Daewoo 450, 460, D20S-3(B3.3), D30S-3(B3.3), D25S-3(B3.3) user guide

...

Service Manual

B3.3 Diesel Engine

Lift Trucks D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3), D32S-3(B3.3), D33S-3(B3.3)

Skid Steer Loaders 450/450Plus, 460/460Plus

SB4135E00 Jan. 2004

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section or the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/maintenance publication. Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DAEWOO cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by DAEWOO is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DAEWOO dealers have the most current information available.

ARNIN

Index

Introduction

About the Manual................................................... 4

How to Use the Manual ......................................... 4

Illustrations............................................................. 6

Symbols ................................................................. 5

Engine Identification

Engine Diagrams ................................................... 9

Engine Views....................................................... 9

Engine Identification .............................................. 7

Engine Dataplate ................................................. 7

Specifications......................................................... 8

Troubleshooting Symptoms

Procedures and Techniques .................................20

Troubleshooting Symptoms Charts.......................20

Coolant Contamination .......................................34

Coolant Loss.......................................................35

Coolant Temperature above Normal...................38

Engine Cranks But Will Not Start

(No Exhaust Smoke) ..........................................22

Engine Difficult to Start or Will Not Start

(Exhaust Smoke) (Continued) ............................24

Engine Difficult to Start or Will Not Start

(Exhaust Smoke) ................................................23

Engine Has Poor Respones ...............................25

Engine Power Output Low (Continued) ..............29

Engine Power Output Low..................................28

Engine Runs Rough or Misfires..........................27

Engine Stops During Operation ..........................26

Engine Vibration Excessive ................................41

Engine Will Not Crank or Cranks Slowly ............21

Excessive Exhaust (Black Smoke) .....................30

Excessive Noise (Continued) .............................40

Excessive Noise .................................................39

Fuel consumption Is Excessive ..........................33

Lubricating Oil Consumption Excessive .............31

Lubricating Oil Contaminated .............................32

Lubricating Oil Pressure Is Low..........................36

Oil Level Rises....................................................37

Complete Engine

Engine Testing

Complete Engine.................................................. 89

Measuring Compression Pressure..................... 89

Testing and Adjusting the Fan Belt Tansion ....... 91

Fuel System ......................................................... 92

Checking and Adjusting Fuel Injection Timing ... 92

Injector ................................................................. 95

Assembly ........................................................... 98

Disassembly....................................................... 97

Testing................................................................ 95

Lubricating System............................................. 100

Measuring Oil Pressure ................................... 100

Rocker Levers ...................................................... 87

Adjusting Valve Clearance ................................. 87

Specifications

Camshaft and Camshaft Bushing ...................... 105

Capscrew Markings and Torque Values - Metric 115 Capscrew Markings and Torque Values - U.S.

Customary.......................................................... 116

Capscrew Markings and Torque Values ............. 115

Connecting Rod, Piston Ring and Piston Pin..... 111

Crankshaft.......................................................... 106

Cylinder Block .................................................... 104

Cylinder Head .................................................... 103

Cylinder .............................................................. 109

Flywheel ............................................................. 108

Fraction, Decimal, Millimeter Conversions......... 117

Newton-Meter to Foot-Pound Conversion

Chart .................................................................. 118

Oil Pump ............................................................ 112

Pipe Plug Torque Values.................................... 118

Piston ................................................................. 110

Regulator Valve.................................................. 113

Rocker Arm Shaft, Push Rod and Tappets......... 102

Tap-Drill Chart - U.S. Customary and Metric ...... 119

Thermostat ......................................................... 114

Timing Gear........................................................ 107

Valves, Valve Guides, and Springs .................... 101

Weight and Measures - Conversion Factors...... 120

Special Tool

Special Tool List ................................................. 121

Complete Engine ..................................................42

Engine Assembly ................................................61

Engine Disassembly ...........................................42

Diesel Engine Index

About the Manual

This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine-related problems and to provide recommended repair procedures. The material in this manual covers all Signature engines. The manual is divided into sections. Each section is equivalent to a group used in Cummins filmcard system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem.

This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be performed, regardless of the numerical order of the steps. The user must use the Section Contents pages or the Index at the back of the manual to locate specific topics when not using the troubleshooting trees.

How to Use the Manual

This manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms, Section TS. The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem.

(Step 1) Locate the symptom on the Section Contents pages of Section TS.

Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title.

(Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a

probable cause of the problem, starting at the top with the simplest and easiest to repair, and continuing downward to the most difficult. The right column of boxes provides a brief description of the corrective action with a reference number to the correct procedure used to make the repair.

(Step 3)

(Step 4) The Troubleshooting Symptom Charts are based on the following assumptions:

Locate the probable cause in the left column; then turn to the procedure

referenced in the right column.

1. The engine has been installed according to the manufacturer's specifications.

2. The easiest repairs are done first.

3. "Generic" solutions cover problems with the most common applications and original equipment manufacturer (OEM).

Diesel Engine Introduction

Symbols

The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below:

WARNING – Serious personal injury or extensive property damage can result if the

CAUSION – Minor personal injury can result or a part, an assembly or the engine can be

warning instructions are not followed.

damaged if the Caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque

PERFORM an electrical MEASUREMENT.

Diesel Engine Introduction

Refer to another location in this manual or another publication for additional information.

The component weighs 23kg [50lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.

Illustrations

Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.

The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

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Diesel Engine Introduction

Engine Identification

Engine Dataplate

The engine dataplate shows specific information about the engine. The engine serial number (ESN) and control parts list (CPL) provide information for ordering parts and for service needs.

NOTE: The engine dataplate must not be changed

unless approved by Cummins Engine Company, Inc.

00900248

00900249

Diesel Engine Engine Identification

Specifications

Performance D20/25/30/32/33S-3

Standard - SAEJ1995 Air Cleaner - without but with 3.0kPa intake restriction

Test Condition

Rated Power kW(PS) 43.4 (59) @ 2200 rpm 48.5 (65) @ 2600 rpm Max Torque Nm(kgf-m) 202 (20.6) @ 1600 rpm 214 (21.8) @ 1600 rpm Torque Rising

BSFC

General Engine Data Naturally Aspirated

Engine Weight (Dry) Less Flywheel and Electronics 245 kg [540 lb] Compression Ratio 18.8 Bore 95 mm [3.74 in] Stroke 115 mm [4.528 in] Displacement 3.26 liters [199 in³] Firing Order 1-2-4-3

Valve Clearance:

Rotation Viewed from the Front of the Engine Clockwise

Lubrication System Naturally Aspirated

Regulating Valve Opening Pressure 490 kPa [71 psi]

Lubricating Oil Capacity:

Lubricating Oil Pressure at Idle (Minimum Allowable) 69 kPa [10 psi] Lubricating Oil Pressure at Rated (Minimum Allowable) 245 kPa [35 psi] Oil Filter Differential Pressure to Open Bypass Valve 98 kPa [14 psi] Number of liters [qt] from Low to High 1.5 liters [1.6 qt]

Cooling System Naturally Aspirated

Coolant Capacity (Engine Only ) 4.5 liters [4.75 qt] Standard Modulating Thermostat

Range: Maximum Pressure Cap @ Sea Level 50 kPa [7 psi]

Air Induction System Naturally Aspirated

Maximum Allowable Intake Restriction at Rated Speed and Load with Dirty Filter Element

Exhaust System Naturally Aspirated

Maximum Allowable Exhaust Restriction at Rated Speed and Load with Dirty Filter Element

Fuel System Naturally Aspirated

Maximum Allowable Restriction to the Fuel Transfer Pump or Filter Head Must Not Exceed Maximum Allowable Return Line Restriction Must Not Exceed Inlet Pressure to the Injection Pump Range 0.00 kPa [0.00 psi] to 39.0 kPa [5.00 psi]

Electrical System Naturally Aspirated

Minimum Recommended Battery Capacity with Light Accessories*: Minimum Recommended Battery Capacity with Heavy Accessories**: Maximum Allowable Resistance of the Starting Circuit: *Typical light accessories include: Alternator, small steering pump, and disengaged clutch. **Typical heavy accessories include: Hydraulic pump and torque converter.

Muffler - without but with 10.0kPa exhaust restriction Alternator - without Fan - without

7.4 % for 2200rpm rating 20.0% for 2600rpm rating @Rated Power g/kWh 227 @2200rpm 236 @ 2600rpm @Max Torque g/kWh 219 @1600rpm 226 @ 1600rpm

Intake Exhaust

Total System Standard Oil Pan Only

Start Fully Open

12-VDC Starter 550 CCA

12-VDC Starter 730 CCA

12-VDC Starter 0.0012 ohms

7.5 liters [8.0 qt] 8.0 liters [8.5 qt]

0.35 mm [0.014 in]

0.50 mm [0.020 in]

7.0 liters [7.4 qt]

82° C [180° F] 95° C [203° F]

762 mm H2O

[30 in H2O]

190.5 mm Hg

450/450Plus,460/460Plus

75 mm Hg

[3 in Hg]

75 mm Hg

[3 in Hg]

[7.5 in Hg]

Diesel Engine Engine Identification

Engine Diagrams

Engine Views

The following illustrations show the locations of the major external engine components, filters, and other service and maintenance points. Some external components will be at different locations for different engine models.

1. Intake Manifold

2. Starting Motor

3. Fuel Injection Pump

4. Crankshaft Pulley

Intake Side

(Naturally Aspirated)

00900138

5. Fan

6. Fuel Filter

7. Oil Fill Cap.

Diesel Engine Engine Identification

1. Oil Fill Cap

2. Thermostat Housing

3. Alternator

Exhaust Side

(Naturally Aspirated)

00900139

4. Dipstick

5. Oil Filter

6. Exhaust Manifold.

Diesel Engine Engine Identification

Front View

(Naturally Aspirated)

00900140

Rear View

(Naturally Aspirated)

00900141

Diesel Engine Engine Identification

1. Oil Strainer

2. Oil Pump

3. Oil Cooler (Optional)

4. Regulator Valve

5. Oil Filter

6. Safety Valve

7. Crankshaft

Exhaust Side

(Naturally Aspirated)

00900146

8. Camshaft

9. Piston

10. Intake and Exhaust Valve

11. Rocker Arm

12. Timing Gear

13. Cooling Water.

Diesel Engine Engine Identification

1. Bushing

2. Gear Drive (number of teeth: 7)

3. Pump cover

4. Oil Pump Drive Gear (number of teeth: 22)

5. Driveshaft

6. Drivenshaft

7. Driven Gear (number of teeth: 7)

Oil Pump

00900148

8. Regulator Valve

9. Valve Spring.

Oil pump

• Type: Gear Type

• Pump Speed: Engine Speed x 1.182.

Regulator Valve

• Set Pressure: 490 ± 50kPa [71 ± 7psi].

Diesel Engine Engine Identification

1. Fuel Injection Pump

2. Overflow Valve

3. Fuel Solenoid

4. Fuel Injection Nozzle

Fuel System

00900149

5. Fuel Tank

6. Water-in-Fuel Sensor (WIF)

7. Fuel Filter

8. Hand Priming Pump.

Diesel Engine Engine Identification

1. Pump Holder

2. Fuel Injection Pump Drive Gear (number of teeth: 52)

3. Drive Shaft

4. Fuel Injection Pump (Body)

5. Fuel Filter

6. Fuel Injection Pipe (No. 1)

7. Fuel Injection Pipe (No. 2)

8. Fuel Injection Pipe (No. 3)

9. Fuel Injection Pipe (No. 4)

10. Spill Tube

Fuel Injection Pump

00900150

A. Fuel Inlet (from Fuel Tank) B. To. Fuel Tank C. To Fuel Injection Pump D. To Fuel Injection Nozzle.

Fuel Injection Pump

• Maker: Zexel

• Type: VE

• Lubrication Method: Forced Lubrication with Fuel

Governor

• Type: Mechanical, All-speed Type.

Diesel Engine Engine Identification

1. Fuel Drain Line Connector

2. Nozzle Holder

3. Adjusting Shim

4. Nozzle spring

5. Spring seat

6. Intermadiate Plate

7. Nozzle Body

8. Retaining Nut

9. Needle.

Fuel Injection Nozzle

00900151

A. Fuel Inlet (from injection pump) B. Fuel Injection (to cylinder) C. Fuel Return (to fuel tank).

Fuel Injection Nozzle

• Maker: Zexel

• Injection Pressure: 40 MPa

• Adjustment of Injection Pressure: By Shim.

Diesel Engine Engine Identification

1. Radiator

2. Thermostat

3. Water Temperature Gauge

4. Water Pump

5. Water Manifold

Cooling System

00900147

6. Cylinder Head

7. Piston

8. Cylinder Block

9. Oil Cooler (optional). A. From Oil Pump (oil).

Diesel Engine Engine Identification

1. Filtered Air

2. Intake Manifold

3. Intake Valve Port.

Air Intake System

00900227

Diesel Engine Engine Identification

1. Exhaust Valve Port

2. Exhaust Manifold

Exhaust System

00900232

Diesel Engine Engine Identification

Procedures and Techniques

A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved.

The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.

It is not possible to include all the solutions to problems that can occur; however, these charts are designed to stimulate a thought process that will lead to the cause and correction of the problem.

Follow these basic troubleshooting steps:

• Get all the facts concerning the complaint

• Analyze the problem thoroughly

• Relate the symptoms to the basic engine systems and components

• Consider any recent maintenance or repair action that can relate to the complaint

• Double-check before beginning any disassembly

• Solve the problem by using the symptom charts and doing the easiest things first

• Determine the cause of the problem and make a thorough repair

• After repairs have been made, operate the engine to make sure the cause of the complaint has been

corrected

Troubleshooting Symptoms Charts

Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row of blocks from top to bottom. Follow through the chart to identify the corrective action.

Diesel Engine Troubleshooting Symptoms

Engine Will Not Crank or Cranks Slowly

This is symptom tree T-002.

Cause Correction

Defective wiring of starting circuit

Specific gravity of battery electrolytr is low, or

Battery voltage is low

Staring motor is malfunctioning

Troubleshoot and repair starting circuit wiring

including relays and switches.

Check the alternator. If the alternator checks

Out, replace the battery.

Replace the staring motor.

Ring gear tooth surface is chipped or damaged

Replace ring gear.

Diesel Engine Troubleshooting Symptoms

Engine Cranks But Will Not Start (No Exhaust Smoke)

This is symptom tree T-003.

Cause Correction

Fuel level low in the tank

Improper fuel is being used

Clogged fuel tank air breather hole

Fill the supply tank.

Drain fuel and replace with correct fuel.

Clean the fuel tank breather.

Engine does start when voltage is applied to

the fuel cut solenoid valve

Engine does not start when voltage is applied

to the fuel cut solenoid valve

Clogged prefilter

Clogged fuel filter or strainer

Clogged or leaking fuel piping

Feed pump is damaged or seized

Injector are plugged

damaged

Injection pump driveshaft or driveshaft key is

Troubleshoot and repair the circuit wiring.

Replace the fuel cut solenoid valve.

Clean the prefilter.

Clean or replace the fuel filter or strainer.

Clean and repair the fuel piping.

Replace the feed pump.

Replace the injectors.

Repair or replace the injection pump.

Diesel Engine Troubleshooting Symptoms

Engine Difficult to Start or Will Not Start (Exhaust Smoke)

This is symptom tree T-004.

Cause Correction

Starting aid malfunctioning or heater mount

Does not become warm

Speed: 150 rpm)

Improper fuel is being used

Crank speed is too slow (minimum crank

Replace the starting aid.

Verify drive units are not engaged. Check the

Battery and recharge or replace.

Drain fuel and replace with correct fuel.

Clogged air cleaner element

Clogged prefilter

Clogged fuel filter or strainer

Leakage, clogging, air in fuel system

Injection pump timing is incorrect

(Continued)

Clean or replace the air cleaner element.

Clean the prefilter.

Clean or replace the fuel filter or strainer.

Repair and clean the fuel filter or strainer.

Retime the injection pump.

Diesel Engine Troubleshooting Symptoms

Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)

Cause Correction

Overhead adjustments are not correct

Overhead components are damaged

Defective or clogged injection nozzle

Injection pump is malfunctioning

Worn piston ring or cylinder resulting in low

compression

Measure and adjust the overhead settings.

Inspect the rocker levers, rocker shafs, and

valve for excessive damage. Replace as

necessary.

Replace the defective or clogged injection

nozzle

Repair or replace the injection pump.

Replace the worn piston ring or cylinder.

Diesel Engine Troubleshooting Symptoms

Engine Has Poor Respones

This is symptom tree T-005.

Cause Correction

Clogged air cleaner element

Clogged fuel tank air breather hole

Clogged prefilter

Clean or replace the air cleaner element

Clean the fuel tank breather.

Clean or replace the fuel filter or strainer.

Clogged fuel filter or strainer

Clogged or leaking fuel piping

Overhead adjustments are not correct

Resulting in low compression

Turbocharger does not rotate freely

Defective or clogged injection nozzle

Injection pump is malfunctioning

Defective contact of valve or valve seat

Clean and repair the fuel piping

Clean and adjust the overhead settings.

Measure and adjust the overhead settings.

Replace the cylinder head.

Replace the turbocharger.

Replace the defective or clogged injection

nozzle.

Repair or replace the injection pump.

Worn piston ring or cylinder resulting in low

Compression

Diesel Engine Troubleshooting Symptoms

Replace the worn piston ring or cylinder.

Engine Stops During Operation

This is symptom tree T-006.

Cause Correction

Chassis powertrain is damaged or overloaded

Fuel level low in the tank

Clogged fuel tank air breather hole

Refer to the OEM’s service manuals.

Fill the supply tank.

Clean the fuel tank breather.

Clogged prefilter

Clogged fuel filter or strainer

Clogged or leaking fuel piping

Feed pump piston is damaged or seized

Overhead components are damaged

Injection pump is malfunctioning

Gear train damaged or seized

Piston or connecting rod is damaged

Crankshaft bearing is damaged

Clean the prefilter.

Clean and or replace the fuel filter or strainer.

Clean and repair the fuel piping.

Replace the feed pump.

Inspect the rocker levers, rocker shafts, and

valves for excessive damage. Replace as

necessary.

Replace the injection pump.

Refer to OEM’s service manuals.

Replace damaged piston or connecting rod.

Replace damaged crankshaft bearing.

Diesel Engine Troubleshooting Symptoms

Engine Runs Rough or Misfires

This is symptom tree T-007.

Cause Correction

Fuel level low in the tank

Clogged fuel tank air breather hole

Low idle speed is adjusted too low

Fill the supply tank.

Clean the fuel tank breather.

Adjust the low idle speed.

Clogged prefilter

Clogged fuel filter or strainer

are clogged or have air in them

nozzle are clogged or have air in them

Injection pump is malfunctioning

Line between the fuel tank and feed pump

Line between the feed pump and the injector

Clean the prefilter.

Clean or replace the fuel filter or strainer.

Clean and repair the lines.

Replace the injection pump.

Diesel Engine Troubleshooting Symptoms

Engine Power Output Low

This is symptom tree T-008.

Cause Correction

Improper fuel is being used

Clogged air cleaner element

Clogged fuel tank air breather hole

Drain and replace the fuel with the correct fuel.

Clean or replace the air cleaner element.

Clean the fuel tank breather.

fuel lever linkage is bent or not adjusted

correctly

Clogged prefilter

Clogged fuel filter or strainer

Clogged or leaking fuel piping

Feed pump is defective

Overhead adjustments are not correct

(Continued)

Full throttle can not be achieved because the

Repair or adjust the fuel lever linkage.

Clean the prefilter.

Clean and or replace the fuel filter or strainer.

Clean and repair the fuel piping.

Replace the feed pump.

Measure and adjust the overhead settings.

Diesel Engine Troubleshooting Symptoms

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