are

inexperienced or have no such instruments may not remove or adjust them.

Following the continuous increasing and improvement of 6M33 series diesel engine

variants, all changes will be made without further notice. Please access http://www.weichai.com

to obtain the latest product information.

Recommendations and opinions on further product improvement from you are welcome.

July, 2016

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Special Notice
 Before the operations, the operator of the diesel engine must carefully read this maintenance

manual and strictly abide by the operation and maintenance practices specified in this

manual.

 The diesel engine has been tested strictly in accordance with the testing specification of

our company before delivery. It’s prohibited to adjust the ECU data or increase the power

of the diesel engine without permission. Note that failure to observe this requirement

shall invalidate the warranty provided by Weichai Power;

 The rotor of the turbocharger generally rotates at high speeds when the engine is in

operation. It is strictly prohibited to have any moving objects (for examples, hands, tools,

cotton yarns) appear near the inlet of the turbocharger, otherwise serious injury or damage

could occur. The rotor can only be removed by turbocharger maintenance specialists or by

the service stations authorized by Weichai Power.

 The number of uses for important bolts is limited and shall not exceed the specified reuse

times.

 The oil and fuel added to the diesel engine must be of the grades specified in the operation

and maintenance manual. Dedicated clean filters must be used for the addition. Before

addition, the fuel shall settle for 72 hours. Before driving the vehicle, check that the coolant

and oil levels meet the requirements;

 It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply

of non-filtered air into the cylinders.

 Before using a new engine, 50h commissioning shall be carried out;

 After the cold start of the diesel engine, slowly increase the engine speed, instead of running

at high speed suddenly or long-term idling. After the running under heavy load, run the

engine at low speed for 5~10min before stopping, instead of stopping the engine suddenly

(except special cases);

 After the engine is stopped, if the temperature of working environment is probably below 0℃

and the coolant without antifreeze additive is used, fully drain the coolant from the water

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

tank and engine;

 The checking and repair for all parts of the electric system must be fulfilled by the

professional electric technicians;

 The checking and repair for all parts of electronic control system must be fulfilled by the

professionals of our service station;

 The diesel engine is oil sealed at the time of delivery to prevent rusting. The oil sealing

period for diesel engine is generally one year. At the expiration of one year, it should be

checked and take necessary supplemental measures.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Chapter I General Information .......................................................................................................... 1

1.1 Exterior View of Diesel Engine ............................................................................................... 1
1.2 Model Meaning of Diesel Engine ............................................................................................ 4
1.3 Basic Parameters of the Diesel Engine .................................................................................... 4
1.4 Hoisting of Diesel Engine ........................................................................................................ 5
1.5 Unsealing of Diesel Engine ..................................................................................................... 5
1.6 Preparations before Start .......................................................................................................... 7
1.7 Start of Diesel Engine .............................................................................................................. 7
1.8 Running of Diesel Engine ........................................................................................................ 8
1.9 Stop of Diesel Engine ............................................................................................................ 10
Chapter II Maintenance Guide of Diesel Engine ............................................................................. 11
2.1 Fuel, Lubricating Oil, Coolant, and Auxiliary Materials for Diesel Engine .......................... 11
2.1.1 Fuel ............................................................................................................................. 11
2.1.2 Lubricaing oil .............................................................................................................. 11
2.1.3 Engine cooling system ................................................................................................ 12
2.1.4 Auxiliary materials ...................................................................................................... 12
2.2 Daily Maintenance ................................................................................................................. 13
2.3 Maintenance items ................................................................................................................. 15
2.4 Engine maintenance for long-term storage ............................................................................ 19
Chapter III Typical Malfunctions and Troubleshooting of Diesel Engine ..................................... 20
3.1 Diagnostic Method ................................................................................................................. 20
3.2 Common Failures and Troubleshooting Method ................................................................... 21
3.2.1 Start failure of diesel engine ....................................................................................... 21
3.2.2 Engine stopped soon after starting .............................................................................. 22
3.2.3 Insufficient engine power ........................................................................................... 22
3.2.4 Excessive fuel consumption........................................................................................ 23
3.2.5 Engine exhaust gas is black ........................................................................................ 24
3.2.6 Engine exhaust gas is white or blue ............................................................................ 24
3.2.7 Oil gathering at the air inlet port and inlet pipe of turbocharger ................................ 25
3.2.8 Rotating speed unstable .............................................................................................. 25
3.2.9 Oil pressure is too low ................................................................................................ 25
3.2.10 Coolant temperature is too high ................................................................................ 26
3.2.11 Parts wear too fast ..................................................................................................... 26
3.2.12 Excessive noise level ................................................................................................ 27
3.2.13 Starting motor does not work.................................................................................... 27
3.2.14 Starter motor is powerless ......................................................................................... 28
Chapter IV Disassembly and Assembly of the Diesel Engine ....................................................... 29
4.1 Overview ................................................................................................................................ 29
4.1.1 Danger signs................................................................................................................ 29
4.1.2 Safety signs ................................................................................................................. 30
4.1.3 Special tools ................................................................................................................ 31
4.1.4 Precautions for health protection ................................................................................ 31

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

4.1.5 Environmental protection measures ............................................................................ 32

4.1.6 Precautions for disassembly and assembly of the diesel engine ................................. 32
4.2 Cylinder Head Group ............................................................................................................. 33
4.2.1 Cylinder Head Group Disassembly and Assembly Overview .................................... 33
4.2.2 Disassembly, Inspection, Maintenance and Assembly of Engine Lifting Plates ........ 34
4.2.3 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head Cover ........ 35
4.2.4 Disassembly, Inspection, Maintenance and Assembly of Lubricating Oil Pipe ......... 37
4.2.5 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head ................... 38
4.3 Engine Block Group .............................................................................................................. 44
4.3.1 Disassembly, Inspection, Maintenance and Assembly of Engine Block .................... 44
4.3.2 Disassembly, Inspection, Maintenance and Assembly of Flywheel Cover ................ 48
4.3.3 Disassembly, Inspection, Maintenance and Assembly of Front End Cover ............... 50
4.4 Crank and Connecting Rod Mechanism ................................................................................ 52
4.4.1 Disassembly, Inspection, Maintenance and Assembly of Crank and Connecting Rod
Mechanism ........................................................................................................................... 52
4.5 Valve mechanism ................................................................................................................... 57
4.5.1 Disassembly, Inspection, Maintenance and Assembly of Valve Train ........................ 57
4.5.2 Disassembly, Inspection, Maintenance and Assembly of Camshaft ........................... 58
4.5.3 Disassembly, Inspection, Maintenance and Assembly of Rocker Arm and Rocker
Arm Shaft ............................................................................................................................. 60
4.5.4 Disassembly, Inspection, Maintenance and Assembly of Tappet and Push Rod ........ 63
4.5.5 Disassembly, Inspection, Maintenance and Assembly of Valve ................................. 64
4.5.6 Disassembly, Inspection, Maintenance and Assembly of Gear Train ......................... 66
4.6 Intake and exhaust system ..................................................................................................... 69
4.6.1 Removal and Installation of the Intake and Exhaust System ...................................... 69
4.6.2 Disassembly, Inspection, Maintenance and Assembly of Intake Manifold ................ 70
4.6.3 Disassembly, Inspection, Maintenance and Assembly of Exhaust Manifold ............. 72
4.6.4 Disassembly, Inspection, Maintenance and Assembly of Turbocharger System ........ 73
4.6.5 Disassembly, Inspection, Maintenance and Assembly of Air Filter System ............... 77
4.7 Fuel system ............................................................................................................................ 79
4.7.1 Removal and Installation of Fuel System ................................................................... 79
4.7.2 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump ......... 81
4.7.3 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel Pipe ... 84
4.7.4 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector...................... 86
4.8 Cooling System ...................................................................................................................... 87
4.8.1 Overview of cooling system ....................................................................................... 87
4.8.2 Disassembly, Inspection, Maintenance and Assembly of Thermostat ........................ 88
4.8.3 Disassembly, Inspection, Maintenance and Assembly of Water Pump ...................... 89
4.8.4 Disassembly, Inspection, Maintenance and Assembly of Outlet Water Pipe .............. 90
4.8.5 Disassembly, Inspection, Maintenance and Assembly of Oil-gas Separator .............. 92
4.8.6 Disassembly, Inspection, Maintenance and Assembly of Fan .................................... 94
4.9 Lubrication System ................................................................................................................ 95

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

4.9.1 Overview of lubrication system .................................................................................. 95

4.9.2 Disassembly, Inspection, Maintenance and Assembly of Oil Pump Assembly .......... 96
4.9.3 Disassembly, Inspection, Maintenance and Assembly of Centrifugal Oil Filter ........ 98
4.9.4 Disassembly, Inspection, Maintenance and Assembly of Oil Cooler and Oil Filter... 99
4.9.5 Disassembly, Inspection, Maintenance and Assembly of Oil Pan ............................ 102
4.9.6 Use and Replacement of Oil ..................................................................................... 103
4.10 Startup system .................................................................................................................... 104
4.10.1 Overview of startup system .................................................................................... 104
4.10.2 Disassembly, Inspection, Maintenance and Assembly of Starter Motor ................ 106
Appendix A Recommended Torques for Standard Bolts ........................................................... 108
Appendix B Recommended Torques for Hollow Bolts ............................................................. 109

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Chapter I General Information

1.1 Exterior View of Diesel Engine

Figure 1-1 Exterior view of 6M33 series diesel engine

Figure 1-2 Free End of 6M33 Series Diesel Engine

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Figure 1-3 Flywheel End of 6M33 Series Diesel Engine

Figure 1-4 Intake Side of 6M33 Series Diesel Engine

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Figure 1-5 Exhaust Side of 6M33 Series Diesel Engine

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

1.2 Model Meaning of Diesel Engine

6 M 33 X XXX EX XX

Variant code

Emission level

Power code

Type code
Displacement

Moteur diesel

Number of cylinders

1.3 BasicParameters of the Diesel Engine

Table 1-1 Main Parameters of 6M33 Series Diesel Engine

Intake 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 Mechanical pump
Intake valve: 0.3±0.03
Cold valve clearance (mm)
Exhaust valve: 0.4±0.03
Valve timing Intake valve open before TDC: (34±5)°
Intake valve close after BDC: (40±5)°
（valve clearance: intake, 0.3; exhaust,
Exhaust valve open before BDC: (61±5)°
0.4） Exhaust valve close after TDC: (27±5)°
Thermostat open temperature (℃) 77
Starting method Electric
Lubricating method Pressure lubrication
Oil capacity (L) 60.5
Cooling method Water cooling, forced circulation
Oil pressure (kPa) 450～650
Crankshaft rotation direction (view from
Clockwise
free end)

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Length 1820
Overall
Width 1036
dimentions (mm)
Height 1406
Weight (kg) 2090

1.4 Hoisting of Diesel Engine

During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist

in tilted or one sided. Hoist up and down should be slowly. (See Figure 1-6).

Correct Wrong

Figure 1-6 Diesel Engine Hoisting

1.5 Unsealing of Diesel Engine

◆ After the diesel engine is unpacked, the user shall firstly check the diesel engine and its
accessories as per the delivery packing list, and check the engine appearance for damage

and loose connections before carrying out the following tasks:

(1) Wipe the anti-rusting layer and anticorrosive agent on the exposed parts;

(2) Check the water plug and oil plug, check for water temperature and oil temperature

sensors, and ensure that all parts to be self-provided are completely fitted.

Notice: Do not start the diesel engine before it’s correctly installed and connected at the final

position. When the diesel engine is running in an enclosed environment, keep well ventilated to

ensure that the exhaust gas is drained to the open air.

◆ Adding of engine oil

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

(1) The engine oil shall meet the specification, otherwise it will probably lead to insufficient

engine oil pressure and thus abnormal wear and difficult to start. The engine oil must be

extremely clean.

(2) Tightening the drain plug.

(3) Open the oil filler cap and add the engine oil. The engine oil must be filtered by the filter

screen before adding.

(4) Place the diesel engine at a level position and withdraw the oil dipstick to check the oil

level. For the first adding, add the oil till the level reaches the upper limit of oil dipstick.

(5) Tighten the oil filler cap.

◆ Adding of fuel
(1) The diesel fuel used shall meet the specification.

(2) The diesel fuel used must be clean. It's better to place the diesel fuel under stationary state

for more than 72 hours before adding. The diesel fuel shall be added into the fuel tank via

the built-in filter screen.

◆ Air bleeding of fuel system

(1) Loosen the outlet port screw of the fuel delivery pump by half turn. Operate the manual

pump of fuel delivery pump, till the diesel fuel overflows, and then tighten the screw.

(2) Loosen the air bleeding screw on the fuel filter. Operate the manual pump of fuel delivery

pump, till the diesel fuel overflows, and then tighten the screw.

(3) Loosen the fuel return port screw of fuel pump, operate the manual pump of fuel delivery

pump, till the diesel fuel overflows, and then tighten the air bleeding screw.

(4) Continue to operate the manual pump, check the fuel pipeline for presence of leakage, and

then tighten the manual pump.

◆ Adding of coolant

The coolant is mixed from softened clean water and anticorrosive agent or antifreeze. Ensure

to strictly abide by the specification of the additive manufacturer during mixing.

Add coolant through the water filler port of radiator or heat exchanger and bleed the air from

the cooling circulation system.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

1.6 Preparations before Start

 Check the coolant level

Check the coolant level. If the coolant is insufficient, add coolant. If the diesel engine remains

hot, do not add a great deal of coolant. Dramatic temperature change could cause damage to the

engine parts. If there is no coolant under special cases, it’s allowed to slowly add cold water in

moderate temperature. Add the coolant through the filler port, till the coolant overflows. Start the

engine. While the engine is running (1,000r/min), continue to add the coolant, till the coolant level

is stable, and finally install the filler port cap.

 Checking of fuel level

Check the fuel level or fuel tank.

 Check the engine oil level

The engine oil level shall be between upper and lower markings on the oil dipstick. If

necessary, add engine oil through the engine oil filler port.

 Check all accessories of diesel engine for reliable connections and solve any abnormal

phenomenon. Check the starter system for normal wiring and check and ensure that the

battery is sufficiently charged.

1.7 Start of Diesel Engine

 Before starting the engine, operate the acceleration and stop control levers on the fuel

injection pump to ensure flexible motions. Rotate the crankshaft of diesel engine for

several turns to ensure smooth rotation.

 Turn the key to position “1” to power on the control panel. The “oil pressure warning

lamp" automatically will turn on for 10s (Sfety line test of ultra-low engine oil pressure).

It’s recommended to test the indicator lamps, bulbs, and buttons once (by pressing the

touch button 10 on the control panel).

 Turn the key to position “START” to start the engine and then release the key. The key

will automatically return to position “1”.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

At the start of diesel engine, if the diesel engine fails to start within 10s, immediately release

the button and wait for 1min before retry.

If the engine can’t be started by three consecutive attempts, stop the attempt and find out and

solve the malfunction before retry.

During the working of engine, the “oil pressure warning lamp” and the "battery power”

indicator lamps are all off.

All indicator lamps are off during normal running of engine.

In event of abnormality, the “horn” will issue warning sound.

◆ The auxiliary starter shall be used to start the diesel engine under cold temperature. By

activate the electric heating flange via relay, the engine can be started successfully under

low-temperature environment.

1.8 Running of Diesel Engine

◆ After the start of diesel engine, idle the engine for 3min, and then increase the speed to
1000r/min to 1200r/min with some load. Only when the coolant temperature is above

60ºC and the oil temperature is above 51ºC, can the engine running with full load. The

load and speed should be increased gradually.

◆ In the first running-in period of 60h (the first 3000km running), the diesel engine should
work with load less than the moderate load.

◆ When driving in slops, decrease the speed in time. The diesel engine should not work for a

long time at maximum torque. Also, the engine should not be operated for a long time

under the low-speed and low-load conditions to avoid oily smoke.

◆ Parameters and checking locations to be observed at all times during operation are as

below:

a) Oil pressure of main oil passage:≥200 kPa(idling working conditions), (450~650) kPa

(rated working coditions).

b) The oil temperature in main oil passage:(85~105) ℃.

c) Coolant outlet temperature:(75~95) ºC.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

d) Exhaust temperature after turbine: ≤550 ºC.

e) Intake temperature after intercooler: (50~60) ºC.

◆ Check the exhaust color, to estimate the performance of the injector and the load of the

engine. In the case of serious black or white smoke, stop and check the engine.

◆ Check the diesel engine for presence of water, gas, and oil leakages. If any, stop the

engine for troubleshooting.

◆ The operator should acknowledge the following features of the engine:

a) The fuel consumption is relatively low at max torque, and increases along with the
rotation speed rise.

b) The torque reaches its peak value within the medium speed range;

c) The engine power increases along with the speed rise, and reaches its rated value at
rated speed.

◆ Precautions for running under cold environments;

a) Fuel: Choose diesel fuel of different grades depending on the environmental

temperature in winter.

b) Lubricating oil: Choose lubricating oil of different viscosities depending on the

seasons.

c) Coolant: Add antifreeze additive into the cooling system and choose the coolant of

different grades depending on the ambient temperature.

d) Start: The auxiliary starter can be adopted if necessary in winter. After starting the

engine, only operate the engine with load and high speed when the oil pressure and

water temperature are normal.

e) Before the cold season begins, be sure to check the electrolyte liquid level, viscosity

and unit voltage. If the engine is not going to be operated for a long time and under

very low temperatures, the battery should be removed and stored in a warmer room.

f) Shut-down of the engine: When shutting down the engine in a cold climate, unload the

engine first and then run the engine at idling speed for 1 to 2 minutes. And then stop

the engine after the water and oil temperaturesdecreased. The coolant with antifreeze

additives should not be drained out after shutdown. Otherwise, open the drain valve or

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

plug on the engine body, oil cooler cover, radiator and water inlet pipe to drain the

coolant completely to prevent the engine from being frost cracked.

1.9 Stop of Diesel Engine

◆ Avoid shutting down the engine at full load. Before the shut-down, engine load and speed

should be reduced, and the engine should operate at idle speed or low-load condition for 3

to 5 minutes to allow the piston, cylinder head, liner, bushing and turbocharger have

enough time to cool down, in order to avoid cylinder and bearing damage. This is

particularly important for turbocharging engines because the bearing and oil seal in the

turbocharger are to be affected by the high temperature of the exhaust gas. When the

engine is running, the heat will be transferred away by the cycling lubricating oil. But

when the engine shuts down suddenly, the turbocharger temperature will increase greatly

and cause the bearing get stuck or oil seal failing.

◆ Turn the key switch to position “OFF” or press the stop button to stop running of engine,
till the flywheel stops rotation or the speed indicator on the instrument panel points zero.

◆ For the engines that there is no antifreeze in the circulating water, drain the cooling water

after shut-down in cold weather to prevent freezing damage to the engine. The draining

valve under the oil cooler can be used to drain the water inside the engine. The drain plug

on the radiator should also be removed to discharge the cooling water in the radiator.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Chapter II Maintenance Guide of Diesel Engine

2.1 Fuel, Lubricating Oil, Coolant, and Auxiliary Materials for Diesel Engine

2.1.1 Fuel

Summer: 0# diesel (GB252)

Winter: Generally -10# light diesel (GB252). Choose -20# diesel for environmental
temperature below -15ºC and -35# diesel for environmental temperaturebelow -30ºC.
The fuel used must meet the requirements specified in Table C.6 of Appendix C of GB17691
or Table D.1 of Appendix D of GB 20891-2007 (for non road diesel engine).

2.1.2 Lubricaing oil

For Weichai Power Stage II, China III, EGR series and China IV, China V series diesel engines,
grade CF-4, CH-4, CI-4 and CJ-4 oil should be used respectively. For gas engine, special oil for gas
engine should be used.
For the first filling of oil pan, the oil level should be reach the upper marking on dipstick. The
oil capacity of 6M33 series diesel engine is about 60.5L, and oil grade should be CF-4 or above.
See Table 2-1 for the relationships between oil viscosity and temperatures.

Table 2-1Viscosity selection based on ambient temperatures

SAE viscosity grade Applicable environmental temperature (ºC)
0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40
20W-50 -15-45

Note:
1) Before starting the diesel engine, allways check the engine oil level in oil pan.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

2) Do not check the oil level while the diesel engine is running.

2.1.3 Engine cooling system

The freezing point specification for Baudouin engine special coolant includes -25ºC, -35ºC,
and -40ºC. Please choose Baudouin special coolant of different freezing points based on the local
environmental temperature.The principle is to choose the coolant with freezing point lower than the
local minimum temperature of about 10 degrees, see Table 2-2.

Table 2-2 Baudouin Special Coolant for Heavy-Duty Engines

Variety Product category Packing specification
HEC-Ⅱ-25
Heavy-duty engine coolant HEC-Ⅱ-35 4kg, 10kg
HEC-Ⅱ-40

Note:
1) Make sure to periodically check the coolant and, to prevent the corrosion damage,
timely replace depending on actual situations.
2) It’s prohibited to use water or low quality coolant as the engine coolant.

2.1.4 Auxiliary materials

The auxiliary materials and sealant application is shown in table 2-3 amd table 2-4.
Table 2-3 Auxiliary Materials Used for Diesel Engines
SN. Name Color Purpose and location
Molykote pulver Applied on flat and smooth metal surface to
1 (fine molybdenum Black prevent seize
powder) For example, the outer surface of cylinder liner
Molykote G-N
Lubrication before the lubricating oil pressure
Plus
builds up.
2 (Molybdenum Dark grey
For example, applied onto the intake valve
disulfide, oil
stem
solution)

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Table 2-4 Sealant Application of Diesel Engine

Brand Main use Application locations Remarks
Flywheel housing bolt
Camshaft thrust bearing bolt
Camshaft gear bolt
Rocker shaft bracket nut
It’s applied onto Intake manifold bolt
the threads to Intercooler bracket bolt
Weichai special prevent loosening Injection pump intermediate
sealant 242 due to vibration, gear bolt
with moderate Injection pump gear bolt
As an option,
strength Injection pump camshaft nut
DriLoc204 can
Injection pump flange bolt
be used for
Oil pump bolt
pre-coating of
Fuel filter seat bolt
the thread
Suction fildter bolt
Water drain valve bolt
Turbocharger oil inlet bolt
Slide valve screw plug of oil
Weichai special Applied onto outer filter seat
sealant567 threads for sealing Screw plugs in fuel, oil and
cooling water pipelines (do not
coat for plug with copper
washer)
Weichai special Sealing between
Bowl plug
sealant277 core and hole
Weichai special Joint faces of engine body and
sealant oil pan
510/silicon Joint faces of rear end gear
Coated on the
sealant chamber and engine body
bright metal
Joint faces of rear end gear
surface for sealing
chamber and flywheel housing
Joint faces of front end cover
and engine body

2.2 Daily Maintenance

Check the oil level

The proper oil level is shown in figure 2-1. Add oil from filler port if necessary. Do not start
the engine if engine oil level is above the H mark or below the L mark of the oil dipstick.
After the diesel engine is stopped, wait for at least 5min and then check the oil level, in order

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

to enable the engine oil to flow into the oil pan.

Oil dipstick

Figure 2-1 Oil dipstick

 Check the fuel level

Turn on the power switch, check the fuel level in fuel tank or check the fuel tank directly.
 Check for presence of water, gas, and oil leakages
The whole engine shall be free of water, air, and oil leakage.
 Check the fan
Visually check the blade of fan for damage and check connecting bolts for secure fastening.
 Check the belt
The belt is automatically tensioned through tensioner. Check the tension of belt by
pushing the belt with hand.

Belt

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Figure 2-2 Check the belt

 Check if the sound is normal

 Check whether exhaust gas has a normal color
The normal color of exhaust gas is light grey. If there is color change, check the engine for
troubleshooting.
 Check the connection of outer parts and accessories for secure fastening.
 Check if the speed and vibration of diesel engine are normal.

2.3 Maintenance items

In addition to the daily maintenance, fulfill the following items:

 Replace diesel engine oil (as shown in Figure 2-3)
Unscrew the oil drain plug from the bottom of oil pan to fully drain the engine oil and then
tighten the oil drain plug. Open the oil filler cap and add oil. At the same time, observe the marking
of the oil dipstick, till the required oil level is reached, and then install the oil filler cap.

Oil filler port

Drain plug Oil filter

Figure 2-3 Oil filler port, drain plug and oil filter

 Replace engine oil filter or filter element

Replace the engine oil filter as the following steps:
A. Disassemble the used oil filter;

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

B. Fill the new filter completely with clean engine oil;

C. Before installing new engine oil filter, apply engine oil onto the rubber gasket;
D. After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal;
E. Start the diesel engine and check for oil leakage.
 Check and adjust the intake and exhaust valveclearances
A. Under the cold status of diesel engine, turn the engine crankshaft (along the rotation
direction of flywheel) to the compression top dead center of 1st and 6thcylinders. In such
case, the notch on the flywheel is aligned with the pointer on the flywheel housing.
B. Disassemble the valve rocker cover from the cylinder head and judge whether the 1st or 6th
cylinder is at compression stroke (there is a gap between intake/exhaust valve and rocker
for the cylinder under the compression stroke).

Figure 2-4 Adjustment of valve clearance

C. Using the feeler gauge, check the clearance between valve bridge top plane and valve
rocker arm (figure 2-5). If the clearance is too large or too small, adjust the adjustment
bolt on the rocker to meet the above-mentioned clearance requirement.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Adjustment
bolt

Clearance of intake valve and exhaust valve are all of 0.3mm

Figure 2-5 Valve clearance

D. After the checking of 1st cylinder or 6th cylinder, turn the engine crankshaft for 360º to
make the 6th or 1st cylinder to working stroke and then check and adjust the remaining
valves.

Table 2-5 Adjustable Valves of Cylinders in the Compression Stroke

1st 2nd 3rd 4th 5th 6th
cylinder cylinder cylinder cylinder cylinder cylinder
1st cylinder Intake and Intake Exhaust Intake Exhaust Non-adjus
compression exhaust valve valve valve valve table
stroke valves
6th cylinder Non-adjus Exhaust Intake Exhaust Intake Intake and
compression table valve valve valve valve exhaust
stroke valves

 Replacement of fuel filter element

Replace the fuel filter as the following steps:
A. Remove the old fuel filter element. Remove the water collector installed on the primary
filter if it is reusable.
B. Lubricate the sealing surface.
C. Tighten the filter by hand, till the seal surface comes into contact with the interface.
D. Continue tighten the filter by hand, till the filter is securely installed (about 3/4 turn).
E. Bleed the air, till there is no presence of air bubble.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

F. Conduct the leakage test.

Fuel filter

Figure 2-6 Fuel filter

 Check the intake system

Check the intake hose for crakcks due to aging and check the clamp for loosening. Tighten or
replace parts if necessary, to ensure tightness of the intake system.

Intake
Exhaust manifold
manifold

Figure 2-7 Intake and exhaust manifolds

 Check the air filter element

The maximum intake resistance of diesel engine is no higher than 7kPa; Check the maximum
intake resistance only when the diesel engine is running at rated speed under full load. When the
intake resistance reaches the maximum permissible limit, clean or replace the filter element as per
the manufacturer’s instructions.

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Caution: It’s absolutely prohibited to run the engine without air filter, otherwise dust
and impurities will get into the diesel engine and cause early wear of engine.
Disassemble the filter element from the air filter and flap lightly the end face to fall off the
dust or blow backward (from the inside out) with compressed air.

High pressure air pipe

Figure 2-8 Cleaning of filter element

Caution: Do not damage the filter paper,
Do not clean the filter paper with water or oil, and
Do not clap or knock the filter element forcibly.

2.4 Engine maintenance for long-term storage

 Clean the diesel engine

 Protection method:
○Warm up the engine and drain the oil, clean the oil filter, and add anti-rust oil;
○Discharge the fuel, and addanti-rust mixed oil;
○ Drain the water, and add coolant with rust inhibitor;
○Start the engine and run without loadfor 15 ~ 25minutes;
○Drain the oil, fuel and coolant;
○Perform protection measures to other parts.
 Protection during storage
○Use lids or plastic sheeting to block the inlet and outlet of oil, gas and water;use VCI film
to protect the entire diesel engine.
○ Add packaging if you need to transport the engine.

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

Chapter III Typical Malfunctions and Troubleshooting of Diesel Engine

6M33 series diesel engine is designed and manufactured under strict quality assurance system
and each delivered diesel engine passed the specified tests. In addition, the diesel engine is a kind
of high precision machinery and the long-term guarantee of its functionality is closely related to the
normal maintenances. The causes leading to earlier failure of diesel engine are generally as below:
◆ Operation against rules or improper management and use.
◆ Failure to fulfill maintenance as specified or even repair instead of maintenance.
◆ Unqualified parts, especially the counterfeit products procured due to temptation of cheap
prices, which will greatly shorten the service life of diesel engine;
◆ Inappropriate grade of fuel or lubricating oil or unqualified fuel or lubricating oil.

3.1 Diagnostic Method

The commonly used diagnostic methods for engine failures are generally:
◆ Observation: Observe the characteristics, such as exhaust, to determine the failure (Fig.
3-1).
◆ Listening: According to the abnormal sound, determine the nature and extent of the failed
location (Fig. 3-2).

Figure 3-1 Observation Figure 3-2 Listening

◆ Cylinder shut-down method: Shut down one of the cylinder to determine whether the
malfunction occurs in that cylinder. This method stops fuel supply to the suspected cylinder to offer
a chance to tell the difference before and after shut-down, which could help find the failed location

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or further narrow down the search range.

◆ Comparative method: For some assembly or parts, replace them to determine whether
there is failure.
Note:
(1) Determine the cause of engine failure is a very careful work. Do not disassemble the
engine or remove parts until understanding the cause, otherwise not only the problems can’t be
eliminated, the engine will also suffer from more serious failures due to improper assembling after.
(2) For high-pressure fuel pump, turbocharger and other key components, the maintenance and
inspection not only need special equipment, but also need staff with experience. Customers should
not arbitrarily disassemble or adjust the engine.

3.2 Common Failures and Troubleshooting Method

3.2.1 Start failure of diesel engine

Cause Troubleshooting
(1) Starter does not work Troubleshoot the electric circuit failure
(2) Ambient temperature is too low Use auxiliary starting device
Expel the air; Check the pipe joints for leakage and repair
(3) Air trapped in fuel system
if any
(4) The inlet filter screen or hose of
Remove dirt. Check fuel cleanliness
fuel supply pump clogged
Check the plunger and delivery valve; Repair or replace
(5) Faulty fuel injection pump
the damaged parts
(6) Damage or leakage of valve train
Check and adjust
or fuel supply pipe
(7) High-pressure fuel pipe damaged
Repair or replace
or fuel leakage
(8) Fuel injector failure Check the atomization of fuel injector
Check the valve and cylinder gasket for leakage and
(9) Insufficient compression
check for worn piston rings; Repair or replace the faulty
pressure in cylinder
parts if any

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

3.2.2 Engine stopped soon after starting

Cause Troubleshooting
Check the fuel pipe and its joint for leakage; Check
(1) Air trapped in fuel system whether the bleeder screw is securely tightened; Expel
the air out of the fuel system
Take down the filter body. Remove dirt and moisture; If
(2) Fuel filter clogged
necessary, replace the filter element
(3) Poor fuel quality with excessive
Clean the filter, and replace fuel
moisture
Check, clean and repair the piston and valve of the fuel
(4) Fuel supply pump does not work
supply pump
(5) Idle speed too low Re-adjust

3.2.3 Insufficient engine power

Cause Troubleshooting
Check the air filter and intake pipe; Clean or
(1) Intake system (air filter) clogged
replace the filter element
Check and adjust the valve timing; Check the
(2) Exhaust back pressure is too high
exhaust pipe for clogging. Remove clogging if any
(3) Insufficient pressure in turbocharging Check and troubleshoot the leakage in the
system connecting pipe
(4) Turbocharger works abnormal Replace the assembly
(4-1)Compressor, turbine flow passage
Clean or replace
clogged
(4-2) Floating bearing failure Replace
(4-3)Carbon or sludge deposit in the back
Clean
of turbine and compressor

(5) Intercooler damaged or leaks air Replace or repair

Check the fuel pipe and its joint for leakage; Check
(6) Fuel pipe leaks or clogged the fuel filter for contamination; Tighten and clean
the fuel pipe; Replace the fuel filter element
Clean the fuel tank, fuel filter and fuel pipe;
(7) Poor fuel quality
Replace fuel
(8) Excessive wear of fuel injection pump
Repair or replace
or governor
(9) Smoke limiter diaphragm of fuel
Repair or replace
injection pump is damaged
(10) The air pipe of smoke limiter is
Replace
damaged
Check fuel injection pressure; Check the injector
(11) Instable atomization of fuel injector
for soot deposition; Adjust and repair the injector

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

(12) Incorrect valve or fuel supply timing Check and adjust

(13) Upper speed limit of governor too
Check and adjust
low
(14) Engine oil level in oil pan too high Referring to the oil dipstick, drain excessive oil
Check the compression pressure in the cylinder
(15) Gas leakage from cylinder gasket while the diesel engine is hot; Replace the
damaged cylinder gasket
(16) Worn or broken piston ring. Excessive Replace the piston ring or bearing shell, or
bearing shell gap overhaul the diesel engine
(17) Worn or scratched cylinder liner or
Repair or replace
piston

3.2.4 Excessive fuel consumption

Cause Troubleshooting
Check the air filter and intake pipe for
(1) Intake system clogged
clogging; Remove clogging if any
Check the exhaust pipe and brake valve for
(2) Exhaust back pressure too high
clogging; Remove clogging if any
Replace fuel in accordance with the
(3) Poor fuel quality
requirements
Check the fuel pipe for clogging; Remove
(4) Fuel pipe clogged
clogging if any
Check the fuel pipe for leakage; Remove
(5) Leakage of fuel pipe
leakage if any
(6) Instable atomization of fuel injector Check, adjust and repair the fuel injector
Adjust the valve clearance and fuel supply
(7) Incorrect valve or fuel supply timing advance angle in accordance with the
requirements
(8) Gas leakage from cylinder gasket Check the compression pressure in the cylinder
(9) Excessive bearing shell gap, diesel engine
Check and overhaul the diesel engine
overhaul is needed
Replace the cylinder liner, piston and piston
(10) Piston scuffing
rings
(11) Insufficient pressure in turbocharging Check and troubleshoot the leakage in the
system connecting pipe
(12) Turbocharger works abnormal Check and replace the assembly
(13) Damage or leakage in intercooler Replace or repair

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3.2.5 Engine exhaust gas is black

Cause Troubleshooting
(1) Intake pipe clogged or high exhaust back
Clean the intake or exhaust pipe
pressure
(2) Poor fuel quality Clean the fuel system, replace fuel
(3) Incorrect valve or fuel supply timing Adjust according to requirements
(4) Instable atomization of fuel injector Check, repair or replace
(5) Excessive fuel injection Check and adjust
(6) Insufficient pressure in turbocharging Check and troubleshoot the leakage in the
system connecting pipe
(7) Turbocharger works abnormal Check and replace the assembly
(8) Damage or leakage in intercooler Replace or repair
(9) Incorrect working point of smoke limiter Readjust

3.2.6 Engine exhaust gas is white or blue

Cause Troubleshooting

(1) Poor fuel quality with excessive moisture Replace fuel

Check the operating temperature of the
(2) Coolant temperature is too low
thermostat; Replace it if necessary
(3) Sealing ring of turbocharger damaged Check and replace
(4) Thrust bearing of turbocharger damaged Check and replace
(5) Oil return pipe of turbocharger clogged Clean or repair
(6) Instable atomization of fuel injector Check and repair
(7) Incorrect valve or fuel supply timing Check and adjust
(8) Low compression pressure, incomplete Check the piston rings, cylinder liner and
combustion, piston scuffing cylinder gasket; Repair the damaged ones
(9) Piston ring or cylinder liner insufficiently
Continue running-in
running-in
(10) Piston ring gaps not staggered Adjust or reassemble
(11) Piston oil ring failure Replace
(12) Excessive clearance between piston and
Repair, replace
cylinder liner

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

3.2.7 Oil gathering at the air inlet port and inlet pipe of turbocharger

Cause Troubleshooting

(1) Turbocharger sealing failure Repair or replace

(2) Oil-gas separator failure Replace

(3) Oil pan level too high, excessive oil Check and release appropriate amount of oil

3.2.8 Rotating speed unstable

Cause Troubleshooting

(1) Poor fuel quality with moisture or wax Replace fuel

Check the fuel suction pipe and its joint for
(2) Fuel suction pipe is sucking air in
tightness; Expel the trapped air
(3) The governor weight or speed spring
Check and adjust
(mechanical pump) is not working properly
(4) Uneven fuel supply Check and adjust
(5) Unstable atomization of fuel injector Check and repair
Check and clean the compressor flow passage,
(6) Turbocharger surging
remove the fouling and soot deposition
(7) Turbocharger bearing damaged Replace

3.2.9 Oil pressure is too low

Cause Troubleshooting

(1) No or insufficient oil in oil pan Add oil

(2) Engine oil grade is not compliant Replace with compliant engine oil
(3) Coolant temperature or engine oil Check whether the cooling system works
temperature is too high normally
(4) Excessive resistance in engine oil filter Replace with a new filter element
(5) Engine oil cooler clogged Check and clean
Check the flow passage of air
(6) Clogging or breakage of suction filter,
compressor;Remove dirt and soot deposition if
engine oil pipe, or washer of pipe joint
any
(7) Leakage from inlet pipe of engine oil pump Check, repair or replace the inlet pipe and its

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

joint
(8) Pressure regulator valve in main oil passage
Check, clean or repair the valve
failure
(9) Main oil passage clogged Check and clean
(10) Excessive bearing shell gap, or damaged
Check and replace
bearing shell
(11) Excessively-worn parts and components Check and overhaul the diesel engine
Check whether diesel fuel smell comes from the
engine oil; Measure the flash point of the engine
(12) Diesel fuel leaking into engine oil
oil, which shall not be lower than that of new
engine oil

3.2.10 Coolant temperature istoo high

Cause Troubleshooting

(1) Coolant level in expansion tank is too low Check for leakage; Add coolant
(2) Radiator of expansion tank clogged Clean the radiator
Adjust the belt tension in accordance with the
(3) Slack water pump belt
requirements
(4) Damaged washer or worn impeller of water
Check, repair or replace
pump
Check the water pipe, pipe joint and washer;
(5) Damaged water pipe is sucking air in
Replace the damaged ones
(6) Thermostat failure Replace
(7) Expansion tank clogged Check, clean and repair the expansion tank
Check the oil level; If any leakage, repair it and
(8) Insufficient oil in oil pan
add engine oil

3.2.11 Parts wear too fast

Cause Troubleshooting

(1) Air filter element is unqualified or damaged Check and replace the air filter element
Check the intake pipe, gasket and connecting
(2) Short circuit of air intake system
sleeve; Repair or replace the damaged ones
(3) Engine oil filter element is not replaced Replace the filter element at the required
timely interval
Check the oil level; Check for and repair
(4) Insufficient oil in oil pan
leakage. Add engine oil

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

(5) Engine oil grade is not compliant Replace with compliant engine oil
(6) Engine oil quality failure to meet
Use engine oil of compliant grade
requirements
(7) Oil passage clogged Clean the oil passage
(8) Piston ring is broken or worn Replace the piston ring
(9) cylinder liner or piston is worn or piston Take down and inspect the piston and cylinder
scraping liner; Repair or replace the damaged ones
(10) Crankshaft axis is not in line with the axis
Check and repair the mounting bracket
of driven shaft
Check the cumulative driving distance to see
(11) Part/component is worn excessively
whether overhaul is needed

3.2.12 Excessive noise level

Cause Troubleshooting

(1) Poor fuel quality Replace the fuel

(2) Coolant temperature is too low Check the thermostat and replace it if necessary
(3) Incorrect valve or fuel supply timing Check, repair or adjust

(4) Instable atomization of fuel injector Check, repair or adjust

(5) Excessive fuel injection Check and adjust
Check the connecting bolt, replace the damaged
(6) Vibration damper is worn
component
(7) Valve leakage or improperly adjusted Take down the valve, inspect and adjust
(8) Excessive gear clearance or broken gear
Check and replace the damaged gear
teeth
(9) Cylinder liner or piston is worn or piston
Check, repair or replace
scraping
(10) Push-rod is bent or broken, rocker arm is
Replace
broken
(11) Piston ring is broken or worn Check and replaced the damaged piston ring

3.2.13 Startingmotor does not work

Cause Troubleshooting

(1) Fuse burnt Replace the fuse

(2) Poor contact of circuit Check the circuit, and tighten the terminals

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Maintenance Manual of 6M33 Series Industrial Diesel Engine

(3) Insufficient charge of battery Check, charge or replace the battery

Inspect and repair the starter motor or replace
(4) Short circuit of starter motor
the starter assembly
(5) Poor contact of electric brush Clean or replace the electric brush

3.2.14 Starter motor is powerless

Cause Troubleshooting

(1) Battery is undercharged Charge or replace the battery

(2) Bearing bush is worn Replace the assembly

(3) Poor contact of electric brush Clean or replace the electric brush
Clean the oil stain; Polish the commutator by
(4) Commutator is dirty or burnt using sandpaper, or replace the commutator
assembly
(5) Terminal unsoldered Resolder

(6) Poor contact of switch Check and repair the switch

Adjust the operating torque of the clutch or
(7) Clutch is worn or slipping
replace the clutch assembly

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Industrial 6M33 Series Diesel Engine Service Manual

Chapter IV Disassembly and Assembly of the Diesel Engine

4.1 Overview

During dismantling and assembling of diesel engine, please follow operating instructions in
this manual strictly and pay attention to operation steps containing danger and safety marks, so as
to ensure personal safety and avoid accidents.
For the reason that the diesel engine is dismantled in reverse installation procedures, only one
item is selected for instruction in this maintenance manual unless otherwise specified herein.
Tightening torque of special bolts will be specified in relevant installation procedures, and
unless otherwise specified herein, please refer to Chapter V, Tightening Torque of Standard Bolts.

4.1.1 Danger signs

This sign is a world-recognized “safety warning sign” for industrial purposes, which stresses
the importance of the following information. Please make sure that you know what potential risks
are and how to ward off such risks. The violation of such warning information can lead to property
loss, personal injury and even personal casualty.
The common danger signs are usually used to indicate general warning. In this manual, the
warning informations are classified as per the levels of hazard effect (minor injury-related, severe
injury-related, and death related).

This warning sign indicates a potential hazard which can lead to serious
injury even death or great property loss, if the occurrence cannot be
avoided.

This warning sign indicates a potential hazard which can lead to

slight injury or property loss, if the occurrence cannot be avoided.
WARNING
It can also be used to hazardous operation warning.

CAUTION The cautions in this manual can indicate how to properly operate
and safely use the engine manufactured by the company.
However, the potential hazards cannot be removed by reading the
manual. The considerations will not be beneficial to the correct
use unless the implicatureis properly understood.
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Industrial 6M33 Series Diesel Engine Service Manual

The warning information in the manual cannot cover all possible conditions! To apply an
application or method beyond those recommended in this manual, make sure that the operation will
never cause any danger to you, to others or to the equipment.

4.1.2 Safety signs

Table 4-1 Safety signs

Picture Definition
Wear hand protectors

Wear ear protectors

Wear eye protectors

Wear a head protector

Wear foot protectors

Wear protective mask

Wear protective clothing

No fire

No smoking

No mobile phones

Danger: Battery acid liquor

Danger: Live cables and electric shock hazard

Combustibles

Keep away from suspended heavy objects!

Fire extinguisher available at a nearby position

During use of the diesel engine, many potential dangers may occur without any signs. Hence,
this manual cannot give warning instructions for all kinds of potential danger. If the procedures
taken by you are not recommended ones, please ensure the same procedures are safe to operate and
do not result in any damage to property.

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Industrial 6M33 Series Diesel Engine Service Manual

4.1.3 Special tools

To use a method or tool beyond those recommended in this manual, the user shall always
ensure the personal safety, avoid danger of life to the user or to others, meanwhile, make sure that
the use, maintenance or repair method will not result in damage risk or safety hazard.

4.1.4 Precautions for health protection

The following “health care considerations” are specified to reduce the risk of engine
maintenance staffs suffering from any contamination.
a) Avoid repeated exposure to used oil for a long time;
b) Wear the protective clothing and water-proof gloves properly, if available;
c) Do not place the oily rag in the pocket;
d) Avoid contaminating clothes especially underwear with oil;
e) Wash working clothes regularly, and throw away the oil-impregnated clothes and shoes that
cannot be cleaned up;
f) In case of cut and injury, take first-aid measures as soon as possible;
g) Before working, always apply some protective cream which will make it easier to remove
the oil in case that the skin is contaminated with mineral oil;
h) Use soap and hot water, or liquid soap and nail brush to wash hands for the convenience of
removing all oil stains. If the grease secreted by skin is washed off, the product containing lanum
can moisturize the skin;
i) Do not clean the skin with any gasoline, kerosene, fuel, thinner or solvent;
j) If the skin is discomfort, seek for medical care immediately;
k) Remove oil from the parts before transportation, if available;
l) If the eyes are under threaten, wear goggles or protective mask. Always prepare eyes wash
liquid within reach;
m) To repair the engine, do not splash oil or other liquid on the floor. If hydrocarbon or other
liquid leaks unexpectedly, take all essential measures to isolate the area to keep the environment
clean and to protect the personnel from injury;
n) The hydrocarbon, ethylene, glycol or petroleum shall be transferred, stored and recycled
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Industrial 6M33 Series Diesel Engine Service Manual

under the safety and environment standard in the local country.The following "Precautions for
health protection" are to reduce pollution risks.

4.1.5 Environmental protection measures

Please observe relevant environmental protection laws and regulations with respect to disposal
of waste oil and hydrocarbons. For details, consult local officials.

4.1.6 Precautions for disassembly and assembly of the diesel engine

1) Most accidents in connection with use, maintenance and service of diesel engine are
resulted from failure to observe safety rules and basic precautions. So, you should know risks you
face and take corresponding preventive measures to avoid occurrence of accidents. To conduct
operation, maintenance and service of the diesel engine, you should be trained, and have relevant
skill and use appropriate tools.
2) Failure to follow relevant instructions given in this manual may result in serious accidents,
even endangering the operator's life. Baudouin(Weifang) Power Co., Ltd. cannot foresee all
potential risks. Similarly, guidelines and instructions specified in this manual are not exhaustive.
3) Before proceeding with maintenance or repairing, a signboard containing "Don't Use" or a
similar sign should be placed on the starter switch.
4) Before use of the barring rod, necessary preventive measures should be taken.
5) Ensure that the maintenance site and surrounding environment are suitable for safe
operation.
6) Ensure the maintenance workshop or area around the diesel engine is clean and neat.
7) Before working, please take off your ring, necklace and watch. Please wear a suitable
working uniform.
8) Before working, please check whether corresponding protective equipment (goggles, gloves,
shoes, masks, working uniform, helmet, etc.) are within effective life.
9) Do not use faulty or unsuitable tools.
10) Stop the diesel engine during maintenance or service.

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Industrial 6M33 Series Diesel Engine Service Manual

4.2 Cylinder Head Group

4.2.1 Cylinder Head Group Disassembly and Assembly Overview

1) Exploded view
The cylinder head is located on the upper portion of the cylinder block and combined with
piston head to form the combustion chamber. The parts connected with the cylinder head include
air filter, intake manifold, exhaust manifold, water outlet pipe, fuel injector, cylinder head cover,
cylinder head gasket, and some parts of valve mechanism, as shown in the Figure 4-1.

Cylinder head cover

Fuel injector
Rocker arm High pressure
Thermostat oil pipe
Water outlet pipe
Exhaust manifold Intake manifold
Cylinder head
lubricating oil pipe
Oil-gas Air filter
separator

Figure 4-1 Connected parts of cylinder head

2) Disassembly
a) The disassembling steps are indicated in turn:
b) Disassemble the air filter. Refer to the disassembling instruction of intake and exhaust
system for details.
c) Disassemble the fuel return pipe of fuel injector and the high pressure fuel pipe. Refer
to the disassembling instruction of fuel system for details.
d) Disassemble the thermostat and water outlet pipe.
e) Disassemble the exhaust manifold. Refer to the disassembling instruction of intake

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Industrial 6M33 Series Diesel Engine Service Manual

and exhaust system for details.

f) Disassemble the intake manifold. Refer to the disassembling instruction of intake and
exhaust system for details.
g) Disassemble the front and rear lifting plates.
h) Disassemble the cylinder head cover and the gasket.
i) Dismantle the fuel injector, see the dismantling instructions of fuel systemfor details;
j) Disassemble the rocker arm assembly and push rod. Refer to disassembling
instruction of valve mechanism for details.
k) Disassemble the lubricating oil pipe of cylinder head.
l) Disassemble the cylinder head assembly and the cylinder head gasket.
m) Disassemble the inner and outer springs of valve, upper and lower seats of intake and
exhaust valvesprings, valve cotters, and valves. Refer to disassembling instruction of
valve mechanism for details.
n) Disassemble the valve stem sealing sleeve;
3) Assembly
The assembly procedure is in reverse order of disassembly procedure.

4.2.2 Disassembly, Inspection, Maintenance and Assembly of Engine Lifting Plates

1) Exploded view

Engine
hanger plate
Hexagon
bolt

Figure 4-2 Exploded View of Engine Hanger Plate

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Industrial 6M33 Series Diesel Engine Service Manual

2) Disassembly
a) Disassemble the parts fixed on the hanger plate, loosen the hexagon bolts fixing the
engine hanger plate in turn, and take out the hanger plate, as shown in Figure 4-2:
3) Inspection and Maintenance
a) Before installation the hanger plates, distinguish the front hanger plate from the rear
one. The front hanger plate shall be installed at the front side of the engine (the fan
side). The rear hanger plate shall be installed in the rear side of the engine (the
flywheel side);
b) Check the front and rear hanger plates for cracking and other failure and check the
hexagon head bolts for presence of failure. Replace with new parts if necessary.
4) Assembly
a) Tighten the M12 hex bolts that attach the hanger plates to the end plates.

4.2.3 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head Cover

1) Exploded view
Hexagon socket
Cylinder head cylindrical head screw
cover
Rubber O-ring
Cylinder head
cover gasket

Figure 4-3 Exploded View of Cylinder Head Cover

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Industrial 6M33 Series Diesel Engine Service Manual

2) Disassembly
a) Loosen the cylinder head cover bolts in turn and vertically take out the cylinder head
cover and cylinder head cover gasket, as shown in the Figure 4-3.
3) Inspection and Maintenance
a) Check the cylinder head cover for presence of cracking and other damage. If any,
replace with new cylinder head cover;
b) Upon detection of oil permeation or leakage at cylinder head cover gasket, check the
cylinder head gasket for failure and replace with new cylinder head cover gasket.
4) Assembly
a) The cylinder head cover gaskets can be used only once. Replace with new ones in
case of repair. Before installing cylinder head cover gasket, check and ensure that new
cylinder head cover gasket is free of manufacturing and use defects and damages;
b) Wipe clean the top face of cylinder head and assemble cylinder head gaskets correctly
in turn;
c) Apply oil to the rubber O-ring, install O-ring into groove of cylinder head cover, wipe
clean the cylinder head cover, and assemble the cylinder head covers onto the cylinder
head in correct sequence;
d) Install and tighten the cylinder head cover bolts.

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Industrial 6M33 Series Diesel Engine Service Manual

4.2.4 Disassembly, Inspection, Maintenance and Assembly of Lubricating Oil Pipe

1) Exploded view

Flanged bolt
Hose clamp
Cylinder head
Hollow bolt lubricating oil pipe

Sealing gasket

Cylinder head
lubricating oil inlet pipe
Hollow bolt

Combination
sealing washer

Figure 4-4 Exploded View of Cylinder Head Lubricating Oil Pipes

2) Disassembly
a) Loosen the hollow bolts fixed on the cylinder block and cylinder head and take out the
lubricating oil pipes of cylinder head, as shown in Figure 4-4:
3) Inspection and Maintenance
a) Check the oil pipes for presence of oil permeation and leakage. Upon detection of oil
permeation or leakage, judge the failure state and replace with new lubricating oil
pipes or sealing gaskets.
4) Assembly
a) Fix the cylinder head lubricating oil pipe assembly onto the cylinder head and cylinder
block by using hollow bolts with sealing gasket.

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Industrial 6M33 Series Diesel Engine Service Manual

4.2.5 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head

1) Exploded view

Auxiliary bolt,
cylinder head

Main bolt,
cylinder head Washer
Clamping
block
Cylinder head

Valve stem
sealing sleeve

Cylinder head
gasket

Figure 4-5 Exploded View of Cylinder Head

2) Disassembly
As shown in Figure 4-5:
a) Loosen nuts of cylinder head auxiliary bolts and take out clamping blocks;
b) Loosen the cylinder cover main bolts;
c) Before disassembling the cylinder head, ensure that the fuel injectors are disassembled,
otherwise the fuel injector nozzle will be easily damaged during the placement of
cylinder head;
d) Disassemble the cylinder head and place the disassembled cylinder head on a paper
board to avoid wearing upper surface of combustion chamber and other sealing
surfaces. If the more than one cylinder heads aredisassembled, mark the cylinder
heads with cylinder numbers for problem analysis;
e) Disassemble the cylinder head gasket. And mark the cylinder numbers on the cylinder
head gaskets for problem analysis;
f) Check and replace the cylinder head auxiliary bolts if necessary;
g) Dismantle the intake and exhaust valves by referring to Instructions for Dismantling
of Valve Mechanism;
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Industrial 6M33 Series Diesel Engine Service Manual

h) Disassemble the valve stem sealing sleeve by using the special tooling or use pliers to
clamp the outer wall of valve stem sealing sleeve and rotate upward to lift out the
valve stem sealing sleeve.
3) Inspection and Maintenance
a) Cylinder head
 Before dismantling of the cylinder head, first inspect whether there is water
leakage, oil leakage, gas leakage and other abnormal phenomena, so as to accurately locate
position where the problem occurs, and accurately analyze the problem.
 Clean the cylinder head, and clean the surface of the combustion chamber, valve
seat, intake and exhaust valves, intake and exhaust ports, and remove the carbon deposit
and mucilage, as well as inspect surface conditions.
b) Appearance inspection
 Inspect discoloration and crack of the cylinder head carefully, and in case of crack,
carry out penetrant inspection.
c) Valve sinkage
 The valve sinkage is the vertical distance from the bottom surface of the valve to
the bottom surface of the cylinder head, and the difference between the valve sinkage
measurement value and the required value can reflect the wear of the valve and valve
seat. It is possible to use depth micrometer to measure the valve sinkage as shown in
Figure 4-6;

Figure 4-6 Depth Micrometer

 For the required valve sinkage value, refer to the Table 4-3, and if the valve
singkage exceeds the permissible range, it is required to replace the cylinder head with
a new one to ensure reliability of the engine. If the valve sinkage does not exceed the
permissible value, dismantle the valve for inspection and then inspect the sealing
surface of the valve seat ring. Check whether there is apparent wear and abnormal

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Industrial 6M33 Series Diesel Engine Service Manual

damage to the valve and the sealing surface of the valve seat ring.

Table 4-3 Required Valve Sinkage Values

Required Valve Sinkage Values
(mm)
Intake 0.6~1.1
Exhaust 1.2~1.7
d) Clearance between valve stem and valve guide
 The inside diameter of the valve guide is the contact surface between the valve
guide and the valve, and if the clearance between valve stem and valve guide exceeds
the permissible value due to wear, it will result in influence on guiding effect of the
valve, reducing reliability of the diesel engine operation. The inside diameter of the
valve guide can be measured by use of an inside micrometer, as shown in Figure 4-7.
Using an outside diameter micrometer, measure the outside diameter of the valve guide.
The permissible range is (0.035~0.065)mm for the clearance between intake valve stem
and valve guide and is (0.055~0.085)mm for the clearance between exhaust valve stem
and valve guide. If out of the permissible range, replace the cylinder head to ensure the
working reliability of the diesel engine.

Figure 4-7 Inside micrometer

e) Cylinder head gasket

 In case of gas leakage, water leakage, oil leakage and other problems at the
cylinder head gasket, it is required to inspect the cylinder head gasket and replace it
wherever necessary.
 Inspect whether there is visible damage to the cylinder head gasket and analyze
the cause. The cylinder head gasket should be replaced with a new one after being
dismantled.
f) Valve stem sealing sleeve
 Before disassembling, observe the rubber lip of valve stem sealing sleeve for
presence of damage. Once being disassembled, replace with new valve stem sealing
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Industrial 6M33 Series Diesel Engine Service Manual

sleeve.
g) Cylinder head bolt
 The cylinder head main bolt can be reused for at most three times.
4) Assembly
a) Install the cylinder head gasket;

Figure 4-8 Cylinder head gasket

 The cylinder head gasket can be used once only, and in case that it is returned for
repairing, it must be replaced with a new one;
 Wipe clean the top plane of cylinder block and place the cylinder head gasket as
per the corresponding pin holes;
 Inspect whether the cylinder head gasket is assembled properly.
b) Attach the cylinder head gasket and then install the cylinder head to the cylinder
block;
 Wipe clean the cylinder head carefully and ensure that there is no dust, debris,
sand and other contaminants, and then further wipe clean the bottom surface of the
cylinder head;
 Inspect whether there is foreign bodies in the cylinder, and the top surface of
cylinder head gasket is clean;
 Use the guide rods to screw them into the cylinder head bolt holes;
 The cylinder head gasket shall be free of distortion, deformation, and damage.
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Industrial 6M33 Series Diesel Engine Service Manual

c) Install the cylinder head main bolts loosely. Apply an appropriate amount of
lubricating oil to the threads and support faces of cylinder head main bolts.
d) Add the clamping blocks and circular washers, loosely install the cylinder head
secondary bolts, and assemble end plates on two ends of cylinder block;
e) Apply an appropriate amount of lubricating oil to the threads and support faces of
cylinder head secondary bolts;
f) Tighten the cylinder head main and secondary bolts in five rounds:
①For the 1st round: Pre-tighten the main bolts in the numerical sequence with the torque
of 80N.m; then pre-tighten the secondary bolts in the alphabetic sequence (A-->G，
H-->N) with the torque of 80N.m. Before pre-tightening the secondary bolts, be sure to
loosen them, which have already been slightly tightened manually;
②For the 2nd round: Tighten the main bolts by 60º in the numerical sequence; then tighten
the secondary bolts by 60º in the alphabetic sequence;
③For the 3rd round: Tighten the main bolts by 60º in the numerical sequence; then tighten
the secondary bolts by 60º in the alphabetic sequence;
④For the 4th round: Tighten the secondary bolts by 60º in the alphabetic sequence;
⑤For the 5th round: Tighten the secondary bolts by 30º in the alphabetic sequence.

Figure 4-9 Tightening sequence for cylinder head main bolts

Figure 4-10 Tightening sequence for cylinder head auxiliary bolts

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Industrial 6M33 Series Diesel Engine Service Manual

g) Assemble the sealing bush of the valve stem on the valve guide;

Figure 4-11 Valve stem sealing sleeve

 The valve stem sealing sleeve can be only used once. Make sure to replace with
new one in case of repair;
 Check the valve stem sealing sleeve for presence of defect and check valve stem
sealing sleeve spring for intactness;
 Install valve stem sealing sleeve on valve guide;
 Apply lubricating oil to the lip of valve stem sealing sleeve;
 Use valve stem sealing sleeve assembling tool and rubber hammer to install the
valve stem sealing sleeve.

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4.3 Engine Block Group

4.3.1 Disassembly, Inspection, Maintenance and Assembly of Engine Block

1) Exploded view

Figure 4-12 Exploded View of Engine Bloock

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Industrial 6M33 Series Diesel Engine Service Manual

Figure 4-13 Exploded View of Engine Block

2) Detailed list of parts

The names and quantities of the parts of engine block are shown in Table 4-4:

Table 4-4 Detailed list of parts of the engine block

Position Designation Quantigy

1 Engine Block 1
2 Cylinder Liner 6
3 O-ring 12
4 O-ring 6
5 O-ring 6
6 Main Bearing Cap 6
7 Thrust Bearing Cap 1
8 Main Bearing Bolt 14
9 Camshaft bush 1
10 Camshaft bush 6
11 Bowl Plug 5
12 Parallel Pin 1
13 φ10 Pulling Rivet 5
14 Piston Nozzle Set 6
15 Parallel Pin 16
16 Bowl Plug 4
17 Handhole Cover 1

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Industrial 6M33 Series Diesel Engine Service Manual

Position Designation Quantigy

18 Gasket 1
19 Oil Filling Tube 1
20 Hexagon Head Bolt 2
21 Plain Washer 1
22 Rivet 1
23 Oil Filling Plug 1
24 Lowerthrust plate 1
25 Upperthrust plate 1
26 Handle Cover Gasket 3
27 Hexagon Head Bolt 39
28 Handhole Cover 1
29 Handle Cover Gasket 1
30 Handhole Cover 2
31 Main Bearing Upper Shell 7
32 Main Bearing Lower Shell 7
33 Sensor Seat 1
34 O-ring 1
35 Hexagon Screw Plug 1
36 Screw Plug 1
Hexagon Socket Head Cap
37 Screw
4

3) Disassembly
The disassembly of the engine block group is in the reverse order of assembly.
4) Inspection and Maintenance
a) Check the machined surfaces of the engine block for burrs, oil stain, and
collision-caused damage. If any, remove them using an oilstone, abrasive paper or
towel.
b) Check the oil passages, water passages, and cavities in the engine block for metal
chips, burrs, and flashes. If any, remove them using an air blower gun or wire brush.
c) Try installing the tappet. Check the roughness and chamfer of the tappet hole. Check
the tappet hole for burrs and flashes.
d) Check the chamfer of the cylinder liner hole for collision-caused damage.
e) No impression may be found in any seal surface.
5) Assembly
a) Apply evenly Loctite 277 threadlocker to the mating face of the cup plug. Install the
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Industrial 6M33 Series Diesel Engine Service Manual

cup plug to the right side, front end, and rear end of the cylinder block. Remove the
surplus threadlocker from the cup plug;
b) Using the expander, expand the corresponding locations in the cylinder block, then put
gently the thrust main bearing cap and other main bearing caps in place. A dowel pin
is used for positioning the thrust bearing cap. Before installing the thrust bearing cap,
install the thrust plate.
c) Apply a proper amount of lubricating oil to the threads and support surfaces of the
fourteen M24 main bearing bolts. First pre-tighten these bolts. Then tighten them in
the sequence (A~N). Two tightening methods may be used.
 Manual tightening
1st round: Pre-tighten the main bearing bolts in the sequence to the torque of
(180±10) Nm;
2nd round: Tighten these bolts by 60º in the sequence;
3rd round: Tighten these bolts by 60º in the sequence.
 Tightening with a pneumatic impact wrench
1st round: Pre-tighten the main bearing bolts in the sequence to the torque of
(180±5) Nm;
2nd round: Tighten these bolts by 120º in the sequence.

Front
end

Figure 4-14 Schematic Diagram of Engine Block

d) Tap the parallelpin into the pin hole in the engine block. Align the pin hole in the
piston cooling nozzle with the parallel pin. Tighten the hollow bolt to the torque of 45
Nm.
6) Torque specification
The bolts except for those important ones shall be tightened according to the general
tightening specification.
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4.3.2 Disassembly, Inspection, Maintenance and Assembly of Flywheel Cover

1) Exploded view

Figure 4-15 Exploded View of Flywheel Cover

2) Detailed list of parts

The names and quantities of the parts of flywheel cover are shown in Table 4-5:

Table 4-5 Detailed list of parts of the flywheel housing

Position Designation Quantity

1 Flywheel Housing 1
2 Timing Gear chamber 1
3 Cover Plate 1
4 Cover Plate 1
5 Hexagon Head Bolt 3
6 Hexagon Head Bolt 3
7 Rear Oil Seal 1
Flywheel Housing Coupling
8 Ring
1

9 Hexagon Head Bolt 10

10 Hexagon Head Bolt 2
11 Hexagon Head Bolt 8
12 Hexagon Head Bolt 6
13 Hexagon Flange Bolt 4
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Industrial 6M33 Series Diesel Engine Service Manual

Position Designation Quantity

14 Hexagon Flange Bolt 6

15 Hexagon Head Bolt 3
16 Hexagon Flange Bolt 6
17 Washer 1
18 Hexagon Screw Plug 1
19 Parallel Pin 4
20 Hexagon Flange Bolt 2
21 Indicator 1
Hexagon Socket Head Cap
22 Screw
2

23 Handhole Cover Plate 1

Hexagon Socket Head Cap
24 Screw
2

25 Gasket 1

3) Disassembly
The removal of the flywheel cover is in the reverse order of installation.
4) Inspection and Maintenance
a) Check for completeness of parts against the table of parts.
b) Check the statuses of flywheel housing, engine block, and timing gear chamber and
ensure that all junction surfaces are free of burrs, oil dirt, and impact damages.
5) Assembly
a) Clean and degrease the mating faces of the timing gear chamber and flywheel housing.
Apply silicone sealant to the mating face of the timing gear chamber.
Strike the parallel pin into the engine body and mount the flywheel housing onto the
timing gear chamberby using the overhead crane. Apply Loctite 242 threadlocker to the
threads of the eight M12×120 bolts and the six M12×85 bolts. To fix the flywheel
housing to the timing gear chamber, tighten these bolts in the sequence as shown in
Figure 4-16 to the torque of (120±10)Nm (for flanged hex bolts) or (105±10) Nm (for
hex bolts). After the proper tightening, add the paint sealing for the bolts.

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Industrial 6M33 Series Diesel Engine Service Manual

Figure 4-16 Sequence for Tightening the Flywheel Housing Bolts

b) Apply a proper amount of lubricating oil to the mating faces of the front oil seal and
the crankshaft timing gear. Using the special tool, press the oil seal onto the crankshaft
timing gear. The axial distance from the oil seal to the inner face of the flywheel
housing shall be 3mm.

4.3.3 Disassembly, Inspection, Maintenance and Assembly of Front End Cover

1) Exploded view

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Industrial 6M33 Series Diesel Engine Service Manual

Figure 4-17 Exploded View of Front End Cover

2) Detailed list of parts

The names and quantities of the parts of front end cover are shown in Table 4-6:

Table 4-6 Detailed list of parts of the front end cover

Position Designation Quantity

1 Front cap 1
4 Parallel pin 2
3 Front oil seal 1
2 Hexagon head bolt 14

3) Disassembly
The removal of the front end cover is in the reverse order of installation.
4) Inspection and Maintenance
a) Check that the mating faces of the cylinder block and the oil pan are clean without
grease or impact damage.
5) Assembly
a) Strike the dowel pin into the mating face of the engine block;
b) Apply evenly silicone sealant onto the front end cover;
c) Mount the front end cover onto the engine body by using overhead crane. Apply a
little Loctite 242 threadlocker to the threads of the bolt. Tighten the bolts.

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Industrial 6M33 Series Diesel Engine Service Manual

4.4 Crank and Connecting Rod Mechanism

4.4.1 Disassembly, Inspection, Maintenance and Assembly of Crank and Connecting

Rod Mechanism

1) Exploded view

1. Engine block
2. Crankshaft assembly
3. Main bearing shell
4. Main bearing cap
5. Main bearing bolt
6. Piston and
connecting rod
7. Crankshaft timing
gear
8. Parallel pin
9. Flywheel housing
10. Flywheel assembly
11. Flywheel bolt
12. Oil pump gear
13. Front end cover
14. Vibration damper
bolt
15. Vibration damper
16. Pulley
17. Pulley bolt

Figure 4-18 Exploded View of Crank and Connecting Rod Mechanism

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Industrial 6M33 Series Diesel Engine Service Manual

18. Trapezoidal-barrel-face piston

ring
19. Twist-taper-face piston ring
20. Coil spring-loaded oil ring
21. Piston
22. Circlip
23. Piston pin
24. Connecting rod shank
25. Connecting rod upper bearing
shell
26. Connecting rod lower bearing
shell
27. Connecting rod cap
28. Connecting rod bolt
29. Parallel pin

Figure 4-19 Exploded View of Piston and Connecting Rod

2) Preparation before removal

 Tools: Torque wrench, automatic tightening machine, overhead crane, guide stud,
and long nose pliers
 Preparations before disassembling:
a) Remove the belt before removing the pulley (16) and the vibration damper (15);
b) Remove the flywheel housing (9), front end cover (13), main bearing cap (4), and
the piston and connecting rod (6) before removing the crankshaft assembly (2).
3) Disassembly
a) Using the torque wrench, remove the pulley bolts (17). Remove the pulley assembly.
Remove the vibration damper bolts (14), then the vibration damper (15).
b) Align the automatic tightening machine with the flywheel bolts (11). Start the
automatic tightening machine to tighten the flywheel bolts (11). Screw the guide stud
into the threaded hole at the rear end of the crankshaft assembly (2). Screw two M12
bolts into two holes in the flywheel bolt circle, with the two holes just opposite to each
other at both ends of the diameter of flywheel bolt circle. Draw the flywheel assembly
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Industrial 6M33 Series Diesel Engine Service Manual

out of the flywheel housing (9). Attach the slings of the overhead crane to the two
M12 bolts. Using the overhead crane, remove the flywheel. Remove the guide stud.
c) After removal of the flywheel housing (9), remove the crankshaft timing gear (7).
Remove the parallel pin (8).
d) Using the torque wrench or tightening machine, remove the connecting rod bolts (28)
from the observation hole in the engine block. Remove the connecting rod caps (27).
Draw the piston group (18, 19, 20, 21, 22, and 23) together with the connecting rod
shank (24) out of the cylinder liner. Remove the upper and lower bearing shells (25,
and 26) of the connecting rod.
e) Using the long nose pliers, remove the internal circlip (22) from the piston (21).
Remove the piston pin (23) and the connecting rod shank (24). Using the piston ring
spreader, remove the trapezoidal-barrel-face piston ring (18), twist-taper-face piston
ring (19), and coil-spring-loaded piston ring (20);
f) Turn the engine block upside down. Remove the main bearing cap (4) and main
bearing lower shell (3). Using the overhead crane, liftand move the crankshaft
assembly (2). Remove the main bearing upper shell (3).
4) Inspection and Maintenance
a) Apply lubricating oil to the flanged faces of the flywheel bolt. Tighten the flywheel
bolts in the sequence as shown in Figure 4-20:
 Manual tightening:
Tighten the bolts in three rounds: 1st round, to the torque of 80Nm; 2nd round, to the
torque of 300Nm, and 3rd round, to the torque of (600±50)Nm.
 Usethe tightening machine:
First, slightly tighten the bolts manually. Then tighten the bolts, using the tightening
machine in two rounds: 1st round, to the torque of 300Nm, and 2nd round, to the
torque of (600±25)Nm. Finally, apply paint to the bolts.

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Industrial 6M33 Series Diesel Engine Service Manual

Figure 4-20 Flywheel Bolts Tightening Sequence

b) Apply lubricating oil to the heads of the crankshaft pulley bolts. Tighten the bolts in a
diagonal sequence in two rounds: 1st round, to the torque of 80Nm, and 2nd round, to
the torque of (300±20)Nm.
c) Apply lubricating oil to the heads of the vibration damper bolts. Tighten the bolts in a
diagonal sequence in two rounds: 1st round, to the torque of 80Nm, and 2nd round, to
the torque of (140±10)Nm.
d) Apply lubricating oil to the threads and support surfaces of the connecting rod bolts:
 Manual tightening:
Tighten the bolts in three rounds: 1st round, to the torque of 70Nm; 2nd round, to the
torque of 200Nm, and 3rd round, to the torque of (350±30) Nm.
 Use the tightening machine:
First, slightly tighten the bolts manually. Then tighten the bolts, using the tightening
machine, in two rounds: 1st round, to the torque of 200Nm, and 2nd round, to the
torque of (350±15)Nm.
Finally, apply paint to the bolts. These bolts can be reused for at most three times.
5) Assembly
a) Heat the oil pump gear (12). Place it onto thefront end journal of the crankshaft
assembly (2). Place the parallel pin into the pin hole at the rear end of the crankshaft.
Turn the engine body upside down. Clean the main bearing holes. Place the main
bearing shells (3) in these holes. Apply a proper amount of lubricating oil to the main
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Industrial 6M33 Series Diesel Engine Service Manual

bearing shells. Using the overhead crane, move the crankshaft assembly (2) into the
main bearing holes in the engine block (1). Install the main bearing caps (4) according
to the requirements;
b) Using the piston ring spreader, install the trapezoidal-barrel-face piston ring (18),
twist-taper-face piston ring (19), and coil-spring-loaded piston ring (20) to the pistons
(21). Place the connecting rod shank into the inner chamber of the piston. Insert the
piston pin (23) through the piston pin hole and connecting rod bushing, and fix the
piston pin by using circlips (22);
c) Push the already-assembled piston group (18, 19, 20, 21, 22, and 23) together with the
connecting rod shank (24) into the cylinder liner. Using the torque wrench or
tightening machine, tighten the connecting rod bolts (28) according to the
requirements;
d) Clean the crankshaft timing gear (7) andinstall it onto the rear end of the crankshaft
with aligning the parallel pin (8);
e) After installation of the flywheel housing (9), screw the guide stud into the threaded
hole at the rear end of the crankshaft. Using the overhead crane, align the pin hole in
the flywheel with the parallel pin (8), hoist the flywheel andpush the flywheel onto the
crankshaft assembly (2) with the help of the guide stud. Remove the guide stud, and
tighten the flywheel bolts (11) by using the tightening machine;
f) After installation of the front end cover, tighten the vibration damper bolts (14), for
fixing the vibration damper (15) to the crankshaft pulley (16); and tighten the
crankshaft pulley bolts (17), for fixing the crankshaft pulley (16) to the crankshaft
assembly (2).

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4.5 Valve mechanism

4.5.1 Disassembly, Inspection, Maintenance and Assembly of Valve Train

1) Exploded view
Intake rocker arm Exhaust rocker arm
assembly assembly
Sleeve
Rocker arm shaft
Hexagon bolt Hexagon bolt
Rocker arm Rocker arm support
support
Valve bridge subassembly Valve bridge base
Upper retainer for the valve spring Valve collet
Outer valve spring Inner valve spring
Cylinder head Lower retainer for the valve spring

Exhaust valve Intermediate gear shaft

Pushrod Intermediate gear subassembly
Tappet Camshaft assembly Spacer
Hexagon bolt Hexagon bolt

Engine block Hexagon bolt

Hexagon
bolt Intermediate gear subassembly
Camshaft timing gear
Thrust plate

Figure 4-21 Exploded View of Valve Train

2) Disassembly
a) Remove the rocker arm shaft support, rocker arm, and rocker arm shaft. For
details, refer to section 4.4.3;
b) Remove the intake and exhaust valves. For details, refer to section 4.4.5;
c) Remove the tappet and push rod. For details, refer to section 4.4.4;
d) Remove the gear train. For details, refer to section 4.4.6.
e) Remove the camshaft. For details, refer to section 4.4.2;
3) Assembly
a) Install the camshaft. For details, refer to section 4.4.2;
b) Install the gear train. For details, refer to section 4.4.6;
c) Install the tappet and push rod. For details, refer to section 4.4.4;
d) Install the intake and exhaust valves. For details, refer to section 4.4.5;
e) Install the rocker arm support, rocker arm, and rocker arm shaft. For details,
refer to section 4.4.3.

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4.5.2 Disassembly, Inspection, Maintenance and Assembly of Camshaft

1) Exploded view

Camshaft assembly

Hexagon bolt

Hexagon bolt

Camshaft timing gear

Thrust plate

Figure 4-22 Exploded View of Camshaft

2) Disassembly
a) Turn the camshaft, and inspect whether the camshaft and timing gear are
flexible, without blockage;
b) Use a dial indicator to inspect the camshaft for axial float;
c) Check the backlash between the camshaft timing gear tooth and the mating gear
tooth;
d) On the working bench for installation and dismantling of the engine, turn the
crankshaft to enable the camshaft timing gear to be at the top dead center of the
1st cylinder. Inspect whether the hexagon bolts of the camshaft are loosened.
Dismantle the hexagon bolts of the timing gear and camshaft timing gear;
e) Dismantle the hexagon bolts of the thrust plate for the camshaft, dismantle the
thrust plate, and lightly remove the camshaft. It is required to protect the

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Industrial 6M33 Series Diesel Engine Service Manual
camshaft bearing shell from being impacted.
3) Inspection and Maintenance
a) Inspect whether the cam surface in contact with the tappet is worn or not, and
whether the main bearing journal is seized or worn;
b) Inspect whether the hexagon bolts fixing the timing gear is bent or deformed,
and tooth broken of the camshaft timing gear occurs or the tooth surface is worn
seriously.
4) Assembly
a) After dismantling, inspect the camshaft and timing gear. If wear occurs or a big
deviation in other parameters is produced, it is required to repair them, or have
them replaced with a new camshaft and/ or timing gear;
b) Clean the camshaft bore, inspect the camshaft bushing for damages due to
impacting. Repaired part is not allowed to use. Apply an appropriate amount of
lubricating oil into the camshaft bushing by an oiler, without any oil flow or
drip;
c) Install the camshaft, wipe clean the camshaft, check the camshaft for collision
damage, connect the camshaft and camshaft guide sleeve together, and apply an
appropriate amount of lubricating oil. Insert carefully the camshaft and the
camshaft guide through the camshaft bushing. Be sure not to cause damage to
the camshaft bushing;
d) Place the camshaft thrust plate at the rear end of the engine. The grade 10.9
M8×20 hex bolts shall be used to fix the thrust plate. Apply Loctite 242
threadlocker to the heads of the bolts. Tighten the bolts to the torque of 32Nm;
e) Note that the axial clearance between the thrust plate and camshaft shall be
uniform. Check that the camshaft can rotate smoothly without sticking.

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4.5.3 Disassembly, Inspection, Maintenance and Assembly of Rocker Arm and

Rocker Arm Shaft

1) Exploded view
Exhaust rocker Intake rocker
arm assembly Socket head cap screw
arm assembly
Socket head cap screw Rocker arm
shaft
Sleeve

Rocker arm
support
Rocker arm
support

Valve bridge
Valve bridge subassembly
subassembly

Cylinder
head
Valve bridge base

Figure 4-23 Exploded View of Rocker Arm and Rocker arm Shaft
2) Disassembly
a) Turn the crankshaft, and observe whether the rocker arm is rotated flexibly;
b) Measure clearance of individual valves, and inspect change in clearance of the
valves;
c) If the rocker arm rotates inflexible, or the valve clearance varies greatly, loosen
the socket head cap screw, and carefully remove the rocker arm support, rocker
arm, and the sleeve. Make marks on them to avoid confusion with those of other
valves.
3) Inspection and Maintenance
a) Clean the rocker arm, observe appearance of the rocker arm, and determine
whether there is crack and other defects;
b) Inspect whether the rocker arm hole is worn or abraded, and measure its
diameter;
c) Inspect the rocker arm adjusting screw, and determine whether the arc surface
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Industrial 6M33 Series Diesel Engine Service Manual
ofthe other side of the rocker arm is worn;
d) Check the oil passages for blockage;
e) Measure diameters of the rocker arm hole and rocker arm shaft, and then
calculate their fit clearance.
4) Assembly
a) Inspect whether the parts to be assembled are clean, and free from collision
damages, scratches and rust;
b) Install the valves. See the relative section. Slightly tighten manually the four
M10×35 socket head cap screws, for fixing the valve bridge base to the cylinder
head. Apply a proper amount of lubricating oil to the valve bridge base. Dripping
of lubricating oil shall not be permitted;
c) Clean the intake rocker arm assembly, exhaust rocker arm assembly, rocker arm
support, rocker arm shaft, sleeve, and socket head cap screw. Install rivets at
both ends of the rocker arm shaft. Apply a proper amount of lubricating oil to the
mating face of the rocker arm shaft. Dripping of lubricating oil shall not be
permitted;
d) Insert the rocker arm shaft through the intake rocker arm, sleeve, and exhaust
rocker arm. Then place them on the rocker arm supports. Align the gap of the
rocker arm shaft with the threaded holes in the rocker arm supports. The bosses
of the rocker arm supports shall be placed opposite to each other;
e) Insert the four M10×75 socket head cap screws into the threaded holes in the
rocker arm supports;
f) Apply Loctite 242 threadlocker to the threads of the bolts for the valve bridge
base. Tighten the bolts. Apply lubricating oil to the valve bridges. Install the
valve bridges to the valve bridge base. Check that the valve bridges can move
smoothly in the valve bridge base without sticking. In the case of any sticking,
replace the valve bridges.
g) Check that the valve bridges align with the valves. In the case of any
misalignment, adjust the valve bridge base. Finally, tighten the bolts for the
valve bridge base;
h) Slightly tighten manually the socket head cap screws for fixing the rocker arm
shaft subassembly to the cylinder head;
i) Apply Loctite 242 threadlocker to the threads of the screws for fixing the rocker
arm shaft supports. Tighten the screws to the torque of 54Nm. The axial

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clearance of the rocker arm shaft shall be 0.4 to 0.6mm.
j) Check and adjust the clearances of intake and exhaust valves:
① Turn to the top dead center of each cylinder and adjust the valve clearance.
Specified cold valve clearances: (0.3±0.03)mm for the intake valves, and
(0.4±0.03) mm for the exhaust valves;
② Sequence for adjusting valve clearances: With the piston of the 1st cylinder
staying at top dead center, adjust the intake valve clearances of the 1st, 2nd
and 4th cylinders, and the exhaust valve clearances of the 1st, 3rd and 5th
cylinders. Rotate the crankshaft by 360º, and then adjust the remaining valve
clearances
③ Check the valve timing of the 1st cylinder and record the result.
Valve timing of 6M33 series diesel engine:
Intake valve opens: (34±5)º before top dead center.
Intake valve closed: (40±5)º after bottom dead center.
Exhaust valve opens: (61±5)º before bottom dead center.
Exhaust valve closed: (27±5)º after top dead center.

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4.5.4 Disassembly, Inspection, Maintenance and Assembly of Tappet and Push

Rod

1) Exploded view

Cylinder head Push rod

Tappet

Engine block

Figure 4-24 Exploded View of Tappet and Push Rod

2) Disassembly
a) After the rocker arm and rocker arm shaft have been dismantled, directly remove
the pushrod and tappet, and put them aside in sequence;
3) Inspection and Maintenance
a) Clean the push rod and tappet;
b) Check the oil passages of the tappet and push rod for blockage;
c) Check the push rods for bending and excessive wear;
d) Check the ball end and socket end of the push rod for excessive wear;
e) Check the surface and end face of the tappet for excessive wear;
f) Check the mating socket of the tappet for excessive wear.
4) Assembly
a) Check the tappet and pushrod, and replace them with a new one if necessary.
Before assembling of the tappet, clean it with compressed air, and inspect
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whether the oil hole is smooth;
b) Evenly apply some clean lubricating oil onto the engine block tappet hole and
the cylindrical surface of the valve tappet;
c) Lightly put the tappet into the tappet hole that the tappet can be returned freely
in the tappet hole by hand, and the resistance force should be even;
d) Fix the rocker arm shaft support to the cylinder head. Check the push rod for dirt
and welding defect;
e) Apply some clean lubricating oil onto the pushrod in such a manner that the ball
end has adequate lubricating oil.
f) Assemble the pushrod, and lightly put the pushrod through the cylinder head and
into the tappet socket end.

4.5.5 Disassembly, Inspection, Maintenance and Assembly of Valve

Upper retainer for

the valve spring Valve collet

Inner valve spring Outer valve spring

Lower retainer for
Cylinder head the valve spring

Intake valve Exhaust valve

Figure 4-25 Exploded View of Valve

1) Disassembly
a) Using the valve spring compressor or an overheadvalve spring pincer or another
equivalent tool, compress squarely the valve spring,remove the valve collet.
Remove the upper retainer for the valve spring, and the inner and outer valve
springs;
b) Remove the valve from the cylinder head.

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2) Inspection and Maintenance

a) Inspect whether the valve stem and valve stem end surface are worn;
b) Inspect whether the valve cone is worn or damaged;
c) Inspect whether there is carbon deposit at the valve cone and arc surface;
d) If the valve is worn or seriously carbon-deposited or has other bad phenomena, it
is required to change the used valve with a new one.
3) Assembly
a) Apply some molybdenum disulfide paste on the intake and exhaust valve stems
evenly, and assemble the intake and exhaust valves into the cylinder head,
ensuring that the intake and exhaust valves can slide in the guide without
blockage;
b) Install the lower retainer for the valve spring. Check that the valve spring come
in close contact with the lower retainer. If necessary, replace the spring or
retainer. It is not permitted to rudely strike the springs into place;
c) Install the seal sleeve of valve stem, the valve spring, and the upper retainer for
the valve spring;
d) Using the valve collet installer, install the valve collet;
e) After installation of the valve collet, tap the intake and exhaust valves using a
rubber hammer so that the valve collets come in close contact with the upper
retainers for the valve springs. If the valve collet fail to come in contact with the
upper retainer for the valve spring, identify the cause for troubleshooting.

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4.5.6 Disassembly, Inspection, Maintenance and Assembly of Gear Train

1) Exploded view

1. Crankshaft timing gear

2. Camshaft timing gear
3. Hexagon flange bolt
4. Intermediate gear shaft
5. Intermediate small gear
6. Spacer a
7. Hexagon flange bolt
8. Idler gear shaft
9. Idler gear
10. Spacer b
11. Hexagon flange bolt
12. Fuel injection pump
gear
13. Parallel pin
14. Intermediate big gear
15. Hexagon flange bolt
16. Pressure plate
17. Hexagon flange bolt

Figure 4-26 Exploded View of Gear System

2) Disassembly
a) Check the mounting marks and ensure that the bolts are installed to their original
locations. Manually rotate the flywheel until the piston of the 1st cylinder
reaches top dead center. Check if the timing mark is correct.
b) Loosen the flanged hex bolts (15). Remove the intermediate big gear (14).
c) Remove the crankshaft timing gear (1);
d) Loosen the hex bolts (17). Remove the pressure plate (16) and
fuelinjectionpump gear (12);
e) Loosen the flanged hex bolts (3). Remove the camshaft timing gear (2);
f) Loosen the flanged hex bolts (7). Remove the spacer a (6), fuelinjectionpump
idler gear (9) and fuelinjectionpump idler-gear shaft (8);
g) Loosen the flanged hex bolts (11). Remove the spacer b (10), intermediate small
gear (5), and intermediate gear shaft (4).
3) Inspection and Maintenance
a) Inspect whether the threads of the mounting bolts are in good condition;

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b) Inspect the individual gears for tooth surface spalling or tooth flank breakage,
and the load bearing surface of the bolt is crushed, and the tapped holes or
through holes on the gear are deformed;
c) Check the intermediate gear shaft and intermediate gear bushing for excessive
wear. Check their oil orifices for clogging.
4) Assembly
a) Before the assembly, check that all the parts are free of manufacturing and
functional defects including damage;
b) Install the intermediate gear shaft (4) to the engine block. Install the intermediate
small gear (5). Tighten the flanged hex bolts (7) for the spacer a (6) to the torque
of (70±5)Nm. Manually rotate the gear to check whether it can rotate smoothly;
c) Rotate the intermediate small gear (5) so that one of its two marked teeth
moving to the lower left and the other marked tooth moving to the lower right.
Install the idlergear shaft (8) to the engine block. Fix the idler gear (9), and
spacer b (10) to the oil idlergear shaft (8) using the flanged hex bolts (11), which
shall be tightened to the torque of (95±5)Nm. Note: At the moment, two marked
teeth of the idler gear move to the upper left and another two marked teeth move
to the upper right, and the lower right marked tooth of the intermediate small
gear lies in the middle of the upper left two teeth of the idler gear. Check
whether the two gears rotate smoothly;
d) Rotate the intermediate small gear (5) to the state before installing idler gear.
Position the camshaft timing gear (2) using the dowel pin. Fix the camshaft
timing gear to the camshaft using the flanged hex bolts (3), which shall be
tightened to the torque of (65±5)Nm. Note: At the moment, the lower left
marked tooth of the intermediate small gear lies in the middle of the two marked
teeth of the camshaft timing gear, and the pin hole in the camshaft timing gear
becomes horizontal;
e) The installation of the fuel injection pump shall be completed. Fix the
fuelinjectionpump gear (12) and pressure plate (16) to the fuel injection pump
using the flanged hex bolts (17), which shall be tightened to the torque of
128Nm. Note: At the moment, the lower left marked tooth of the intermediate
small gear lies in the middle of the upper right two teeth of the idler gear, and the
marks on the gear, pressure plate and fuelinjectionpump hub align with each
other. The arrangement of rear gear trainis shown in Figure 4-27;

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Figure 4-27 Arrangement of Rear Gears

f) Manually rotate the flywheel until the piston of the 1st cylinder reaches top dead
center. Referring to the dowel pin already installed to the crankshaft, install the
crankshaft timing gear (1). At the moment, the pin hole in the crankshaft timing
gear (1) lies at the 12 o’clock position;
g) Install the dowel pin to the intermediate small gear (5) that has already been
installed. Referring to the dowel pin, fix the intermediate big gear (14) to the
intermediate small gear (5) using the flanged hex bolts (15), which shall be
tightened to the torque of (30±5)Nm. Note: At the moment, the marked tooth of
the intermediate big gear lies in the middle of the two marked teeth of the
crankshaft timing gear.

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4.6 Intake and exhaust system

4.6.1 Removal and Installation of the Intake and Exhaust System

1) Exploded view
Intake manifold Air filter

Exhaust manifold
Turbocharger

Figure 4-28 Exploded View of Intake and Exhaust System

2) Disassembly
a) Loosen the fixing bolts and the hose clamps of the air filter. Remove the air filter and
its hose;
b) Loosen other hose clamps. Remove the outlet joint pipe from the turbocharger
compressor;
c) Loosen the exhaust manifold heat shield fixing bolts. Remove the exhaust manifold
heat shield assembly;
d) Loosen the inlet and outlet oil pipes fixing bolts of the turbocharger. Remove the inlet
and outlet oil pipes and their gaskets;
e) Loosen the exhaust tailpipe fixing bolts and the turbocharger fixing bolts. Remove the
turbocharger;
f) Loosen the exhaust manifold fixing bolts. Remove the exhaust manifold and its gasket.
For details, refer to section 4.6.3 “Disassembly, Inspection, Maintenance and
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Assembly of Exhaust Manifold”

g) Loosen the intake manifold fixing bolts. Remove the intake manifold and its gasket.
For details, refer to section 4.6.2 “Disassembly, Inspection, Maintenance and
Assembly of Intake Manifold”.
3) Assembly
The assembly procedure is in reverse order of the disassembly procedure.

4.6.2 Disassembly, Inspection, Maintenance and Assembly of Intake Manifold

1) Exploded view

Figure 4-29 Exploded View of Intake Pipe

2) Detailed list of parts

The names and quantities of the parts of intake manifold are shown in Table 4-7:

Table 4-7 Detailed list of parts of the intake manifold

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件数
序号 Pos 中文名称Designation 英文名称Designation
Quan.
1 进气管 Intake Manifold 1

2 进气管垫片 intake manifold gasket 6

3 平垫圈 Plain Washer 12
4 六角头螺栓 全螺纹 Hexagon Head Bolt Full Thread 12

5 进气接管垫片 Intake Connecting Pipe Gasket 3

6 进气管盖板 Intake Cover 1

7 弹簧垫圈 Spring Washer 8

8 内六角圆柱头螺钉 Hexagon Socket Head Cap Screw 4

9 加热器 Heater 1
10 进气接管 Intake Connecting Pipe 1

11 内六角圆柱头螺钉 Hexagon Socket Head Cap Screw 4

12 密封垫圈 Sealing Washer 1

13 螺塞 Screw plug 1

3) Disassembly
a) Loosen the socket head cap screws for the heater. Remove the heater and its intake
connectingpipe;
b) Loosen the socket head cap screws for the intake manifold cover. Remove the intake
cover and its gasket;
c) Loosen the intake manifold bolts in sequence, and remove the intake manifold and its
gasket.
4) Inspection and Maintenance
a) Check the intake manifold for welding defects. If necessary, replace it with a new one;
b) Check whether the intake manifold gasket is deformed, damaged or absence, and if
any, it is required to replace.
5) Assembly
a) The installation of intake manifold is in the reverse order of removal. The intake
manifold fixing bolts shall be tightened to the torque of 23 Nm.

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4.6.3 Disassembly, Inspection, Maintenance and Assembly of Exhaust Manifold

1) Exploded view

Figure 4-30 Exploded View of Exhaust Pipe

2) Detailed list of parts
The names and quantities of the parts of exhaust manifold are shown in Table 4-8:

Table 4-8 Detailed list of parts of the exhaust manifold

序号 Pos 中文名称Designation 英文名称Designation 件数Quan.

1 排气管 Exhaust Manifold 2

2 膨胀管 Expansion Pipe 2

3 中间排气歧管 Middle Exhaust Manifold 1

4 排气管衬垫 Exhaust Manifold Gasket 6

5 卡箍 Clamp 4
6 套筒 Sleeve 24

7 排气管螺栓 Exhaust Manifold Bolt 24

3) Disassembly
a) Loosen the clamps of the expansion joint of exhaust manifold;
b) Loosen the exhaust manifold fixing bolts. Remove the front and rear exhaust
manifolds and their gaskets;
c) Remove the expansion joint and the intermediate exhaust manifold and its gasket.
4) Inspection and Maintenance
a) Inspect whether the exhaust manifold is cracked or damaged, and the flange is
deformed, and if any, it is required to replace the exhaust manifold with a new one;
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b) Check the exhaust manifold flange for leakage, and replace if necessary;
c) Check whether the exhaust manifold gasket is deformed, damaged or absence, and if
any, it is required to replace;
d) Check the expansion joint and clamps for soot. If any, replace them with new ones.
5) Assembly
The installation of exhaustmanifold is in the reverse order of removal, and it should be
noticed during installation that:
a) Be sure to securely tighten the clamp for the expansion joint and exhaust manifold;
b) The exhaust manifold bolts should be applied with anti-seize sealant (molybdenum
disulfide), and tightened to a torque of (60±5) Nm, and the bolt can be re-used twice at
most.

4.6.4 Disassembly, Inspection, Maintenance and Assembly of Turbocharger System

1) Exploded view

Figure 4-31 Exploded View of Turbocharger System

2) Detailed list of parts

The names and quantities of the parts of turbocharger system are shown in Table 4-9:

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Table 4-9 Detailed list of parts of the turbocharger system

序号 Pos 中文名称Designation 英文名称Designation 件数Quan.

1 涡轮增压器 Turbocharger 1

2 增压器垫片 Turbocharger Gasket 1

3 双头螺柱 Double End Stud 4
4 2型全金属六角锁紧螺母 All-metal Hexagon Flange Locknut 4
5 涡轮增压器进油管垫片 Turbocharger Oil-inlet Pipe Gasket 1
6 增压器进油管组件 Turbocharger Oil-inlet Pipe Set 1
7 内六角圆柱头螺钉 Hexagon Socket Head Cap Screw 2
8 接头体 Connector 1

9 增压器进油管组件 Turbocharger Oil-inlet Pipe Set 1

10 管接头 Pipe Joint 1
11 卡箍 Clamp 3
12 六角法兰面螺栓 Hexagon Flange Bolt 3
13 增压器回油管垫片 Turbocharger Oil-outlet Pipe Gasket 1
14 增压器回油管组件 Turbocharger Oil-inlet Pipe Se 1
15 内六角圆柱头螺钉 Hexagon Socket Head Cap Screw 3

16 O型橡胶密封圈 O-ring 1
17 固定板 Fixed Plate 1
18 组合垫圈 Assembled Sealing Washer 1
19 增压器支架 Turbocharger Bracket 1
20 增压器支架 Turbocharger Bracket 1
21 六角头螺栓 Hexagon head bolt 4

22 六角法兰面螺栓 Hexagon Flange Bolt 2

23 全金属六角法兰锁紧螺母 All-metal Hexagon Flange Locknut 2
24 六角法兰面螺栓 Hexagon Flange Bolt 2

3) Disassembly
The disassembly procedure is in reverse order of assembly procedure.
4) Inspection and Maintenance
a) Inspect operation condition of the rotor
By lightly turning the air compressor impeller with hand, rotation of the impeller by more than
one turn indicates that it is in normal condition. If the impeller stops immediately, it indicates that
the bearing is worn abnormally or collision or jamming between the rotating part and the stationary
part occurs, it is required to analyze the causes and carry out troubleshooting.

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b) End playinspection of rotor

Enable the dial indicator probe to be against the compressor end, and push and pull the rotator
shaft axially with hand, and measure and record the difference indicated on the dial indicator, as
shown in Figure 4-32. The end play of rotor should be within 0.088mm~0.118mm, and in case of
exceeding this range, it indicates that the thrust bearing plate or thrust plate and bearing body are
worn, and it is required to analyze causes and eliminate the problem.

Figure 4-32 Diagram for measurement of axial clearance

c) Inspection of radial clearance of the compressor impeller

Press the compressor impeller with hand in radial direction, and use a plug gauge to measure
the minimum and maximum clearance between the compressor impeller and compressor scroll, as
shown in Figure 4-33. This value should be within 0.4mm~0.8mm, and in case of exceeding this
range, it is required to inspect the bearing, and eliminate the problem.
Note: The measurement should be carried out in cold state of the turbocharger.

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Figure 4-33 Diagram for measurement of radial clearance

d) Daily Maintenance：
 Inspect whether the connecting pipe between the turbocharger and the engine is
loosened or not, and if any, eliminate the problem;
 Inspect the turbocharger for gas or oil leakage, and if any, it is required to timely
eliminate the problem;
 Inspect whether the fastening screws of the turbocharger are loosened or not, and
if any, it is required to eliminate the problem in time;
 Inspect the air filter, and if the air filter has excessive dust accumulation, it
required to clean it in time.

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4.6.5 Disassembly, Inspection, Maintenance and Assembly of Air Filter System

1) Exploded view

Figure 4-34 Exploded View of Air Filter System

2) Detailed list of parts

The names and quantities of the parts of air filter system are shown in Table 4-10:

Table 4-10 Detailed list of parts of the air filter system

序号 Pos 中文名称Designation 英文名称Designation 件数Quan.

1 空滤器支架 Air Filter Bracket 1

2 空气滤清器 Air Filter 1

3 进气接管 Compressor Intake Pipe 1
4 进气接管 Connecting Pipe 1
5 气路连接胶管 Air Connecting Rubber 1

6 卡箍 Clamp 1
7 卡箍 Clamp 3
8 转接头 Hexagon Head Bolt，Full Thread 1

9 压差报警器 Air Filter Service Alarm Indicator 1

10 六角法兰面螺栓 Hexagon Head Bolt，Full Thread 4
11 2型全金属六角锁紧螺母 Nut 6

12 六角法兰面承面带齿螺栓 Hexagon Head Bolt，Full Thread 2

13 垫块 Pad 2
14 六角法兰面承面带齿螺栓 Hexagon Head Bolt，Full Thread 2

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3) Disassembly
The Disassembly procedure is in reverse order of assembly procedure.
4) Inspection and Maintenance
a) The maximum permissible intake resistance of diesel engine is 7kPa; Check the
maximum intake resistance only when the diesel engine is running at rated speed
under full load. When the intake resistance reaches the permissible limit, clean or
replace the filter element as per the manufacturer’s instructions.
b) Disassemble the filter element from the air filter and tap lightly the end face to fall off
the dust or blow backward (from inside out) by compressed air.
Caution:
 Do not damage the filter paper;
 Do not clean the filter paper with water or oil; or
 Do not tap and knock the filter element forcibly.
5) Assembly
a) Install the air filter bracket to the engine;
b) Install the air filter;
c) Connect the pipe between the intake manifold and air filter. Fix the pipe using clamps.

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4.7 Fuel system

4.7.1 Removal and Installation of Fuel System

1) Overall layout of fuel system

Figure 4-35 Overall layout of fuel system

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2) Exploded view

High-pressure fuel
pipe assembly
Fuel injector
assembly

Fuel injection pump

assembly

Low-pressure fuel
pipe assembly Shutting-down device
assembly
Fuel filter assembly

Figure 4-36 Exploded View of Fuel System

3) Disassembly
a) Remove the low-pressure fuel pipe;
b) Remove the high-pressure fuel pipe;
c) Remove the fuel injector;
d) Remove the fuel filter;
e) Remove the high-pressure fuel pump;
4) Assembly
The assembly procedure is in reverse order of disassembly procedure.

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4.7.2 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump

1) Exploded view

Fuel injection
pump

Hexagon flange
Hexagon flange bolt Rubber O-ring
bolt

Hollow bolt
Sealing washer
Fuel Plain Hexagon flange
Pressure
injection washer bolt
plate Lubricating oil pipe of
pump hub
fuel injection pump

Fuel Fuel Type 1 hexagon nut

Hexagon injection injection
Fuel injection pump
flange bolt pump Fuel injection
pump flange bracket support pump bracket

Figure 4-37 Exploded View of Fuel Injection Pump

2) Disassembly
a) Remove the flanged hex bolts forfixing fuel injection pump flange to the gear
chamber;
b) Remove the fuel injection pump and gear subassembly from the engine;
c) Remove the locking nut of the fuel injection pump;
d) Remove the flanged hex bolts for fuel injection pump body and fuel injection pump
flange;
e) Remove the fuel injection pump flange.
3) Inspection and Maintenance
a) The structure of fuel injection pump is shown in Figure 4-38. Manually rotate the
flywheel until the piston of the 1st cylinder reaches top dead center. At the moment,
the groove mark in the fuelinjectionpump gear and that in the fuelinjectionpump
flange shall align with each other.

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1—Inlet fuel pipe；2—High-pressure fuel outlet；3—Return fuel pipe joint；4—Speed

governor；5—Fuel delivery pump；6—Inlet oil pipe joint
Figure 4-38 Structure of Fuel Injection Pump

4) Assembly
a) Fix the fuel injection pump body, fuel injection pump flange and fuel injection pump
hub using the flanged hex bolts;
b) Install the fuel injection pump drive gear and pressure plate so that the mark on the
drive gear aligns with the groove mark in the pressure plate. The drive gear locking
nut M24×1.5 shall be tightened to the torque of (300~340)Nm;
c) Rotate the fuelinjectionpump gear so that the marks in the fuelinjectionpump drive
gear, fuel injection pump hub, pressure plate and fuel injection pump flange align with
each other as shown in Figure 4-39;

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Vertical
direction of
the engine

Mark in the fuel injection

pump flange
Mark in the
fuel-injection-pump
gear

Mark in the pressure plate

Mark in the fuel injection
pump hub

Figure 4-39 Marks of Fuel Injection Pump Flange

d) Manually rotate the flywheel until the piston of the 1st cylinder reaches top dead
center. To prevent the fuelinjectionpump drive gear from rotating during the
installation of alreadyassembled fuel injection pump assembly, temporarily install two
guide studs in the mounting holes of the gear chamber and fuel injection pump flange.
Install the fuel injection pump assembly. After completion of the final installation, the
fuel supply advance angle shall be 20º (which may be altered after type approval).
e) Sequence for tightening the fixing bolts for the auxiliary supports of fuel injection
pump:
Tighten the fixing bolts for the auxiliary supports of fuel injection pump in the
sequence as shown in Figure 4-40.

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Flange hex bolt

Figure 4-40 Sequence for Tightening the Fixing Bolts

4.7.3 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel

Pipe

1) Exploded view

Pipe clamp assembly

High-pressure fuel pipe subassembly

Figure 4-41 Exploded View of High Pressure Fuel Pipe

2) Disassembly
a) Remove the high-pressure fuel pipe bracket;
b) Remove the high-pressure fuel pipe between the pump and the common rail;
c) Remove the high-pressure fuel pipe between the common rail to fuel injector.
Note: Baudouin special sleeve is required for disassembly.

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3) Assembly
The assembly procedure is in reverse order of disassembly procedure.
Note: The nuts for high-pressure fuel pipe joints (M18×1.5 nut at fuel injection pump
end, and M16×1.5 nut at fuel injector end) shall be tightened to the torque of 40Nm.

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4.7.4 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector

1) Exploded view

Figure 4-42 Exploded View of Fuel Injector

2) Inspection and Maintenance

Replacement of the fuel injectors shall be performed by Bosch Authorized Service Station.
3) Disassembly
a) Loosen the hold-down nut of the high-pressure joint;
b) Take out the fuel injector assembly from the cylinder head.

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4.8 Cooling System

4.8.1 Overview of cooling system

The 6M33 series diesel engine only adopts the circulation of heat carrying fluid within a
closed loop.
The long and short circulations of the cooling system are controlled by the thermostat:
 When the temperature of coolant is low, the thermostat closes so that the coolant returns
to water pump via bypass pipeline for cooling circulation, without flowing through the
radiator (Short circulation of coolant).
 When the temperature of coolant is high, the thermostat opens so that the coolant
completely flows through the radiator and then flows into water pump for cooling
circulation (Long circulation of coolant).

Thermostat

Outlet pipe
circulation

Cylinder head
Short

Fan

Cylinder block

Water pump Oil cooler

Water tank

Engine

Figure 4-43 Schematic diagram of cooling system

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4.8.2 Disassembly, Inspection, Maintenance and Assembly of Thermostat

1) Exploded view

Gasket

Thermostat
Thermostat body
Thermostat cover

Figure 4-44 Exploded View of Thermostat assembly

2) Inspection and Maintenance

Immerse the automatic thermostat in a water container, as shown in Figure 4-45. After heating,
measure the water temperature and observe the temperatures of thermostat for consistency with the
temperatures listed in the table below.

Thermometer

Initial opening Lift height at

temperature full opening
(ºC) (ºC)
73 ± 2℃ ≥9.5mm(85℃) Thermostat

Figure 4-45 Schematic Diagram forMeasuring Thermostat Opening Temperature

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4.8.3 Disassembly, Inspection, Maintenance and Assembly of Water Pump

The water pump is located at the front end of diesel engine and is driven by a V-ribbed belt.
The V-ribbed belt automatic tensioner is fixed on the cylinder block through brackets to keep a
sufficient tension of V-ribbed belt.
1) Exploded view

Figure 4-46 Exploded View of Water Pump

2) Detailed list of parts

The names and quantities of the parts of water pump are shown in Table 4-11.

Table 4-11 Detailed list of parts of the water pump

Tightening
SN. Name Quantity Specifications
torque
1 Water pump bracket 1

2 Water pump assembly 1

3 Hexagon flange bolt 3 M12 80Nm

4 Pipe joint 1

5 Rubber O-ring 1

6 Standard spring washer 8

7 Hexagon bolt 4 M10 46Nm

8 Stud 2 M10 46Nm

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Tightening
SN. Name Quantity Specifications
torque
9 Type 1 hexagon nut 2 M10 46Nm

10 Standard spring washer 2

Hexagon socket cylindrical
11
head screw
2 M8 25Nm

12 Rubber O-ring 1

13 Rubber O-ring 1

14 Drain valve subassembly 1

Hexagon socket cylindrical
15
head screw
2 M10 46Nm

3) Disassembly
a) Remove the fan;
b) Remove the V-ribbed belt.
c) Disassemble the water pump.
4) Inspection and Maintenance
a) Check the rotation of water pump bearing, abnormal sound, and failed seal.
b) The belt before assembly shall not be twisted or turned inside out.
5) Assembly
a) Check that the ring seals are not damaged. Replace the damaged ring seal with new
one if necessary;
b) Install the bracket to the water pump;
c) Install the O-ring. Fix the pipe joint to the water pump jacket;
d) Using bolts, fix the water pump bracket and water pump to the engine block;

4.8.4 Disassembly, Inspection, Maintenance and Assembly of Outlet Water Pipe

For the 6M33 series diesel engine, the outlet water pipe of water pump is located at the engine
side and fixed to the cylinder head.
1) Exploded view

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Figure 4-47 Exploded View of Outlet Water Pipe

2) Detailed list of parts

The names and quantities of the parts of outlet water pipes are shown in Table 4-12:

Table 4-12 List of Parts of Outlet Water Pipe

Tightening
SN. Name Quantity Specifications
torque
1 Connecting water pipe 1

2 Rubber O-ring 3

3 Water outlet pipe 2

4 Hexagon flange bolt 12 M8 23Nm

5 Hexagon bolt 4 M8 23Nm

6 Spring washer 4

7 Flange 2

8 Gasket 2

9 Connecting pipe 1

10 Plug screw 1

11 Rubber O-ring 6

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3) Disassembly
Remove the flanged bolts from the outlet water pipe. Remove the outlet water pipe.
4) Inspection and Maintenance
a) Check the joints between the outlet water pipes and the joint between the outlet water
pipe and the cylinder head for leakage;
b) Check that the O-ring is not damaged. Replace the damaged O-ringwith new one if
necessary.
5) Assembly
The assembly procedures are in the reverse order of disassembly procedures.

4.8.5 Disassembly, Inspection, Maintenance and Assembly of Oil-gas Separator

Seen from the front end, the oil-gas separator is located at the front right end of the engine
block. As a result of separation, the gas enters the atmosphere via the outlet pipe, and the oil returns
to the oil pan.
1) Exploded view

Figure 4-48 Exploded View of Oil-gas Separator

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2) Detailed list of parts

The names and quantities of the parts of oil-gas separator are shown in Table 4-13:

Figure 4-13 Detailed list of parts of the oil-gas separator

Tightening
SN. Name Quantity Specifications
torque
1 Hexagon flange bolt 2 M8 23Nm

2 Breather 1

3 Hose clamp 3

4 Oil-gas separator inlet pipe 1

5 Oil-gas separator 1

6 Flat gasket 4

7 Hexagon bolt 4 M10 46Nm

8 Hose clamp 2

9 Pipe clip 1

10 Pipe clip assembly 1

Oil-gas-separator oil return
11 pipe assembly
1

12 Oil-gas separator outlet pipe 1

13 Single-pipe clip assembly 1

14 Gasket 1

3) Disassembly
Loosen the six bolts used for fixing the breather and the four bolts used for fixing the oil-gas
separator, remove the oil-gas separator.
4) Inspection and Maintenance
Check the seal of the oil-gas separator subassembly, replace it if necessary.
5) Assembly
The assembly procedures are in the reverse order of disassembly procedures.

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4.8.6 Disassembly, Inspection, Maintenance and Assembly of Fan

For the 6M33 series diesel engine, a V-ribbed belt is used for driving the fan and a ventilation
fan is used according to the demand of diesel engine for power generation.
1) Exploded view

Figure 4-49 Exploded View of Fan

2) Detailed list of parts

The names and quantities of the parts of fan are shown in Table 4-14:

Table 4-14 Detailed list of parts of the fan

Tightening
SN. Name Quantity Specifications
torque
1 Fan bracket 1

2 Hexagon bolt 4 M14 125Nm

3 Standard spring washer 6

4 Fan 1

5 Spacer block 1

3) Disassembly
Unscrew six hexagon head bolts and take out spacer block, fan, and spring washer in turn.
4) Inspection and Maintenance
a) Check the fan rivets for looseness, check the fan blades for bending, and ensure the
normal working of fan.

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b) Visually observe the V-ribbed belt for cracking and scratch and replace it if necessary.

4.9 Lubrication System

4.9.1 Overview of lubrication system

The schematic diagram of the lubrication system of 6M33 series diesel engine is shown in
Figure 4-50. The lubrication system is a pressurized lubrication system. The gear oil pump is
located at the bottommost place of the engine. The oil pump is driven by the gear on the front of
crankshaft. All lubricating points and accessories requiring lubrication are connected by the
pipeline or conduit in the pressurized lubrication system. The splash lubrication mode is adopted to
lubricate the timing gear. The lubricating oil is splashed to the pistons for continuous cooling.

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Cylinder head Rocker arm

lubricating oil shaft and
Connecting Turboc Main Camshaft pipe rocker arm
rod harger bearing bushing
shell Cylinder
head and
Lubricating oil engine body
Piston pipe of fuel
injection pump
Main oil passage

Piston
cooling
nozzle Bypass valve

Oil cooler Oil filter Engine oil

pump

Centrifugal Strainer
Pressure
regulator of oil filter
cooler

Oil pan

Figure 4-50 Diagram of lubrication system

4.9.2 Disassembly, Inspection, Maintenance and Assembly of Oil Pump Assembly

1) Exploded view

Figure 4-51 Exploded View of Engine Oil Pump

2) Detailed list of parts

The names and quantities of the parts of oil pump are shown in Table 4-15:

Table 4-15 List of engine oil pump parts

1 Engine oil pump body 2 Bushing
3 Bushing 4 Parallel pin

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5 Shaft and gear 6 Shaft and gear

assembly assembly
7 Hexagon bolt 8 Drive gear
9 Pressure-limiting
valve of oil pump

3) Inspection and Maintenance

a) During installation, the backlash of engine oil pump with the crankshaft gear is
(0.2~0.25) mm.
b) While installing the fastening bolts of engine oil pump, apply Loctite 242 to the
threads of the bolts to prevent vibration looseness.
Notice: After the installation of engine oil pump, check the engine oil pump for smooth
rotation. If the rotation of the engine oil pump is tight, the oil pump will be probably
damaged during running of engine.
4) Adjustment of oil pressure
a) Pressure-limiting valve
Two pressure-limiting valves are provided for oil pump. If oil pressure exceeds the opening
pressure of the pressure-limiting valve, i.e. 12bar, the pressure-limiting valve opens to reduce the
pressure in the lubrication system thus ensure the safety of elements in the system. If oil pressure is
below the opening pressure, the pressure-limiting valve closes.

Figure 4-52 Schematic Diagram of Pressure-limiting Valve

b) Pressure regulating valve

The pressure regulating valve is integrated with the oil cooler. It is used to regulate the
pressure in the main oil passage. Its opening pressure and full opening pressure are (5.5±0.25) bar
and (8.5±0.25) bar respectively. The outlet of the pressure regulating valve is connected to the oil
pan. If the pressure in the main oil passage exceeds the opening pressure, the pressure regulating

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valve opens to drain oil thus maintains the pressure in the main oil passage within the set range.

Figure 4-53 Schematic Diagram of Pressure Regulating valve

c) Bypass valve
The bypass valve is also integrated with the oil cooler. If the pressure drop across the oil
cooler is greater than the opening pressure of the bypass valve, i.e. 2bar, the bypass valve opens. In
this case, the oil from the bypass valve directly enters the main oil passage, bypassing the oil
cooler.

Figure 4-54 Schematic Diagram of the Bypass Valve

4.9.3 Disassembly, Inspection, Maintenance and Assembly of Centrifugal Oil Filter

The 6M33 series diesel engine is equipped with a centrifugal oil filter. The inlet oil passage of
centrifugal oil filter and the main oil passage of lubrication system are connected in parallel. The
centrifugal oil filter is installed on the right side of the oil pan.
1) Exploded view

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Figure 4-55 Exploded View of Centrifugal Filter

2) Replacement of the centrifugal filter element

a) Loosen the top nut 5;
b) Take out the intermediate filter cup 1;
Notice: If the nut 4 on the filter cup is loosened, please take out this nut and tighten it
to the fixing seat during reassembling.
c) Disassemble the filter element 2 and sealing gasket 3;
d) Clean the filter cup and fixing seat;
e) Install new filter element and use the sealing gasket 3 attached in new filter element;
f) Reinstall the filter cup, tighten to 20Nm, and ensure that the filter cup is free of
distortion.

4.9.4 Disassembly, Inspection, Maintenance and Assembly of Oil Cooler and Oil

Filter

1) Exploded view

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Figure 4-56 Exploded View of Oil Cooler

2) Detailed list of parts

The names and quantities of the parts of oil cooler are shown in Table 4-16:

Table 4-16 List of oil pump parts

1 Oil cooler assembly 2 Oil filter
Socket head screw
3 Washer 4
plug
Standard spring
5 Plain washer 6
washer
Hexagon socket
Fully-threaded hex
7 8 cylindrical head
bolt
screw
9 Hexagon bolt 10 Hexagon bolt
Oil cooler cover Oil cooler cover
11 12
gasket gasket
Drain valve
13
assembly

The oil cooler is combined with the oil filter. Leaving the oil filter, the oil enters the oil
cooler for cooling.
3) Replacement of the oil cooler core
a) Using an M8 socket head wrench, loosen the M8 socket head screws of the oil cooler

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cover. Using a general wrench, loosen the hex bolts of the oil cooler. Remove the oil
cooler cover. (Drain the coolant from engine before disassembling);
b) Clean the sealing junction surface between oil cooler cover and cylinder block and
replace the oil cooler cover gasket with new one;
c) Disassemble the oil cooler core with a M8 hexagon wrench and clean the flange
junction surface of oil cooler core;
d) Replace the O-ring of oil cooler core;
e) Install new oil cooler core and tighten the M8 hexagon socket head screws;
f) Put the oil cooler cover in original place. Tighten the socket head screws and hex
bolts.
4) Inspection and maintenance essentials of oil cooler
a) Apply Loctite sealant 242 to the threads before tightening the bolts;
b) All oil filters adopt full-flow one-time filter element. In the case of oil filter clogging,
the safety device located at the filter element will operate to prevent oil flow
interruption. Oil flow interruption can cause damage to the bearing shells. Replace the
filter element on schedule. In addition, replace the filter element when replacing the
oil.
5) Replacement of oil filter element
a) Clean the oil filter base;
b) Apply oil (instead of lubricating grease) to the sealing gasket;
c) Tighten the oil filter by hand and rotate by approximately 3/4 turn;

Figure 4-57 Installation diagram of engine oil filter

d) Check the oil level and pre-lubricate the engine. Re-check the oil level and when
necessary add sufficient oil. Ensure that the oil filter is free of oil leakage.
6) Inspection and maintenance of oil filter

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a) Before disassembling the oil filter, remove the dirt from its surrounding area;
b) Loosen the filter element with oil filter wrench during replacement.

4.9.5 Disassembly, Inspection, Maintenance and Assembly of Oil Pan

1) Exploded view

Figure 4-58 Exploded View of Oil Pan

2) Detailed list of parts

The names and quantities of the parts of oil pan are shown in Table 4-17:

Table 4-17 Detailed list of parts of the oil pan

1 Oil pan 2 Gasket
Hexagon socket
3 Cover plate 4
cylindrical head screw
Magnetic screw
5 6 Screw plug
plug assembly
Square-head screw
7 8 Plain washer
plug
Hexagon socket Hexagon socket
9 10
cylindrical head screw cylindrical head screw
Socket head screw
11 Plain washer 12
plug
Oil dipstick
13 Pipe joint 14
assembly

3) Disassembly

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a) Prior to dismantling of the oil pan, drain the oil fully. Place a container uder the oil
drainage plug of the oil pan, and use a screw plug wrench to loosen the drainage plug
to drain the oil;
b) Disassemble the oil dipstick assembly. Do not damage the oil dipstick during
disassembling;
c) Disassemble the bolts connecting the oil pan and cylinder block with a wrench and
then separate the cylinder block from oil pan by using overhead traveling crane
(Notice to remove the silicone sealant at all times during separation and do not hoist
the cylinder block too high);
d) After the separation of oil pan, check the levelness and check for damage.
4) Inspection and Maintenance
Check that the mating faces of the cylinder block and the oil pan are clean without grease or
collision-caused damage.
5) Assembly
a) Apply evenly silicone sealant to the mating face of the oil pan.
b) Using the overhead crane, move the engine block onto the oil pan;
c) Apply Loctite 242 threadlocker to the threads of all the socket head cap screw bolts.
Tighten the bolts and remove the surplus silicone sealant from these bolts;
d) Place washers onto the hex screw plug and pipe joint. Fix them to the oil pan.

4.9.6 Use and Replacement of Oil

1) Oil type
Use CF15W/40 or higher grade of oil as specified by GB11122.
2) Oil tank capacity
For the 6M33 series diesel engine, the standard oil tank has a capacity of approximately 60.5L.
3) Replacement of oil
a) Stop the engine, use the manual pump for the replacement of oil;
b) Place the three-way connector to the "Drain" place shown in figure below;

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Drain

Pre-lubrication

Figure 4-59 Diagram of manual oil pump

c) To collect used oil, connect a pipe to the outlet pipe of the manual oil pump;
d) Repeatedly operate the handle of the manual oil pump until all used oil drains out of
the engine;
e) Place the three-way connector to the "Pre-lubrication" place shown in figure;
f) Add fresh oil via the filler port into the oil pan.
Notice: Add clean oil into diesel engine oil tank, till the oil level reaches the upper
marking of oil dipstick. Start and idle the engine and check the oil filter and drainage plug for
oil leakage. Stop the engine, wait for approximately 5min for the oil to return from upper
parts into oil pan, and check the oil level once again. When necessary, add new oil till the oil
level reaches the upper marking of oil dipstick.

4.10 Startup system

4.10.1 Overview of startup system

1) Overview of starter motor

The starter motor is one of the core parts of vehicle starter system and is functioned to convert
the electric energy of battery to electromagnetic torque and, via the gear and ring gear mechanism,
drive the rotation of engine to start the engine. The starter motor is mainly composed of DC motor,
one-way clutch, starter pinion (or reduction gear train), electromagnetic switch, and starter relay.
The 6M33 series diesel engine is equipped with a 24V, 8.5KW starter motor, the electrical
circuit of which is shown in Figure 4-60.

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Control relay Battery terminal Solenoid

Switch terminal Motor

Circuit diagram

Figure 4-60 The circuit diagram of starter motor

2) Model and category of starter motor

In accordance with the regulations of the industry standard QC/T73-93 Preparation Method of
Product Model for Automotive Electric Equipment of the People’s Republic of China, the
composition of model number for the automotive starter motor is as below:

Variant code

Design sequence number

Power grade
Voltage grade
Product code: QD are the initials of the
Chinese Pinyin of “starter motor”
QD denotes starter motor; QDJ denotes reduction starter motor; QDY denotes permanent
magnet starter motor (including the permanent magnet reduction starter motor).
Voltage grade code: 1 denotes 12V and 2 denotes 24V.
Power grade code: As listed in Table 4-18.

Table 4-18 Alternator power gradenumber

Power
grade 1 2 3 4 5 6 7 8 9
number
Power /
<1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >8
kW

At present, the starter motors equipped on Weichai engines adopt the electromagnetically

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driven flexible engagement mode. According to drive gear engagement mode, it can be divided to
sliding armature starter motor and sliding fork gear starter motor (of which the latter accounts for a
high proportion), and according to drive mechanism, it includes direct drive starter motor (Equal
speed for starter motor rotor and starter motor gear) and reduction gear starter motor (The speed of
starter motor gear is less than rotor speed).

4.10.2 Disassembly, Inspection, Maintenance and Assembly of Starter Motor

1) Exploded view

Stud

Starter motor

Spring washer

Type 1 hexagon nut

Figure 4-61 Exploded View of Starter

2) Disassembly
a) Remove the hex nuts and their spring washers;
b) Hold securely the starter motor, and take it out along the gear rotation axis.

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3) Inspection and Maintenance

The wires of the starter shall be connected correctly and securely.
4) Assembly
a) Install the starter motor;
b) Put the spring washers in place. Tighten the hex nuts.

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Appendix A Recommended Torques for Standard Bolts

Recommended Torques for Standard Bolts

Friction
0.125 (zinc plated) 0.14 (polished)
coefficient
Strength
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
grade
Bolt size Recommended torque, Nm
M4 2.3 2.7 3.8 4.6 2.4 2.9 4.1 4.9
M5 4.7 5.5 8.0 9.5 5.0 6.0 8.5 10
M6 8.0 9.5 13.0 16.0 8.5 10 14.0 17
M8 19 23 32 39 21 25 35 41
M10 39 46 64 77 41 49 69 83
M12 67 80 110 135 72 86 120 145
M14 105 125 180 215 115 135 190 230
M16 165 195 275 330 180 210 295 355
M18 225 270 390 455 245 290 405 485
M20 325 385 540 650 345 410 580 690
M22 435 510 720 870 465 550 780 930
M24 560 660 930 1100 600 710 1000 1200
M27 830 980 1400 1650 890 1050 1500 1800
M30 1100 1350 1850 2250 1200 1450 2000 2400
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 1250 1450 2050 2500 1350 1600 2250 2700

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Appendix B Recommended Torques for Hollow Bolts

Recommended Torques for Hollow Bolts

Recommended tighten torque
Specification Head style
(Nm)
M8×1 Hexagon head 7±1
17±2
Hexagon head 13±2 (Copper bolt and small
M10×1
combination washer)
Flange bolt 20±3
Hexagon head 22±3
M12×1.5
Flange bolt 28±3
Hexagon head 27±3
M14×1.5
Flange bolt 32±3
Hexagon head 30±3
M16×1.5
Flange bolt 36±3
Hexagon head and
M18×1.5 60±5
flange bolts

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