KM/4L22 Diesel Engines

MAINTENANCE MANUAL

THE PEOPLE’S REPUBLIC OF CHINA

LOVOL HEAVY INDUSTRY CO., LTD
 MAINTENANCE MANUAL OF TE SERIES

Preface

This manual provides information on the diagnosis, maintenance and adjustment

of the two mechanisms and five systems of non-road three-cylinder and four-cylinder
engines made in Shandong Huayuan Laidong Engine Co., Ltd. (hereinafter referred to
as Laidong). This manual is intended to be used by maintenance technicians. If nec-
essary, refer to the corresponding volume of drawings of parts when reading this
manual.
To obtain information on product models, drawing numbers and special tools as
mentioned in this manual, call or write to Laidong. All data, illustrations and descrip-
tions collected in this manual are effective when this manual is being edited.
To improve the quality, performance and safety of engines, Laidong will make
changes the design of engine components from time to time. Some texts and illustra-
tions in this manual could vary with the engine being maintained. Contents of this
manual can be changed without notice.
Without the permission of Shandong LOVOL Heavy Industry International
Trading Co., Ltd, no part of this manual may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, including but not limited to
electronic, photocopying and recording. The statement shall cover all the texts,
illustrations and tables contained in this manual.

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 MAINTENANCE MANUAL OF TE SERIES

Contents
Preface ...................................................................................................................................... 1
Part I Overview ................................................................................................................................. 1
Chapter 1 Safety Precautions .................................................................................................... 1
1. Scalding symbol ............................................................................................................. 1
2. No-touching symbol ...................................................................................................... 1
3. Engine hoisting equipment ........................................................................................... 2
Chapter 2 Technical Parameters ................................................................................................ 3
1. Main technical parameters............................................................................................ 3
2. Capacities ...................................................................................................................... 3
3. Overall dimensions ........................................................................................................ 3
4. Technical Parameters..................................................................................................... 4
5. Torque specifications ..................................................................................................... 6
6. Some exposed parts of engine ...................................................................................... 7
Chapter 3 Fuel and Engine Oil................................................................................................... 9
1. Use and precautions for fuel ......................................................................................... 9
2. Engine lubricating oil ................................................................................................... 11
3. Engine coolant ............................................................................................................. 12
Chapter 4 Position of Product Nameplate .............................................................................. 13
1. Information of diesel engine nameplate ..................................................................... 13
2. Fuel injection pump nameplate .................................................................................. 14
3. Position of alternator nameplate ................................................................................ 15
4. Starter nameplate ....................................................................................................... 16
5. Air compressor nameplate .......................................................................................... 17
Chapter 5 Product Features and Accessories .......................................................................... 18
1. Standard configuration ................................................................................................ 18
2. Configuration (optional) .............................................................................................. 19
Part II Dismantlement, Installation and Adjustment ....................................................................... 20
Chapter 1 Dismantling/installing the valve mechanism.......................................................... 20
1. Maintenance equipments and tools ........................................................................... 20
2. Torque and data .......................................................................................................... 20
3. Dismantling the valve mechanism............................................................................... 23
4. Installing the valve mechanism ................................................................................... 31
Chapter 2 Dismantling/installing the crank-link mechanism .................................................. 43
1. Maintenance equipments and tools ........................................................................... 43
2. Torque and data .......................................................................................................... 43
3. Dismantling the crank-link mechanism ....................................................................... 45
4. Installing the crank-link mechanism ............................................................................ 51
Chapter 3 Cooling system ........................................................................................................ 64
1. Maintenance equipments and tools ........................................................................... 64
2. Torque requirements ................................................................................................... 64
3. Dismantling the cooling part ....................................................................................... 65
4. Assembling the cooling part ........................................................................................ 71
Chapter 4 Lubricating System.................................................................................................. 75
1. Maintenance equipments and tools ........................................................................... 75
2. Torque requirements ................................................................................................... 75
3. Dismantling/installing the oil pan parts ...................................................................... 76
3.1 Dismantling the oil pan parts .................................................................................... 76
4. Dismantling/installing the oil pump parts ................................................................... 78
Chapter 5 Electric system ........................................................................................................ 80
1. Maintenance equipments and tools ........................................................................... 80
2. Torque requirements ................................................................................................... 80
3. Dismantling/installing the alternator assembly .......................................................... 81

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 MAINTENANCE MANUAL OF ENGINE

4. Dismantling the alternator subassembly .................................................................... 83

5. Dismantling/installing the starter ............................................................................... 84
Chapter 6 Fuel supply system.................................................................................................. 85
1. Maintenance equipments and tools ........................................................................... 85
2. Torque requirements ................................................................................................... 85
3. Dismantling the fuel supply system............................................................................. 86
4. Assembling the fuel supply system ............................................................................. 90
Chapter 7 Dismantling/installing and adjusting the accessories............................................. 92
1. Data and dimension .................................................................................................... 92
2. Dismantling/installing the intake pipe ........................................................................ 93
3. Dismantling/installing the exhaust pipe...................................................................... 95
4. Dismantling/installing the gear chamber .................................................................... 97
5. Dismantling/installing the flywheel parts ................................................................. 105
Part III Inspection, Adjustment, Fault Diagnosis and Troubleshooting ........................................ 108
Chapter 1 Dynamic Inspection .............................................................................................. 108
1. Overview ................................................................................................................... 108
2. Inspecting engine oil level ......................................................................................... 109
3. Inspecting the coolant level and status ..................................................................... 110
4. Inspecting the fan and belt........................................................................................ 111
5. Inspecting the fuel system......................................................................................... 112
6. Inspecting the air intake and exhaust system ........................................................... 113
7. Inspecting the electric system ................................................................................... 114
Chapter 2 Operating principle ............................................................................................... 115
1. Valve mechanism....................................................................................................... 115
2. Crank-link mechanism ............................................................................................... 117
3. Lubricating System .................................................................................................... 119
4. Fuel supply system .................................................................................................... 120
5. Cooling system .......................................................................................................... 121
6. Electric system ........................................................................................................... 122
Chapter 3 Inspection and adjustment ................................................................................... 129
1. Inspecting valve clearance (mm) ............................................................................... 129
2. Inspecting cylinder pressure...................................................................................... 130
3. Inspecting the engine oil pressure ............................................................................ 131
4. Inspecting fuel injection pump timing ...................................................................... 133
5. Calibration of the fuel injection pump ...................................................................... 134
6. Inspecting atomization by the fuel injector............................................................... 135
Chapter 4 Fault analysis and troubleshooting ....................................................................... 136
1. White smoke ............................................................................................................. 136
2. Blue smoke ................................................................................................................ 136
3. Black smoke or grey smoke ....................................................................................... 137
4. Insufficient compression pressure of cylinders ......................................................... 137
5. Air intake obstructed ................................................................................................. 138
6. Black smoke ............................................................................................................... 138
7. Abnormal sound from the diesel engine ................................................................... 139
8. The engine cannot be operated normally or flames out frequently ......................... 140
9. Low power ................................................................................................................. 141
10. The engine oil is mixed with water .......................................................................... 142
11. Abrupt increase in speed......................................................................................... 142
12. Erratic operation...................................................................................................... 143
13. Engine overheat ...................................................................................................... 143
14. Abnormal coolant temperature .............................................................................. 144
15. No engine oil pressure or low pressure................................................................... 145
16. The engine oil pressure is too high.......................................................................... 145
17. The engine oil temperature is too high ................................................................... 146

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18. High engine oil consumption .................................................................................. 146
19. Low starter speed .................................................................................................... 147
20. Cannot be started or be started difficultly .............................................................. 147
21. The diesel engine is started difficultly ..................................................................... 148

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 MAINTENANCE MANUAL OF ENGINE

Part I Overview

Chapter 1 Safety Precautions

This is a safety symbol. Safety symbols are

found on the tractor or in this manual. They
highlight hazards that may result personal in-
jury.

The tips for operating procedure and safety

precautions must be strictly followed.

1. Scalding symbol

To avoid scalding, stand away from the hot

surfaces of the engine while it is running.

2. No-touching symbol

Do not touch the engine body while the engine

is running.
Do not maintain the engine until it shuts down
and cools for at least half an hour to ambient
temperature.

Other symbols are described in the tractor

maintenance manual or operation instructions.

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 MAINTENANCE MANUAL OF ENGINE

3. Engine hoisting equipment

Correct equipment and method shall be used

for hoisting the engine. Recommended hoist-
ing equipment is as illustrated. Attach the
chains to both of the lifting eyes of the engine.
Never use a single lifting eye.

Before hoisting the engine, check that the lift-

ing eyes are tightened to 44N.m without dam-
age and looseness.

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Chapter 2 Technical Parameters

1. Main technical parameters

Note: Design and technical parameters of the engine may be changed without notice.
Unit Shandong Huayuan Laidong Engine Co., Ltd.
Diesel engine
Model KM385BT KM390BT 4L22BT
Type —— Vertical, water-cooled, 4-stroke diesel engine
Number of cylinders —— 3 4
Bore × Stroke mm 85×90 90×100 85×95
Rated power kW 18.4 22 25.7
Rated speed r/min 2350 2350/2400 2350
N·m/(r/
Maximum torque/speed ≥86/≤1650 ≥108/≤1750 ≥124/1650
min)
Fuel Consumption Rate
under Rated Working Con- ≤278 ≤276 ≤278
dition （g/k
Oil Consumption Rate un- W h）
der Rated Working Condi- ≤2.04 ≤2.72 ≤2.04
tion
Lubrication manner —— Pressurization
Start-up manner —— Electrical starter

2. Capacities

LOVOL
Model Unit TE200/TE204/TE240/
TE300/TE304 TE354
TE244/TE250/TE254
Fuel tank 32
L
Oil pan 5 6

3. Overall dimensions

Diesel engine Unit Shandong Huayuan Laidong Engine Co., Ltd.

Model KM385BT KM390BT 4L22BT
Length 569 600-800 757
Overall
dimen- Width mm 525 480-850 494
sions Height 604 650-800 620
Mass kg 180 220-280 200

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 MAINTENANCE MANUAL OF ENGINE

4. Technical Parameters

4.1 Main technical data

KM385BT diesel engine

No. Rated power/speed (kw/rpm) Maximum torque/speed （N.m/rpm）
1 19.4/2400 90/1480-1680
2 18.4/2350 86/1480-1680
3 17.7/2350 83/1480-1680
4 14.7/2350 69/1480-1680

4.2. Main technical parameters

1 Model KM385BT KM390BT 4L22BT

2 Type Vertical, water-cooled, 4-stroke
3 Number of cylinders 3 3 4
4 Combustion chamber type Direct injection
5 Cylinder bore (mm) 85 90 85
6 Piston stroke (mm) 90 100 95
7 Compression ratio 18 18 18
Rated net power/Rated speed
8 18.4/2350 22/2400 25.7/2350
(kW/rpm)
9 Maximum speed at no load (rpm) ≤2580 ≤2640 ≤2580
Minimum steady speed at no load
10 ≤850 ≤850 ≤850
(rpm)
Minimum fuel consumption at max-
11 ≤248 ≤248 ≤248
imum opening of valve (g/kW.h)
Ratio of engine oil consumption to
12 ≤0.8%
fuel consumption
Ratio of maximum torque with en-
13 gine at full load to the torque with ≥15%
engine at rated operating conditions
14 Total piston displacement (L) 1.532 1.909 2.156
15 Maximum fume at full load (Rb) ≤4.5
16 Exhaust gas temperature (°c) ≤650
17 Engine oil pressure (KPa) 200-400
18 Engine oil temperature (°c) 85-95
19 Cooling water temperature (°c) 75-85
20 Firing order of cylinders 1-3-2 1-3-2 1-3-4-2
Crankshaft rotation direction (viewed
21 Counter-clockwise
towards flywheel)
22 Lubrication manner Pressurization and splashing
23 Start-up manner Electrical starter
24 Overall dimension (L×W×H) 567×494×610 662×497×703 757×494×664
25 Emission GB20891 National II

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 MAINTENANCE MANUAL OF ENGINE

4.3 Technical parameters of main accessories

Fuel injection pump model No.1 pump, or BQ pump

Construction of fuel injection pump Plunger
Diameter of plunger of fuel injection pump ￠8
Needle valve set of fuel injector ZCK154S425

Accessory
Starter
Classification
Model QD1315A or QD138C
Power 2.5KW
Voltage 12V

Accessory
Classification Alternator
Model JF11 or JFWB13A1
Power 350W
Voltage 14V

Water pump
Type Centrifugal
Flow ≥68L/min

Oil pump
Type Rotor type
Flow ≥22L/min

Diesel fuel filter model C0506C

Oil filter model J0810H

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 MAINTENANCE MANUAL OF ENGINE

5. Torque specifications

Torque Remarks
No. Description
N.m
1 Bolts, cylinder head 135-150N.m
Long bolts, rocker arm shaft
2 21-25N.m
base
3 Bolts, connecting rod 50-60N.m
4 Bolts, main bearing cap 115-130N.m
Bolts, connecting water pump
5 to cylinder head and engine 25N·m
body
6 Screw, adjusting belt tension 90N

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 MAINTENANCE MANUAL OF ENGINE

6. Some exposed parts of engine

6.1 Left side of engine

A- Fan B- Crankshaft pulley C- Fuel injection pump D- Oil pan E- Oil filter assembly
F- Engine oil pressure sensor G- Flywheel cover H- Intake pipe

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 MAINTENANCE MANUAL OF ENGINE

6.2 Right side of engine

B
C

A- Cylinder head cover B- Breather C- Alternator D- Starter D

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 MAINTENANCE MANUAL OF ENGINE

Chapter 3 Fuel and Engine Oil

1. Use and precautions for fuel

1.1 Storage of fuel

Do not store fuel too long. If fuel has to be

kept in a tank or transport vehicle for a long
time, add fuel conditioner to prevent concen-
tration.
Contact Lovol's supplier for appropriate use
and maintenance recommendations.

Purchase high-quality clean fuel from the

well-reputed dealers.

Appropriate fuel storage is very important.

The fuel should be stored in a clean warehouse
and fuel tank, and it is required to drain water
and sediments from the bottom of the fuel tank
on a regular basis.

Store fuel in a readily accessible place, and

keep it far away from any building.

Note: In cold seasons, add conditioner into

fuel in storage, or store fuel in bulk, to reduce
fuel coagulation and wax separation.

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 MAINTENANCE MANUAL OF ENGINE

1.2 Precautions for use of fuel

The biodiesel conforming to DIN51606

or diesel with equivalent performance are al-
lowed.
The diesel cannot be mixed with oil or
other type of lubricants.

Before the diesel is injected into the fuel

tank, be certain that the diesel is deposited
(generally above 48 hours), and then filtered
to remove foreign bodies, and prevent severe
wear of the precise parts (plunger and barrel
assembly, delivery valve assembly, and needle
valve assembly) the fuel system resulted from
the foreign bodies.

In case of lack of low condensation point

light diesel in a cold area and in a cold season,
it is possible to use the exhaust gas or circu-
lating water for preheating and heat insulation
of the fuel tank and fuel delivery pipe and im-
proving fluidity of the diesel, so as to use a
high condensation point light diesel.

1.3 Fuel injection

Add fuel referring to the fuel dipstick in fuel

tank.

For fuel addition marks, refer to Maintenance

Manual for TE Series Tractors.

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 MAINTENANCE MANUAL OF ENGINE

2. Engine lubricating oil

Engine oil:
Select engine oil quality grade CD or
higher. Select engine oil viscosity according to
ambient temperature referring to the table be-
low.
Also you can use following other equiv-
alent international brands:
SHELL RIMULA R1 15W/40
MOBIL 15W-40
It is advisable to choose a multi-viscosity
engine oil.
Use of the recommended engine oil
above can extend service life. You may con-
tact LOVOL's supplier for details.

Proper ambient temper-

No. Engine oil designation Remarks
ature

1 15W/40 Above -5℃

2 10W/30 -5℃～-20℃

3 5W/30 Below -20℃

Attention:
1. Select a proper engine oil designation ac-
cording to ambient temperature. Replace en-
gine oil periodically.
2. Do not mix engine oil of different designa-
tions. Failure to do so could cause chemical
reaction thus deterioration of engine oil.

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 MAINTENANCE MANUAL OF ENGINE

3. Engine coolant

Use as cooling water the clean soft water,

such as river water, rain water, snow water and
tap water. Soft water contains fewer minerals.
It generates little foul after heated. Less possi-
bility exists that soft water causes blockage in
the cooling system thus affects heat dissipa-
tion. If soft water is unavailable hence hard
water has to be used, for example, well water,
spring water or other hard water containing
many minerals, softening of the water shall be
performed. The simplest softening method is
to boil the water, wait for a period for deposi-
tion of minerals, and then remove the miner-
als.
If the diesel engine is used in a cold region,
depending on the ambient temperature, add
proper amount of anti-freeze into the cooling
water. The anti-freeze can be the mixture of
alcohol and glycerol or ethanediol.

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 MAINTENANCE MANUAL OF ENGINE

Chapter 4 Position of Product Nameplate

1. Information of diesel engine nameplate

The nameplate of diesel engine carries the

following data: manufacturer name, model,
rated power/rated speed, type approval num-
ber, serial number, manufacturing date, deliv-
ery number, and net weight.

Attention:
For Laidong to accurately provide spare parts,
the customer shall provide Laidong with all
the data indicated on the nameplate.

Position of engine nameplate

The nameplate is found below the intake pipe.

A-Diesel engine nameplate

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 MAINTENANCE MANUAL OF ENGINE

2. Fuel injection pump nameplate

Information of fuel injection pump nameplate

The nameplate of fuel injection pump carries the

following data: model, purchase order number, and
manufacturer name.

A- Position of fuel injection pump nameplate

Position of fuel injection pump nameplate

The nameplate is found right above the fuel injec-

tion pump.

A-Fuel injection pump nameplate

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 MAINTENANCE MANUAL OF ENGINE

3. Position of alternator nameplate

The nameplate of alternator carries the follow-

ing data: power, voltage, drawing number, tel-
ephone number, and manufacturer name.

A-Information of alternator nameplate A

Position of alternator nameplate

A-Alternator nameplate

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 MAINTENANCE MANUAL OF ENGINE

4. Starter nameplate

The nameplate of starter carries the following data:

model, voltage, power, delivery number, manufac-
turing date, and manufacturer name.

A-Information of starter nameplate

A

Position of starter nameplate

A-Starter nameplate

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 MAINTENANCE MANUAL OF ENGINE

5. Air compressor nameplate

The nameplate of air compressor carries the fol-

lowing data: model, speed, displacement, purchase
order number, and manufacturer name.

A-Information of air compressor nameplate

A

Position of air compressor nameplate

A- Air compressor nameplate

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 MAINTENANCE MANUAL OF ENGINE

Chapter 5 Product Features and Accessories

1. Standard configuration

Engine:

4L22BT diesel engine:

4-cylidner

In-line, water-cooled

Vertical, 4-stroke, direct-injection diesel engine

Features of the diesel engine:

Wet-type cylinder liner

Natural aspiration

Direct injection

The standard configuration also includes:

Starter motor

Alternator

Flame heater

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2. Configuration (optional)

Optional: air compressor assembly

A- Air compressor

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Part II Dismantlement, Installation and Adjustment

Chapter 1 Dismantling/installing the valve

mechanism

1. Maintenance equipments and tools

Note:

Special tools

Adjustable torque wrench

2. Torque and data

2.1. Torque requirements

Measurement
Item Parameters Remarks
Unit
Torque
Bolts, cylinder head 135-150N.m
Bolts, main bearing Torque
115-130N.
cap
Bolts, fixing rocker Torque
21-25N.m
arm
Torque
Bolts, connecting rod 50-60N.
Torque
Bolts, flywheel 60-70N.
Torque
Bolts, idle gear 50-60N.m

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 MAINTENANCE MANUAL OF ENGINE

2.2 Data

The data are mainly used for engine overhaul in workshop.

Cylinder head
Valve seat angle:
Exhaust valve ------------------------------------------------------------------------------- 90°±20'
Intake valve----------------------------------------------------------------------------------120°±20'
Diameter of valve guide installation hole -----------------------------------------------13+0.018
0 mm
Leakage test pressure ----------------------------------------------------------------------350-400 KPa
Cylinder head thickness -------------------------------------------------------------------170±0.1 mm
Minimum permissible thickness of cylinder head after machining -----------------169.9 mm

Intake valve
Diameter of valve stem --------------------------------------------------------------------Φ8-0.025
-0.047 mm

Clearance between valve stem and guide -----------------------------------------------0.025-0.069 mm

Maximum clearance between valve stem and guide-----------------------------------0.069 mm
Diameter of valve head---------------------------------------------------------------------Φ35±0.15 mm
Valve face angle ----------------------------------------------------------------------------120 °±20'
Full length------------------------------------------------------------------------------- ---117±0.1 mm
Sealing manner ----------------------------------------------------------Rubber seal ring mounted to valve guide

Exhaust valve
Diameter of valve stem---------------------------------------------------------------------Φ8-0.04-0.55 mm

Clearance between valve stem and guide ------------------------------------------------0.040-0.077mm

Maximum clearance between valve stem and guide------------------------------------0.077mm
Diameter of valve head ---------------------------------------------------------------------Φ29.4±0.1 mm
Valve face angle -----------------------------------------------------------------------------90°±20'
Full length------------------------------------------------------------------------------------117±0.1 mm
Sealing manner -----------------------------------------------------------Rubber seal ring mounted to valve guide

Valve guide
Inner diameter-------------------------------------------------------------------------------Φ8+0.037
+0.015 mm

Outer diameter------------------------------------------------------------------------------Φ13+0.040
+0.022 mm

Clearance between valve guide and hole in cylinder head ---------------------------0.036mm

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Inner valve spring

Installation length --------------------------------------------------------------------------- 35.3 mm
Load on installation length -----------------------------------------------------------------49±2.5 N
Number of effective coil turns--------------------------------------------------------------7
Coil turn direction----------------------------------------------------------------------------Left-handed

Outer valve spring

Installation length ---------------------------------------------------------------------------- 37.5mm
Load on installation length ------------------------------------------------------------------ 88.2±4.4N
Number of effective coil turns---------------------------------------------------------------5.25
Coil turn direction ----------------------------------------------------------------------------Right-handed

Push rod
Diameter of push rod --------------------------------------------------------------------------Φ13-0.016
-0.027 mm

Diameter of hole for push rod in cylinder block -------------------------------------------Φ13+0.018

0 mm
Clearance between push rod and hole in cylinder block ----------------------------------0.016-0.045mm

Rocker arm shaft

Outer diameter----------------------------------------------------------------------------------Φ16-0.016
-0.034 mm

Rocker arm and bushing

Diameter of bushing installation hole-------------------------------------------------------Φ20+0.021
0 mm
+0.068
Outside diameter of bushing------------------------------------------------------------------Φ20+0.035 mm
Interference of bushing with rocker arm--------------------------------------------------- (-0.068)-(-0.014) mm
Inside diameter of bushing after reaming --------------------------------------------------Φ16+0.018
0 mm
Clearance between rocker arm shaft and bushing------------------------------------------0.016-0.052 mm
Maximum permissible clearance between rocker arm shaft and bushing --------------0.052 mm

Camshaft
Diameter of shaft journal 1--------------------------------------------------------------------Φ26 mm
Diameter of shaft journal 2--------------------------------------------------------------------Φ26 mm
Diameter of shaft journal 3--------------------------------------------------------------------Φ26 mm
Clearance between shaft journal and bushing shell for all the journals------------------0.07-0.245 mm

Cam-lobe lift:
Intake valve -------------------------------------------------------------------------------------6.0474 mm
Exhaust valve----------------------------------------------------------------------------------- 6.0289 mm

Axial play:
Manufacturing limit --------------------------------------------------------------------------- 0.07-0.245 mm
Service limit ------------------------------------------------------------------------------------ 0.245 mm

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3. Dismantling the valve mechanism

3.1 Dismantling the cylinder head cover

A
1. Dismantle the nut (A) and gasket set (B) from the C
cylinder head cover (C). Loosen the cylinder head
cover.
B
A-Nut, cylinder head cover
B-Gasket set
C-Cylinder head cover

2. Dismantle the cylinder head cover (A).

A-Cylinder head cover

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3.2 Dismantling the rocker arm assembly

1. Dismantle the bolt (A) for fixing rocker arm

shaft.
A

A- Bolt for fixing rocker arm shaft

2. Dismantle the rocker arm shaft assembly (A).

A

A-Rocker arm shaft assembly

3. Dismantle the push rod (A).

A-Push rod

Attention: Check the push rod for deformation or

damage.

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 MAINTENANCE MANUAL OF ENGINE

4. Dismantle the bolt for fixing breather.

Dismantle the breather (A).

A-Breather

5. Dismantle the fuel filter (see Section 3.2, Chapter

6 of this Part).

6. Disconnect the hose of fuel-water separator (see

Section 3.2, Chapter 3 of this Part)

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3.3 Dismantling the cylinder head assembly

1. Using a torque wrench (N.m indicated), loosen in

the specified sequence the bolts (A) for fixing cyl-
inder head.

A- Bolt for fixing cylinder head

Attention: Loosen the bolts in the diagonal se-

A
quence.
This is to ensure that pressures applied to the cylin-
der head and its gasket are uniform to avoid dis-
placement and deformation.
Remove the cylinder head. Place it on a plane that
may not cause damage to its mating face.

2. Remove the bolts (A) for fixing cylinder head.

A-Bolts for fixing cylinder head A

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 MAINTENANCE MANUAL OF ENGINE

3. Remove the cylinder head.

A-Cylinder head assembly

A
Attention: Since the cylinder head is heavy, it shall
be removed using a hoist, or manually by two per-
sons.
Place the cylinder head at a proper location, with its
mating face upward to avoid scratches.

4. Carefully remove the cylinder head gasket (A).

A-Cylinder head gasket

A

Attention: Check the gasket and replace it if neces-

sary.

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3.4 Dismantling the camshaft assembly

1. Dismantle the timing gear (see Section 7.3,

Chapter 7 of Part II).

2. Dismantle the camshaft (A).

A-Camshaft

3.5 Dismantling the valve tappet

1. Dismantle the crankshaft assembly (see Section

3.1, Chapter 2 of Part II).

2. Dismantle the piston-connecting rod assembly

(see Section 3.2, Chapter 2 of Part II).

3. Dismantle the valve tappet.

A-Valve tappet
A

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3.6 Dismantling the rocker arm of valve

Dismantle the snap rings (A) at both ends of the

rocker arm shaft, then the locknut (G) and the

valve-adjusting screw (F). Dismantle the front

rocker arm seat (D), rocker arms (H and I), and

rocker arm spring (E) from the rocker arm shaft.

A- Snap ring
B- Plug
C- Rocker arm shaft
D- Rocker arm shaft base
E- Spring
F-Adjusting screw
G-Locknut
H-Valve rocker arm
I-Valve rocker arm
J- Rocker arm shaft base

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3.7 Dismantling the intake and exhaust valves

Tool: Valve spring compression tool

Using the valve spring compression tool and the

corresponding attachment, compress the valve
spring to remove the valve split cone.
Dismantle the valve split cone (A). Take out the
upper valve spring retainer (B), outer valve spring
(C), inner valve spring (D), valve stem oil seal seat
(E), valve guide (F), intake valve seat (G), exhaust
valve seat (S), intake valve (H) and exhaust valve
(T) one by one.

A-Valve split cone

B-Upper valve spring retainer
C-Outer valve spring
D-Inner valve spring
E-Valve stem oil seal seat
F-Valve guide
G-Intake valve seat
H-Intake valve
S-Exhaust valve seat
T-Exhaust valve

Attention: Apply a proper mark to the valve head,

which will be used as a reference in valve installa-
tion.

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4. Installing the valve mechanism

4.1 Installing the valve tappet

1. Install the cylinder liner (see Section 4.1, Chapter

2 of Part II).
Keep its mating face clean before installing the
valve tappet.
2. Apply lubricating oil to the valve tappet.

A-Valve tappet A

3. Check the installation hole (A).

A- Installation hole

4. Install the valve tappet.

A-Valve tappet A

The valve tappet shall be installed so that it can

slowly slide without sticking along its installation
hole of an inclination 45°- 60°.

5. Install the crankshaft assembly (see Section 4.2,

Chapter 2 of Part II).
6. Install the timing gear chamber cover (see Sec-
tion 7.3, Chapter 7 of Part II).

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 MAINTENANCE MANUAL OF ENGINE

4.2 Installing the camshaft

1. Install the camshaft (A).

A-Camshaft

Before installing the camshaft, check that its ma-

chined surfaces are free of dirt and scratches, and
then apply clean lubricating oil to these surfaces.
A

2. Tighten the bolt (A) for fixing camshaft.

A- Bolt

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4.3 Installing the intake and exhaust valves

Using the valve spring compression tool and the

corresponding attachment, compress the valve
spring to remove the valve split cone.

Install the intake and exhaust valves in place, refer-

ring to the match marks made when removing them.
A
Install the intake valve seat (G), intake valve guide B
(F), valve stem oil seal assembly (E), inner spring C
(D), outer spring (C), upper valve spring retainer
(A), and valve split cone (B) one by one to the in-
take valve. D

Install the exhaust valve following the same proce-

E
dure.

G
A-Upper valve spring retainer
B-Valve split cone
C-Outer valve spring H
D-Inner valve spring
E-Valve stem oil seal assembly
F-Intake valve guide
G-Intake valve seat
H-Intake valve

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 MAINTENANCE MANUAL OF ENGINE

Installing the valve spring

Replacement of valve spring

Special tools:
Valve spring compression tool
Screw stud attachment
Alignment screw attachment

Attention: The following description is for the re-

placement of valve springs of a single cylinder.
Warning: Wear protective goggles when replacing
valve springs.

1. Dismantle the valve mechanism (see Section 3 of

this Chapter).
2. Rotate the crankshaft counter-clockwise until the
piston where the valve springs are to be replaced
moves to top dead center (at the moment, the intake
valve is about to open and the exhaust valve is not
yet fully closed).
3. Remove the rocker arm assembly (see Section
4.7 of this Chapter).
4. Install the compression tool and the correspond-
ing attachment.
5. Compress the valve spring and remove the valve
split cone. Be sure to compress the spring vertically.
Failure to do so could cause damage to the valve
stem.
Attention: Do not rotate the crankshaft while re-
moving the valve spring.

6. Release the valve spring compression tool. Re-

move the valve spring cap and the valve spring.
7. Install the new inner and outer valve springs.
8. Install the valve spring cap.
Attention: Be sure to compress the spring vertically.
Failure to do so could cause damage to the valve
stem.
9. Compress the valve spring to install the valve
split cone. Remove the compression tool.

Remark: If valve springs of more than one cylinder

have to be replaced, the valve springs of two cylin-
ders can be replaced at the same time. Take the
4-cylinder engine as an example, the valve springs
of cylinders 1 and 4, or of cylinders 2 and 3 can be
replaced at the same time.

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4.4 Correcting the valve seat

Special tools:
Reamer for intake valve seat
Reamer for exhaust valve seat
Guide bar, used along with the reamer
Handle set used along with the reamer

1. Do not move the valve seat before installing the

new valve guide.
2. Insert the guide bar through the valve guide.
Then fix the guide bar.
3. Select a proper reamer. Adjust the reamer blade
so that the expected reaming diameter is equal to
the valve seat diameter. Install the reamer to the
guide bar. Install the handle to the guide bar. Be
sure that the reamer is not below the valve seat.
Otherwise damage could be caused to the reamer
blade.
4. Carefully rotate the handle clockwise. The metal
removed shall be adequately minimal to ensure the
integrity of the valve seat. The valve seat hole shall
be as small as possible.
5. Upon completion of the reaming, remove the
reamer and guide bar. Remove the chips around the
valve seat and guide bar.
6. Install the valve stem. Slightly grind the valve
head and valve seat.

7. Check whether the valve depth is within the per-

missible limit.
Attention: In case of serious damage or wear of
valve seat, thus great difficulty in correction by
reaming, install a valve seat insert.

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 MAINTENANCE MANUAL OF ENGINE

4.5 Measuring the clearance between valve stem

and guide

Checking the valve guide for wear:

The maximum permissible clearance between in-
take valve stem and guide is 0.13 mm, and that be-
tween exhaust valve stem and guide is 0.15mm. If
the clearance exceeds the limit after installing a new
valve stem, it is required to install also a new valve
guide.
The following steps are recommended for measur-
ing the clearance between valve stem and guide
1. Insert a new valve stem through the new guide.
2. Put on the cylinder head a dial indicator with a
magnetic stand. D
3. Raise the valve head by 15mm. Move the probe A
of dial indicator so that it just comes into contact B E
with the valve head fringe. Zero the dial indicator.
Radially moves the valve head away from the probe
until the valve stem comes into contact with the
guide wall.
4. Radially moves the valve head in the opposite
direction until it just comes into contact with the
probe again. Record the reading of the dial indicator. C
If it is equal to or greater than 0.077mm, it is re-
quired to replace the current valve guide with a new
one.
The maximum permissible clearance between valve
stem and guide is 0.077mm when the valve head is
raised by 15mm.

A-Dal indicator
B- Probe
C- Valve head
D- Valve guide
E- Maximum clearance between valve stem and
guide

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 MAINTENANCE MANUAL OF ENGINE

4.6 Installing the cylinder head

Clean the mating face of engine block. Check that

the cylinder head gasket is in the correct direction.

1. Install the cylinder head gasket (A).

A-Cylinder head gasket A

2. Install the cylinder head assembly (A).

A-Cylinder head assembly

Attention
Before closing the cylinder head, align its two
alignment pins with the two alignment holes in the
cylinder block. If no hoist is available, the cylinder
head must be carried onto the cylinder block by two
persons. Careful operation is needed to avoid per-
sonal injury.

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 MAINTENANCE MANUAL OF ENGINE

3. Insert the bolts (A) for fixing cylinder head.

Pre-tighten them in the specified sequence.

A
A-Bolt for cylinder head

4. Tighten the bolts (A) again in the specified se-

quence to the specified torque.

A- Bolt tightening diagram A

Torque --------135 to 150N.m

Attention:

First pre-tighten the bolts, and then tighten them to

the specified torque.

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 MAINTENANCE MANUAL OF ENGINE

4.7 Installing the rocker arm assembly

Check the push rod for deformation. If any, replace

it with a new one.

A
1. Install the push rod (A).

A-Push rod

2. Install the rocker arm shaft (A).

A-Rocker arm shaft

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 MAINTENANCE MANUAL OF ENGINE

3. Tighten the bolt (A) for fixing rocker arm shaft.

A- Bolt for fixing rocker arm shaft

Tightening torque-----------------21-25N.m
A

Inspection
Check the rocker arm assembly for wear and other
damage. Check the clearance between rocker arm
shaft and bushing. If it is greater than 0.13mm, re-
place the rocker arm shaft or bushing.

Attention
1. To replace the bushing, eject it out using a proper
rod.

2. Align the lubrication hole in the new bushing

with that in the rocker arm. Push the bushing into
place.

3. Enlarge the bushing so that the clearance between

rocker arm shaft and bushing is 0.03 to 0.09 mm.
Clean the bushing thoroughly. Check its lubrication
hole for chips.

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 MAINTENANCE MANUAL OF ENGINE

4.8 Adjusting the valve clearance

Tool:

Open-end wrench, flat-tip screwdriver, feeler gauge

Firing order for a 3-cylinder engine: 1-3-2

Valve clearance adjustment rule: When the piston of
cylinder 1 comes to the top dead center, valve
clearance can be adjusted for both the intake and
exhaust valves of cylinder 1, exhaust valve of cyl-
inder 3, and intake valve of cylinder 2.
Intake valve clearance 0.20～0.25 mm
Exhaust valve clearance 0.25～0.30mm

Adjusting steps:
Method for determining the top dead center of
cylinder 1
Rotate the crankshaft counter-clockwise until the
exhaust valve of cylinder 2 is about to open and the
intake valve of cylinder 3 is about to close, then the
piston of cylinder 1 comes to the top dead center.
Adjust the valve clearances in the sequence of 1-3-2,
and following the rule mentioned above.
Adjust the clearances of the intake and exhaust
valves of cylinder 1.
Adjust the clearance of exhaust valve of cylinder
3.
Adjust the clearance of intake valve of cylinder 2.

Then rotate the flywheel for one turn. Adjust the

clearance of intake valve of cylinder 3 and the
clearance of exhaust valve of cylinder 2.

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 MAINTENANCE MANUAL OF ENGINE

4.9 Installing the cylinder head cover

First check the gasket of cylinder head cover for

damage. If any, replace it with a new one.

1. Install the gasket and cylinder head cover.

A-Gasket of cylinder head cover B

B-Cylinder head cover

2. Tighten the bolts (A) for fixing cylinder head

cover.

A- Bolt

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 MAINTENANCE MANUAL OF ENGINE

Chapter 2 Dismantling/installing the crank-link mechanism

1. Maintenance equipments and tools

Special tools:

16/19 Open-end wrench, 13 socket wrench, 18 socket wrench, digital torque wrench, adjustable torque
wrench

2. Torque and data

2.1. Torque requirements

Measurement
Item Parameters Remarks
Unit

Bolts, connecting rod Torque 50-60N.m

Main bearing bolt Torque 115—130N.m

2.2 Data

Piston ring-naturally aspirated engine

First gaseous ring------------------------------------------------chamfer on cylindrical surface and top of inner face
Second gaseous ring---------------------------------------------conical surface, cast iron
Oil ring------------------------------------------------------------spiral spring-weighted
First ring width---------------------------------------- ------------3.6±0.1 mm
Second ring width-------------------------------------------------3.5±0.1 mm
Third ring width---------------------------------------------------3.3±0.1 mm
Clearance of first ring in groove--------------------------------0.095+0.128 mm
Clearance of second ring in groove---------------------------- 0.04-0.072 mm
Clearance of third ring in groove------------------------------- 0.03-0.062 mm
Opening clearance of first ring----------------------------------11-13 mm
Opening clearance of second ring-------------------------------11-13 mm
Opening clearance of third ring--------------------------------- 9-11 mm

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 MAINTENANCE MANUAL OF ENGINE

Connecting rod-naturally aspirated engine

Type-----------------------------------------------------------------------H-section, square end

Positioning of bearing cap and connecting rod---------------------Saw-tooth type
Diameter of hole at big end of connecting rod ---------------------Φ54 +0.019 0 mm
Diameter of hole at small end of connecting rod-------------------Φ310+0.025 mm
Center distance--------------------------------------------------------- 145±0.03 mm

Connecting rod bearing shell- naturally aspirated engine

Type-----------------------------------------------------------------------Steel backing, aluminum/stannum material
Width of connecting rod bearing shell--------------------------------Φ310+0.025 mm
Thickness of connecting rod bearing shell---------------------------2-0.020 -0.033 mm

Clearance of connecting rod bearing shell----------------------------0.04-0.101 mm

Piston pin-naturally aspirated engine

Type-------------------------------------------------------------------------Full floating
Outer diameter------------------------------------------------------------Φ280-0.006 mm
Clearance fit in piston axle sleeve--------------------------------------0.0045-0.0105 mm

Small end bushing-naturally aspirated engine

Type--------------------------------------------------------------------------Full floating
Outer diameter--------------------------------------------------------------Φ31+0.025
0 mm
Inner diameter--------------------------------------------------------------Φ28+0.038
+0.025 mm
Clearance between small end axle sleeve and piston pin-------------0.025-0.042 mm

Crankshaft
Main journal diameter:
4-cylinder engine----------------------------------------------------------Φ80 0-0.019 mm
Front journal width--------------------------------------------------------290+0.1 mm
Central journal width----------------------------------------------------- 290+0.1 mm
Width of all other journals----------------------------------------------- 290+0.1 mm
Crank pin diameter--------------------------------------------------------Φ60 0-0.019 mm
Crank pin width------------------------------------------------------------31 +0.1
0 mm
Flange diameter------------------------------------------------------------Φ800-0.019 mm
Axial play of crankshaft---------------------------------------------------0.075-0.24 mm
Maximum allowable axial play---------------------------------- --------0.24 mm
Journal and fillet radius of crank pin-------------------------------------R3.5 0-0.5 mm

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 MAINTENANCE MANUAL OF ENGINE

3. Dismantling the crank-link mechanism

3.1 Dismantling the crankshaft

1. Dismantle high pressure fuel pipe accessories

(See Section 3, Chapter 6 of this Part for the de-
tails).

2. Dismantle the gear chamber (See Section 7,

Chapter 7 of this Part for the details).

3. Dismantle the flywheel parts (See Section 7,

Chapter 7 of this Part for the details).

4. Dismantle the oil pan parts (See Chapter 4 Sec-

tion 3 for the details)

5. Dismantle the connecting rod bolt A.

A-Connecting rod bolt

A

6. Dismantle the connecting rod cap A and con-

necting rod bearing shell B

A-Connecting rod cap

B-Connecting rod bearing shell

Attention:
Connecting rod bearing shell and connecting rod
cap shall be marked by the sequence of 1, 2, 3 cyl-
inder, which shall be placed neatly without bump so
that it will be installed in sequence for assembly, or
it will influence the performance of diesel engine.
A B

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 MAINTENANCE MANUAL OF ENGINE

7. Dismantle the main bearing cap bolt A succes-

sively.

A-Main bearing cap bolt

8. Dismantle the main bearing cap A.

A-Main bearing cap

A

9. Dismantle main bearing cap A and main bearing

shell B, which shall be placed neatly.

A-Main bearing cap

B-Main bearing shell

Attention:
Dismantle the main bearing cap and main bearing
shell and mark the diesel engine in the sequence of
1, 2, 3, 4 from front to back. It shall be placed neat- A
ly in successively without bump so that it will be B
installed in sequence for assembly, or it will influ-
ence the performance of diesel engine.

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 MAINTENANCE MANUAL OF ENGINE

10. Take down the crankshaft A.

A-Crankshaft

Attention
If suitable lifting tools are not equipped, two per-
sons shall cooperate to lift up the crankshaft togeth-
er.
A

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 MAINTENANCE MANUAL OF ENGINE

3.2 Dismantling the piston connecting rod assembly

Attention:
Clear the carbon deposition on upper cylinder head.
If it is not cleared or not cleared fully, it may cause
damage to the piston ring.

1. Push out the piston connecting rod assembly

from one side of crankshaft by stick or rubber rod.

A-Piston connecting rod assembly

Attention A
Assemble the connecting rod bearing shell and
connecting rod cap after piston connecting rod is
dismantled and place in sequence.

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 MAINTENANCE MANUAL OF ENGINE

3.3 Dismantling the cylinder liner

Special tools:
Tools for dismantling/ replacing the cylinder liner
B
Several cylinder liners shall be dismantled, or
A
pressing machine shall be used when the cylinder
C
linear for installation and production is too tight;
when dismantling single cylinder liner, or when
crankshaft is kept in installation position, manual D
operating tool shall be equipped.

1. Discharge lubricating oil and dismantle lubricat- E

ing oil sump.
2. Dismantle cylinder head assembly.
3. Dismantle piston and connecting rod assembly.
4. Rotate the crankshaft to touch the cylinder liner
to protect crank pin.
5. Place the tool D on cylinder top surface and in F
the middle of cylinder liner E so as to guarantee that
tool base does not press the top of neighboring cyl-
inder liner flange.
6. Place the bearing C into groove at the top of tool
so that plane of bearing will face the bottom of side A-Screw B-Handle C-Bearing D-Special tool
groove. E-Cylinder liner F-Joint
7. Install screw B through bearing and tool top so
that handle A is in the groove at the top of bearing.
Adjust the screw at this position to make the end
lower than bottom of cylinder liner. Install the joint
F onto screw and jack the bottom of cylinder liner
so as to guarantee that two lugs at the top of joint
will be stuck in screw plane. Install gasket and nut
and fasten the nut onto joint.

8. Lubricate the handle ratchet and screw by lubri-

cating oil or similar lubricating oil. Operate the
handle and drag out the cylinder liner from top of
cylinder body.

9. Take out cylinder liner A.

A-Cylinder liner

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 MAINTENANCE MANUAL OF ENGINE

3.4 Dismantling the piston ring and connecting

rod

Dismantle piston ring with suitable piston ring ex-

pander and store the piston ring with corresponding
piston. F

Dismantle piston ring assembly A and check ring B;

take out piston pin F and take out connecting rod E
body B from piston C. Dismantle connecting rod A
bushing E.
B C
D
A-Piston ring assembly
B-Check ring
C-Piston
D-Connecting rod body
E-Connecting rod bushing
F-Piston pin

When disassembling piston pin, push the piston pin

out by hand. If the piston pin is too tight, heat it to
40/50℃ (100/120℉) so that it can be dismantled
easily.

Squeeze the old connecting rod bushing by suitable

joint.

Attention: check the wear condition of piston ring

when disassembly and replace the new ones when
necessary.

Connecting rod bushing shall use special tool for

disassembly so as to avoid damage.

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 MAINTENANCE MANUAL OF ENGINE

4. Installing the crank-link mechanism

4.1 Installing the cylinder liner

Attention:
Damaged or worn cylinder liner must be scrapped.
When replacing cylinder liner, piston ring must be
replaced simultaneously.

Cylinder liner needs not to be replaced under fol-

lowing conditions:
◆Honing lines are clear and visible.
◆Performance and oil consumption of engine are
acceptable.

1. When installing new cylinder liner, coat a layer

of lubricating oil on cylinder liner. Place the cylin-
der liner by aligning at engine body.

A-Cylinder liner

2. Place the cylinder liner into engine body.

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 MAINTENANCE MANUAL OF ENGINE

Attention: Do not knock on cylinder liner by ham-

mer.
1. Completely clean the cylinder liner mounting
bore. A
2. Completely clean the outside surface of cylinder B
liner by safety solvent. C
3. Insert the cylinder liner E into original mounting D
E
bore. Make sure that cylinder liner is vertical and
install the joint D into cylinder liner top so that joint
shaft shoulder is on cylinder liner flange. Place
bearing C in groove position at the top of joint so
that bearing plane will face toward the bottom of
groove.
4. Install the screw A through bearing, joint and
cylinder liner until handle jacks the bearing groove.
In this position, adjust the screw to make the end
lower than cylinder block bottom face.
5. Install joint F into screw to make sure that joint
plane jacks the cylinder block bottom face. Install F
gasket and nut to make sure that screw is in the
middle of cylinder liner and fasten the nut onto
A-Screw B-Handle C-Bearing D-Special tool
joint. E-Cylinder liner F-Joint

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 MAINTENANCE MANUAL OF ENGINE

4.2 Installing the crankshaft

1. Install the cylinder liner (See Section 3 of this

Chapter for details)

2. Install the valve tappet (See Chapter 4.1, Chapter

1, Part II).

Attention:
Before installation, make sure that original mount-
ing bore and bearing bush surface are clean without
foreign substance, or it will influence the fit preci-
sion.

3. Install main bearing shell A.

A
A-Main bearing shell

Attention:
After installing main bearing shell, coat clean lu-
bricating oil on the surface.

4. Install crankshaft assembly A.

Attention:
Before installation, make sure that all processing
surfaces of crankshaft are clean without scratch and
damage.
A

A-Crankshaft
Attention:
Detect the axial clearance: install the magnetic
stand on front end face of engine body so that dial
indicator header will contact front end face of
crankshaft. Zero the dial indicator and push the
crankshaft components from front to back by hand;
check the rotating area of dial indicator pointer, that
is the axial clearance. Crankshaft axial clearance
shall be 0.085～0.275mm.

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 MAINTENANCE MANUAL OF ENGINE

5. Install crankshaft thrust plate.

A-Thrust plate

Attention:
When installing thrust plate, pay attention to make A
the side with oil groove face the crankshaft. When
installing bearing shell, the locating slot of upper
bearing shell on bearing cap shall be on the same
side with the locating slot of bearing shell of origi-
nal mounting bore.

6. Coat a layer of clean lubricating oil on main

bearing cap.

A-Main bearing cap

Attention: The above groove shall be installed in

place when installing.
A

7. Install the main bearing shell A.

Install main bearing shell and main bearing cap and

guarantee that main bearing cap is free of foreign
substance. The surface shall be clean, or it will in- A
fluence the assembly precision.

A-Main bearing shell

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 MAINTENANCE MANUAL OF ENGINE

8. Install the main bearing cap A.

A-Main bearing cap

After installation, refuel clean lubricating oil in

bearing shell. A

9. Install the main bearing cap bolt A.

A- Bolt

10. Fasten the bolt A.

Attention:
When locking the cap, it shall be fastened symmet-
rically and evenly. When fastening every bolt, rotate
the crankshaft by hand. Check whether crankshaft
A
rotates flexibly, thus it is good to timely find the
possible problem during assembly.

A- Bolt

Tightening torque of main bearing cap bolt is

115—130N.M.

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 MAINTENANCE MANUAL OF ENGINE

11. Installation of gear chamber (See Section 7.3,

Chapter 7 of Part II for details).
12. Install crankshaft pulley A.

A-Crankshaft pulley

Attention
When installing crankshaft pulley, copper hammer
A
cannot be directly used for knocking.

13. Install the set bolt.

A- Bolt

Bolt torque-----160-170N.m
A

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 MAINTENANCE MANUAL OF ENGINE

4.3 Installing the piston connecting rod assembly

4.3.1 Installing the piston ring

First gaseous ring (opening clearance: 0.35-0.5mm)

Second gaseous ring (opening clearance:
0.25-0.45mm)
Oil ring component (opening clearance:
0.25-0.45mm)

Attention: detect the opening clearance of piston

ring in standard cylinder liner.

1. Install spring A of oil ring into ring groove.

A-Spring of oil ring

Opening direction of all rings shall be installed in

stagger. To avoid combustible mixed gas leaking
from the opening clearance of piston ring. Opening
direction of all gaseous rings shall be staggered by A
90~120°during assembly;

2. Install oil ring, second gaseous ring, first gaseous

ring by special tool. B
C A
A-Oil ring
B-Second gaseous ring
C-First gaseous ring D
D-Special tool

Attention: When installing piston rod, appropriate

tool shall be selected, or it may damage the piston
ring or piston surface.

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 MAINTENANCE MANUAL OF ENGINE

3. Install the oil ring and gaseous ring onto the pis-
ton.

A-Piston

Attention
◆Opening position of oil ring shall be staggered by
180° with oil ring spring interface.
◆The surface which is printed with manufacturer
logo on gaseous ring shall face the piston top.

B-Engraved logo

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 MAINTENANCE MANUAL OF ENGINE

4.3.2 Installing the connecting rod bushing

Inspection:

◆Check whether connecting rod is deformed.

Note: Big end of connecting rod and small end
bearing bore must be flat and parallel. Check the
two sides of connecting rod axis and the result shall
not exceed +/-0.25mm limit. After installing small B
end bushing, the limit is+/-0.06mm.
◆Check whether small end bushing is worn or
damaged; replace it with new ones when necessary.
◆Clean the connecting rod bore and clear all the
sharp edges.
A
Install connecting rod bushing into small end of
connecting rod.

A-Connecting rod body

B-Connecting rod bushing

Pay attention to the installation process of connect-

ing rod bushing B:
Replace new connecting rod bushing--squeeze ex-
panding bushing bore--bore bushing bore--hone
bushing bore. The distance between small end
bushing bore of connecting rod and big head basic
bore center shall conform to requirement. The key
is to realize locating boring bushing bore.

Press new connecting rod bushing to make sure that

lubrication hole in axle sleeve is at the same side
with lubrication hole of connecting rod top for
alignment.

Connecting rod bushing shall be finished by profes-

sional technicians. It is prohibited to assemble
without permission.

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 MAINTENANCE MANUAL OF ENGINE

4.3.3 Installing the piston pin

Inspection:
◆Check the fit of piston pin and small end bushing
and check whether piston pin is worn.
Before installation, make sure that piston pin and
small end of connecting rod are clean and lubricate
by clean engine lubricating oil.

1. First install one end snap ring into piston.

A-Snap ring

2. Use special equipment to heat the piston.

A-Piston
B-Heating equipment

When installing piston pin, heat the piston to

100℃-120℃evenly by special equipment for in-
A
stallation. Meanwhile, coat clean lubricating oil on
piston pin. It is prohibited to press piston pin when
piston is in cold state.
B
Attention: High temperature. Avoid scalding injury.

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 MAINTENANCE MANUAL OF ENGINE

3. Install piston pin to connect connecting rod with

piston.

A-Connecting rod
B-Piston pin
A
C-Piston

Attention:
When piston is assembling with connecting rod, the
direction shall not be reserve. Pay attention to the B
marking on piston and connecting rod body to as-
semble by marking direction. C
The clearance between small end bushing of con-
necting rod and piston pin shall be
0.0075-0.0125mm.
Fit clearance between piston hole and piston pin
shall be -0.0025mm under normal temperature.

4. Install retainer ring A.

A-Retainer ring

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 MAINTENANCE MANUAL OF ENGINE

4.4 Install piston connecting rod assembly into

cylinder liner

Confirm the installation direction of piston and in-

stall the piston into cylinder liner.

When installing, pay attention that the "marking"

direction at top face of piston shall face the front
end of engine, meanwhile make sure that the open-
ing position of three rings are staggered by 120°.
Attention: Stagger with pin hole. Apply clean lubri-
cating oil on piston ring.

1. Coat lubricating oil on piston ring.

A-Piston

2. Use special tool to sleeve on piston.

A-Special tool

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 MAINTENANCE MANUAL OF ENGINE

3. Install the piston.

A-Piston
B-Special tool
Attention:
Somebody shall knock the piston by stick or rubber
stick on the upper end and somebody shall watch
A
the swing connecting rod at lower end to avoid
connecting rod bumping on crankshaft journal.
Clean the cylinder liner before installation and coat B
clean lubricating oil. Ensure that the bearing cap
hole and bearing shell surface are clean and free of
foreign substance. Refuel clean lubricating oil in
inner surface, or it will influence the fit precision.

4. Install connecting rod cap A

Clean connecting rod bearing shell and connecting
rod cap before installation. Install bearing shell on
bearing cap to guarantee that locating lug is cor-
rectly installed into groove. Lubricate bearing shell
with clean engine lubricating oil. Install bearing
shell cap and make sure that the assembly number
on bearing shell cap is the same with connecting rod
and the half-matching numbers are on the same side.
Install fastener to make sure that bolt head plane
faces connecting rod When nut is adopted as fasten-
er, it must be new. Tighten the new nut to recom-
mended torque evenly.

A-Connecting rod cap A

Attention
When installing, the locating slots installed on up-
per bearing shell of connecting rod bearing cap and
connecting rod body shall be on the same side.

5. Fasten connecting rod bolt.

A-Connecting rod bolt

Fasten connecting rod bolts and tighten successive-

ly.
Attention:
The printed word size of connecting rod and bear-
ing cap shall be the same and on the same side.
A
Bearing caps shall not be changed mutually.
Connecting rod bolt tightening torque--50-60N.m

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Chapter 3 Cooling system

1. Maintenance equipments and tools

Note:

Special tools:
16/19 open wrench
8 socket wrench
13 socket wrench
Digital torque wrench

2. Torque requirements

Measurement
Item Parameters Remarks
Unit
Bolts, connecting water
pump to cylinder head and Torque 25N·m
engine body
Screw, adjusting belt ten-
N 90N
sion

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3. Dismantling the cooling part

3.1 Dismantle the attaching clamp of water outlet

switch

Before dismantling, drain the cooling water.

1. Dismantle the attaching clamp of water outlet

switch.
A
A-Attaching clamp of water outlet switch

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3.2 Dismantle the hose of fuel-water separator

1. Loosen the jacket A

A-Jacket

2. Disconnect the hose of fuel-water separator A

A-Hose of fuel-water separator

A

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3.3 Dismantle fan components

1. Dismantle fan set bolt A

A-Set bolt

2. Dismantle fan A

A-Fan

3. Dismantle fan belt

A-Fan belt

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3.4 Dismantle water pump components

1. Dismantle water pump set bolt A

A-Set bolt

2. Take down water pump cover A

A-Water pump cover

3. Take down water pump assembly A

A-Water pump assembly

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3.5 Dismantle the fan and pulley

Attention:
Before disassembling water pump component,
firstly drain the water in radiator.

1. Dismantle belt A and belt B.

A- Belt from fan to generator.

B- Belt from crankshaft to fan

A
B

2. Dismantle bolt B, take out fan A, fan gasket C

and pulley D.

A-Fan
B-Bolt
C-Fan block D
D-Pulley C
E-Water pump assembly

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3.6 Dismantle the water pump assembly

1. Dismantle bolt A, take out thermostat D.

2. Dismantle bolt F, dismantle water pump assembly,

take out gasket E, cushion block G and gasket H.

A- Bolt
B-Thermostat housing;
C-Thermostat housing gasket;
D- Thermostat;
E-Water pump gasket;
F-Bolt;
G-Water pump flange cushion block;
H-Water pump flange gasket

Attention: Water pump shall not be dismantled by

non-professionals.

3. Dismantle nut, take out water pump connecting

shaft bearing, water seal.
4. Dismantle water pump impeller by special tool.

Attention: Operate carefully to prevent from dam-

aging impeller.
Be careful while disassembling water seal to avoid A
damage. B F
C D E
Water pump connecting shaft bearing shall not be
dismantled by non-special tool.

A-Water pump housing

B-Nut
C-Gasket
D-Water pump connecting shaft bearing
E-Water seal
F-Water pump impeller

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4. Assembling the cooling part

4.1 Installing the water pump assembly

Clean the surface of cylinder liner and cooling liq-

uid and lubricating oil passage; water jacket can be
cleaned by special solvent, which shall follow the
instruction of manufacture when using. A
B F
The basic assembly sequence and disassembly se- C D E
quence for water pump as shall be opposite. How-
ever, except replacing bushing and seal ring, parts
that have been cleaned shall be first checked and
measured. If the wear has exceeded the limit, re-
place the new ones. It can be assembled only after
all parts are qualified.

◆ Fit clearance between water pump shaft and

bearing shall be (0.010-0.012)mm. A-Water pump housing
It is allowed to be (0.010~ 0.030) mm for overhaul.
B-Nut
◆Fit of water pump bearing and bearing hole: it is C-Gasket
generally (0.02- 0.02) mm; it is allowed to be
D-Water pump connecting shaft bearing
(0.02-0.044) mm for overhaul.
E-Water seal
◆After installation, water pump impeller shall be
generally (0.1-0.5)mm higher than pump shaft. F-Water pump impeller

◆After water pump is installed, the clearance be-

tween impeller outer edge and pump case inner cav-
ity is generally 1mm; there shall be (0.075-1)mm
clearance between impeller and pump cover.
◆All bolts and nuts shall be tightened by specified
torque and locking shall be reliable.
◆Drain hole below water pump shall be smooth.
◆ After installation of water pump, lubricating
grease with specified mark shall be refueled to wa-
ter pump bearing.
◆When installing, pay special attention to the axial
clearance between water pump impeller and water
pump housing, clearance between water pump im-
peller and radial seal of housing. Pay attention to
the lubricating conditions of bearing.

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4.2 Installing the water pump components

1. Install water pump gasket A

A-Water pump gasket

2. Install water pump component A

A-Water pump component

3. Fasten water pump set bolt A

A- Bolt

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4.3 Installing the hose of fuel-water separator

1. See Section 4.2 of this chapter for installation of

water pump components.
2. Install the hose of fuel-water separator and fas-
ten.

A-Hose of fuel-water separator

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4.4. Installing the fan

1. Install alternator components (See Section 3,

Chapter 5 of this Part).

2. Install fan A and fasten the bolt.

A-Fan

3. Install belt A

A-Belt

Belt tension ---98N

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Chapter 4 Lubricating System

1. Maintenance equipments and tools

Note:

Introductions for special tools

Open-end wrench or offset ring wrench

2. Torque requirements

Measurement
Item Parameters Remarks
Unit
The engine oil pump is
assembled onto the engine Torque 25N.m
body

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3. Dismantling/installing the oil pan parts

3.1 Dismantling the oil pan parts

1. Empty the oil, and overturn the engine. Disman-

tle the set bolts A of the oil pan part.

A- Bolt

2. Dismantle the oil pan part A

A-Oil pan part

Attention: Pay attention to personal safety during

dismantling because the oil pan is heavy.
A

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3.2 Installing the oil pan parts

1. Install the oil pan gasket A

A-Oil pan gasket

Attention
Install a new oil pan gasket. A

2. Install the oil pump parts (see Section 4.2 in this

chapter)
3. Install the oil pan.

A-Oil pan A

4. Tighten the set bolts A in sequence.

A- Bolt

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4. Dismantling/installing the oil pump parts

4.1 Dismantling the oil pump parts

1. Dismantle the set bolts of the oil pump.

A- Bolt

2. Dismantle the oil pump parts A.

A-Oil pump part

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4.2 Installing the oil pump parts

1. Install the oil pump assembly

A-Oil pump assembly

2. Tighten the bolts A of the oil pump.

A- Bolt

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Chapter 5 Electric system

1. Maintenance equipments and tools

Introductions for special tools

Sleeve

2. Torque requirements

Measurement
Item Parameters Remarks
Unit
Connection between the
Torque 80N.m
starter and flywheel cover

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3. Dismantling/installing the alternator assembly

3.1 Dismantling the alternator assembly

1. Dismantle the nuts A for the adjusting bracket of

the alternator.

A-Nut

2. Dismantle the adjusting bracket A of the alterna-

tor.

A-Alternator bracket

3. Dismantle the alternator A.

A-Alternator assembly
A

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3.2 Installing the alternator

1. Install the alternator assembly A.

A-Alternator

2. For installation of the fan belt, see Section 4.3,

Chapter 3, Part II.
3. Tighten the bolts A for the alternator.

A- Bolt

Attention
The alternator bolts can be tightened unless and A
until the belt is installed properly.

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4. Dismantling the alternator subassembly

4.1 Inspecting the whole machine prior to dismantling

1. The resistance between terminal “F” and “-” is
4~8Ω. If the resistance is too small, the possible
cause is that the field coil is shorted or the insulat-
ing spacer is damaged; if the resistance is too big,
the possible cause is that the brush contacts with the
slip ring poorly; the resistance is infinite, indicating
that the coil is open.
2. The resistance between terminal “+” and “-” is
30~50Ω, and the reverse resistance is above 10KΩ;
if not, the possible cause is that the rectifier or ar-
mature coil is failed.
3. The resistance between terminal “N” and “-” is
8~10Ω, and the reverse resistance is above 10KΩ; if
not, the possible cause is that the rectifier or arma-
ture coil is failed.

4.2 Dismantling the alternator

1. Dismantle the brush and brush holder.
2. Dismantle the screw caps, pulley, fan, and wood-
ruff key.
3. Dismantle the fastening screw.
4. Use a special tool to dismantle the drive end cov-
er (attention that the stator cannot move together
with it).
5. Remove the rotor assembly.
6. Dismantle the screw caps of the 3 terminals on
the component board, and remove the stator assem-
bly.
7. Dismantle the fastening screws on the component
board, and terminal “+” and “N” on the rear end
cover.
8. Remove the component board (attention that in-
dividual insulating washers cannot be lost).
Attention: For the integral alternator, the built-in
voltage regulator can be removed from the carbon
brush holder.

4.3 Assembling the alternator

1. The alternator is assembled in reverse order. in the bearing with a rear end cover to prevent
2. During assembling, the insulating washer be- breakage of the brush.
tween component board, terminal “+”, “F” and “N”
and the housing cannot be omitted.
3. After being assembled, the alternator should op-
erate flexibly.
Note: For the integral alternator, when the rotor is
installed onto the rear end cover, first install the
carbon brush properly, and fasten the brush onto the
housing with a fine wire, and then install the rotor

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5. Dismantling/installing the starter

5.1 Dismantling the starter

1. Dismantle the starter bolt A

A-Set bolt
B-Starter assembly A

Attention: Hold the starter by hands during disman- B

tling, and pay attention to personal safety.

5.2 Installing the starter

1. Install the starter and tighten the bolt B.

A-Starter assembly
B-Bolt

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Chapter 6 Fuel supply system

1. Maintenance equipments and tools

Note:

Introductions for special tools

Sleeve

2. Torque requirements

Measurement
Item Parameters Remarks
Unit
Connection between the
fuel injection pump and Torque 70N.m
the gear chamber

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3. Dismantling the fuel supply system

3.1 Dismantling the accessories for the high

pressure fuel pipe

Prior to dismantling, disconnect the fuel inlet pipe.

1. Dismantle the fuel return pipe part A, and the fuel

pipe B from the fuel filter to the fuel injection
pump. A

A-Fuel return pipe part

B-Fuel pipe from the fuel filter to the fuel injection
pump
B

2. Dismantle the high pressure fuel pipe part A

A-High pressure fuel pipe part

3. Dismantle the Hollow bolt B, and the fuel pipe A

from the fuel delivery pump to the fuel filter.

A-Fuel pipe from the fuel delivery pump to the fuel B

filter
B-Hollow bolt

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4. Dismantle the bolt, and remove the fuel pipe A

from the fuel filter to the fuel injection pump.
A
A-Hollow bolt
B-Fuel pipe from the fuel filter to the fuel injection
pump

5. Dismantle the remaining fuel pipeline A.

A-Other pipeline

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3.2 Dismantling the fuel filter assembly

1. Dismantle the set bolt A for the fuel filter, and

remove the fuel filter assembly B.

A-Bolt
B-Fuel filter assembly A

3.3 Dismantling the fuel injector assembly

1. Dismantle the fuel injector assembly.

A-Fuel injector

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3.4 Dismantling the fuel injection pump assem-

bly

Attention:
Prior to removal of the fuel injection pump and if
no maintenance is required for the fuel injection
pump, it is able to make a mark on the fuel injection
pump and timing gear chamber, respectively, to fa-
cilitate subsequent installation.

A-Mark
A

1. For dismantling of the high pressure fuel pipe,

see Section 3.1 in this chapter.
2. Dismantle the nut A, and remove the gear B.

A-Nut
B-Timing gear assembly of the fuel injection pump
B A
Attention: During re-installation, it is required to
re-adjust fuel supply advance angle and gear timing
of the fuel injection pump.

3. Dismantle the nut B, and remove the fuel injec-

tion pump A.

A-Fuel injection pump assembly A

B-Nut

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4. Assembling the fuel supply system

4.1 Installing the fuel injector

1. Install the fuel injector parts.

A-Fuel injector

Attention
Prior to installation, clean out the carbon deposit in
the fuel injector; if unaccepted, replace the whole
fuel injector assembly.
A

4.2 Installing the fuel pipeline

1. Install the high pressure fuel pipe A

A-High pressure fuel pipe

2. Install the fuel pipeline.

A

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4.3 Installing the fuel filter

1. Install the fuel filter assembly, and connect the

pipeline.

A-Fuel filter assembly

B-Fuel pipeline

Use of an genuine filter is very important, and use

of a wrong filter element will result in damage to
the fuel injection pump.
B
Ingression of contaminants into the fuel system is
not allowed, and it is required to thoroughly wash
surroundings of the connection before it is discon-
nected, as well as after the part is disconnected, all
connections are covered effectively and safely.

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Chapter 7 Dismantling/installing and adjusting the accessories

1. Data and dimension

Camshaft gear
Number of teeth-------------------------------------------------------------------------------------------- 48 teeth
Bore diameter------------------------------------------------------------------------------------------------Φ30 +0.021
0 mm
Outer diameter of camshaft hub---------------------------------------------------------------------------Φ30 +0.021
+0.008 mm

Clearance fit between gear and hub------------------------------------------------------------------ (-0.021)-0.013 mm

Fuel injection pump gear

Number of teeth-------------------------------------------------------------------------------------------- 48 teeth
Bore diameter------------------------------------------------------------------------------------------------Φ100+0.035
0 mm

Crankshaft gear
Number of teeth-------------------------------------------------------------------------------------------- 25 teeth
Bore diameter------------------------------------------------------------------------------------------------Φ36 +0.025
0 mm
Diameter of crankshaft gear hub--------------------------------------------------------------------------Φ36 +0.008
-0.008 mm
Gear transition fit of the crankshaft----------------------------------------------------------------- (-0.008 )-0.032 mm

Idler and hub

Number of teeth--------------------------------------------------------------------------------------------- 39 teeth
Bore diameter------------------------------------------------------------------------------------------------Φ48 +0.025
0 mm

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2. Dismantling/installing the intake pipe

2.1 Dismantling the intake pipe

1. Loosen the fixing nut for the intake pipe, and

dismantle the intake pipe A.

A-Intake pipe assembly

2. Remove the gasket A.

A-Intake pipe gasket

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2.2 Installing the intake pipe

1. Install the gasket A.

A-Intake pipe gasket

Attention: Prior to installation, replace it with a new

one.

2. Install the intake pipe A, and tighten it.

A-Intake pipe assembly

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3. Dismantling/installing the exhaust pipe

3.1 Dismantling the exhaust pipe.

1. Dismantle the nut A.

A-Locknut for the exhaust pipe

B-Exhaust pipe assembly

2. Remove the exhaust pipe gasket A.

A-Exhaust pipe gasket

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3.2 Installing the exhaust pipe

1. Install the exhaust pipe gasket A.

A-Exhaust pipe gasket

Attention: Prior to installation, replace it with a new

one.

2. Install the exhaust pipe A, and install and tighten

the nut B.

A-Exhaust pipe assembly

B-Nut

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4. Dismantling/installing the gear chamber

4.1 Dismantling the gear chamber

1. Dismantle the alternator assembly (Refer to Sec-

tion 3.1, Chapter 5, Part II).
2. Dismantle the fan parts (Refer to Section 3.4,
Chapter 5, Part II).
3. Dismantle the bolt A for the crankshaft pulley,
and remove the pulley B.

A-Bolt for the crankshaft pulley

B-Crankshaft pulley

Attention: During dismantling of the crankshaft

pulley, wedge a woodblock at inner side of the pul- B
ley after loosening the fastening bolt, and use a
hammer to tap the woodblock axially until the
crankshaft pulley is loosened, so as to remove the A
crankshaft pulley.

4. Remove the water pump parts (Refer to Section

3.5, Chapter 3, Part II).
5. Dismantle the set bolt A for the front cover of the
timing gear chamber.

A-Set bolt

6. Dismantle the front cover A of the timing gear

chamber.

A-Front cover A of the timing gear chamber.

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7. Dismantle the bolts for the cover of the timing

gear chamber.

A- Bolt

8. Dismantle the cover A of the timing gear cham-

ber.

A-Cover of the timing gear chamber

9. Dismantle the idle gear bolt A.

A- Bolt

10. Dismantle the idle gear A.

A-Idle gear

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11. Dismantle the starter parts (See Section 4.1,

Chapter 5 of this Part).

12. For dismantling of the flywheel, see Section 7.4,

Chapter 7, Part II.

13. Dismantle the camshaft part A.

A-Camshaft part

14. Dismantle the advancer part A with a special

tool.

A-Advancer part
A

15. Dismantle the advancer A.

A-Advancer part

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16. Dismantle the set bolt A for the timing gear

chamber.

A- Bolt
A

17. Dismantle the timing gear chamber A and fuel

injection pump B.
A
A-Timing gear chamber
B-Fuel injection pump B

Attention: The timing gear chamber is connected

with the fuel injection pump, and they are not sepa-
rated.

Prior to removal of the fuel injection pump and if

no maintenance is required for the fuel injection
pump, it is able to make a mark on the fuel injection
pump and timing gear chamber, respectively, to fa-
cilitate subsequent installation.

18. Dismantle the crankshaft gear A.

A-Crankshaft gear

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4.2 Installing the gear chamber

1. Install the crankshaft (For details see Section 4.2,

Chapter 2 of this Part).
2. Install the idler shaft A.

A-Idler shaft

3. Install the gasket A.

A-Gear chamber gasket

Attention
During installation, replace it with a new one.

4. Install the gear chamber A, and install and tighten

the set bolt B.

A-Gear chamber
B-Bolt B

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5. Install the camshaft part A.

A-Camshaft part

Attention: Prior to installation, ensure that individu-

al surfaces are clean, and free of scratches, and ap-
plied with clean lubricating oil.
Prior to installation of the camshaft, it is required to
install the tappet.

6. Install the set bolt A for the camshaft assembly.

A- Bolt

7. Install the advancer A.

A-Advancer

Apply clean lubricating oil on the mating surface of

the gears.

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8. Install the intermediate idle gear.

A-Intermediate idle gear

B-Align marking

Attention: During installation of the intermediate

idle gear, it is required to align the three timing
marks with corresponding timing marks of the high
pressure fuel pump gear, camshaft gear, crankshaft
timing gear, and finally tighten the bolts.

9. Tighten the intermediate idle gear A.

A-Intermediate idle gear

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10. Install the gasket for the timing gear chamber,

and timing gear chamber cover.

A-Gasket for the timing gear chamber cover

B-Timing gear chamber cover

B A

11. Tighten the bolts for the cover of the timing gear
chamber.

A- Bolt

12. Install the gasket for the front cover of the tim-
ing gear chamber, and front cover of timing gear
chamber, and tighten it.

A-Gasket for the front cover of the timing gear

chamber
B-Front cover of the timing gear chamber

B
A

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5. Dismantling/installing the flywheel parts

5.1 Dismantling the flywheel parts

1. Dismantle the bolt A and lockplate B.

A-Flywheel bolt
B-Lockplate

2. Remove the flywheel part A.

A-Flywheel part

Pay attention to personal safety.

3. Dismantle the bolt A, and remove the flywheel

cover B.
B
A-Set bolt
B-Flywheel cover

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5.2 Installing the flywheel parts

Attention
During installation of the flywheel cover, first apply
clean lubricating oil at rear end of the crankshaft.

A-Rear end of the crankshaft

1. Install the dowel pin A, and install the gasket B.

A-Dowel pin
B-Flywheel cover gasket
B

Attention: During installation, replace the gasket

with a new one.
A

2. Install the flywheel cover A, and install and fas-

ten the bolt B.

A-Flywheel cover
B-Bolt

Attention: Check the rear oil seal on the flywheel

cover, and if damaged, must replace it. B

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3. Install the flywheel A, install the lockplate B and

bolt C.

A-Flywheel
B-Lockplate A
C-Bolt

Attention: Prior to installation of the flywheel, in-

spect whether the dowel pin at the end of the C
crankshaft is lost.

4. Fasten the set bolt A for the flywheel.

A- Bolt

Attention: After installation, turn the flywheel, and

inspect whether it rotates flexibly and is jammed.

Tightening torque of the flywheel bolt--50-60N.m

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Part III Inspection, Adjustment, Fault Diagnosis and Troubleshooting

Chapter 1 Dynamic Inspection

1. Overview

According to operating time and condition of

the engine, inspect the engine oil consumption on a
regular basis or from time to time, and replenish
engine oil in time. Prevent influence on normal use
of the engine due to engine oil problem.

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2. Inspecting engine oil level

Inspection conditions:

◆The machine is stopped at a level ground.

◆The shift lever is at neutral position.
◆The ignition lock is off.
◆The parking brake is pulled tightly.
◆Five minutes after the engine stops.

Inspection steps:

◆Clean surrounding of the oil dipstick.

◆Remove the oil dipstick, and wipe it clean with a
test paper.
◆Install the oil dipstick, and ensure it is installed at
place.
◆Remove the oil dipstick, and inspect whether the
oil level meets the requirements.

Upper scale line

Lower scale line

Normal conditions:

◆The oil level is not too low.

◆The engine oil is not too thick, thin or rare.
◆No diesel smell exists.
◆The oil is free from obvious metal objects, inclu-
sions, or deterioration.

Abnormal conditions:

◆Replenish oil to the level set forth in the specifi-

cation according to the oil dipstick marking.
◆Change the contaminated oil and oil filter.
◆Consult the engine operation manual for details.

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3. Inspecting the coolant level and status

Inspection conditions:
◆The machine is stopped at a level ground.
◆The ignition lock is off.
◆The radiator cover is not overheated.
◆The parking brake is pulled tightly.

Inspection steps:
◆Clean the surroundings of the radiator cover.
◆Turn the radiator cover to relieve the pressure.
◆Dismantle the radiator cover.
◆Check the coolant level and status.
◆Inspect the radiator and water pipe.
◆Inspect the cooling fan.

Normal conditions:
◆The radiator and water pipe are in good condi-
tion, without leakage.
◆The coolant level should not be more than
5mm below sealing surface of the radiator cover.
◆The coolant is clean, and free of oil stains, rust,
deterioration or foreign bodies.
◆The water pipe is connected reliably, without
leakage.

Abnormal conditions:
◆Repair or replace the radiator.

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4. Inspecting the fan and belt

1. Inspect the water pump belt

Inspect whether the water pump belt is cracked, cut,
deformed and worn and torn. Whenever necessary,
it is required to replace the belt and inspect its ten-
sion. As shown in right Figure 7-5, when pressing
the middle part of the belt by exerting a force of
approx. 98N, a 7mm～9mm sag is obtained for a
new belt, and 11mm～13mm for an old belt. Oth-
erwise, it should be adjusted accordingly.
A

Belt tension--------98N

2. Inspect the fan

① During assembling the fan, pay attention to its

rotation direction, and that the side with marking is

forward.
② Visually inspect whether the fan blades are

damaged.
③ Inspect whether the set bolts for the fan are

tightened firmly.

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5. Inspecting the fuel system

The fuel system, through the fuel delivery

pump, delivers the fuel into the high pressure fuel
pump from the fuel tank and via the fuel filter and
low pressure fuel line, and then the fuel is pumped
by the high pressure pump into the high pressure
pipe and is injected into the cylinder (at pressure of
21-23MPa) by the fuel injector, then compressed
and fired in the cylinder; The excessive fuel flows
back to the fuel tank via the fuel return pipe of the
fuel injector.

Attention:
1. The fuel pressure in the fuel injection pump,
high pressure fuel pipe and fuel injector remains
very high, so that loosening any pipe connection is
not allowed during operation of the engine. Other-
wise, it may result in serious personal injury and
damage to property.
2. After stopping the engine, wait for at least
10 minutes, and slowly loosen the pipe connection
of the high pressure fuel system after the fuel pres-
sure is reduced. Connect a pressure gauge to meas-
ure and inspect the fuel pressure.

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6. Inspecting the air intake and exhaust system

1. The air flows through the air filter, enters the air
intake manifold via the heater, and goes into the
port on the cylinder head from the air intake mani-
fold, and is pressurized into the cylinder after being
sucked into the air intake valve, then compressed
and fired in the cylinder.

2. The exhaust gas from combustion goes into the

exhaust port on the cylinder head via the exhaust
valve, and is discharged from the muffler. Inspect
whether the air intake and exhaust system is leaked,
and inspect and confirm that all hose clamps are
tightened tightly.

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7. Inspecting the electric system

There may be explosive gas escaped from the

battery. In order to prevent serious personal injury,
the engine compartment has to be ventilated well
before conducting the work. First, always enable the
cathode (-) cable of the battery to be disconnected,
and connect the cathode (-) cable. Basic electric
system for the battery, starter motor, alternator, and
ignition lock: Inspect that the battery connection is
connected as per requirements, and all cables and
parts required must be matched strictly; then, based
on operating condition of the engine, confirm
whether the electric system is failed. For specific
repairing, it should be carried out by the method for
handling the electric system faults.

Diagram for electric system

1. Alternator 2. Fuel pressure sensor 3. Water temperature sensor 4. Fuel pressure indicator 5. Wa-
ter temperature indicator 6. Ammeter 7. Voltage regulator 8. Fuse box 9. Starter relay 10. Starter
11. Battery 12. Ignition lock 13. preheating plug

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Chapter 2 Operating principle

1. Valve mechanism

1.1 Function of valve mechanism

The cylinder head is used to enclose the top of

the cylinder, and works with the cylinder and piston
to jointly form the combustion chamber and work-
ing chamber. The cylinder head is directly in con-
tact with high temperature gas mixture, withstands
pre-tightening force of the bolts, gas pressure and
alternating stress, so it is required that the cylinder
head should have a certain strength and rigidness,
and be cooled reliably, and have a flat mating sur-
face to ensure reliable sealing.
Function:
When working cycle of the cylinder requires
opening the valve for air change, the camshaft ro-
tates with help of the drive mechanism under driv-
ing of the crankshaft, so as to enable the raised part
of the cam on the camshaft to push the rocker arm
through the tappet, pushrod and adjusting screw;
A
thus, the other end of the rocker arm pushes the
valve downward, enabling the valve to be open and
the spring to be further compressed. After the apex
of raised part of the cam rotates by the tappet, the
B
thrust force is gradually decreased, and the opening
of the valve decreases gradually under action of the C
spring tension until it is closed eventually. In the
compression and power stroke, the valve is always
left closed under action of the spring.
E

According to the requirements for working cy-

D
cle completed in each cylinder of the engine and
ignition sequence, open and close the air intake and
exhaust valves regularly, so that sufficient fresh air
enters the cylinder, and the exhaust gas is dis-
charged from the cylinder in time.

A-Valve rocker arm

B-Valve
C-Tappet
D-Pushrod
E-Camshaft

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1.2 Valve timing

The valve timing means the actual opening and

closing time of the air intake valve and exhaust Upper dead point
valve, which is represented by a doughnut chart for
the crank angle in relation to the crank position of
the upper and lower dead points. This chart is called Exhaust valve
the valve timing chart. Intake closed
valve open

Intake valve open

Before upper dead point 12±3°

Intake valve closed Exhaust Air in-

After lower dead point 38±3° take

Exhaust valve open

Before lower dead point 50±3°

Exhaust valve closed

After upper dead point 14±3°
Intake Exhaust
valve valve open
closed Lower dead
Theoretically, when the intake valve for the point
four-stroke engine is open when the crank is at up- Valve timing chart
per dead point, and closed when the crank is rotated
to the lower dead point; while the exhaust valve is
open when the crank is at lower dead point, and
closed when the crank is at upper dead point. The
air intake time and exhaust time requires a 180°
crank angle, respectively. However, actual speed of
the crankshaft of the engine is very high, and the
time for completing each stroke of the piston is very
short. Thus, the short-time intake or exhaust process
often lead to shortage in intake air or incomplete-
ness in discharge of exhaust gas of the engine, re-
ducing the engine’s power; therefore, the modern
engines adopt the design of prolonging the air in-
take time and exhaust time, that’s to say, the open-
ing and closing time of the valve is not the moment
when the crank is at upper dead point or at the low-
er dead point, but is advanced or prolonged by a
certain angle, so as to improve the air intake and
exhaust condition and enhance the engine’s power
performance.
For different engines, they are different in struc-
ture, type and speed, so the valve timing is also
varied, and is determined based on the engine's
performance requirements and through repeated
tests.

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2. Crank-link mechanism

2.1. Operating principle

Function:
The crank-link mechanism is the transmission
mechanism used to realize the duty cycle of the
combustion engine and complete energy conversion,
as well as transmit the power and change the mode
of motion. During operating, the crank-link mecha-
nism converts the reciprocating motion of the piston
to the rotary motion of the crankshaft in the power
stroke, and outputs the power, and in other three
strokes, i.e., intake stroke, compression stroke and
exhaust stroke, converts the rotary motion of the
crankshaft to the reciprocating motion of the piston.
As a whole, the crank-link mechanism is a
mechanism designed to produce and transmit power
for the engine, and converts thermal energy gener-
ated from combustion of the fuel to mechanical en-
ergy.

Working conditions:
It will withstand high temperature, high pres-
sure, high speed and chemical corrosion action.

Operating principle:
In the power stroke, the piston withstands ex-
pansion pressure exerted by the combustion gas, so
that linear motion of the piston is converted to the
rotary motion of the crankshaft, and output the
A
power. By relying on the rotary inertia of the
crankshaft and flywheel, the piston is driven by the D
connecting rod to move up and down, so as to com- B
plete the exhaust, intake and compression strokes C
and make a preparation for next power stroke.

A-Piston
B-Connecting rod
C-Crankshaft
D-Flywheel

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2.2 Introduction for components

Composition: Crankshaft:
Convert the gas pressure transmitted from the
Engine body components: cylinder block, cylinder
piston connecting rod component to the output
liner, cylinder head, cylinder gasket and oil sump
torque. Then, it is used to drive the valve mecha-
and etc.
nism of the engine and other devices.
Piston connecting rod components: Working conditions: It is impacted by the gas pres-
Piston, piston ring, piston pin, connecting rod and sure, inertia force, inertia torque and varying load.
etc.

Crankshaft flywheel components: Thrust plate:

Crankshaft, flywheel and etc. It is used to ensure that the crank-link mecha-
nism can operate normally when the crankshaft
Function: withstands an axial force.

Piston: Flywheel:
In the power stroke, partial power delivered to
It withstands the gas pressure, and make the
the crankshaft is stored to overcome the resistance
crankshaft rotated through the piston pin and con- force produced in other strokes and drive the
necting rod. crank-link mechanism to overpass the upper and
lower dead points, so as to ensure that the rotational
Working conditions : The force exerted to the
angular velocity and output torque of the crankshaft
piston includes gas pressure and reciprocating iner-
can be kept constant as far as possible, and the en-
tia force. The piston crown directly contacts the
gine is able to overcome short-time overload and
high temperature combustion gas to get the piston
the power produced from the engine is delivered to
crown hot. Under action of the side pressure, the
the clutch.
piston slides along the cylinder wall surface at high
speed. If the poor lubrication condition，the friction
loss is huge and the wear is serious.

Piston ring:
The gaseous ring is mainly used to obtain an
excellent sealing effect and heat transmission.
The oil ring is mainly designed to remove the
excessive engine oil splashed to the cylinder wall,
and form a uniform oil film on the cylinder wall.

Piston pin:
The piston pin is used to connect the piston to
the connecting rod, and transmit the force endured
by the piston to the connecting rod, and vice versa.
It will sustain a huge cyclical impact load in
high temperature condition, and because the piston
pin oscillates within a small angle range, it is diffi-
cult to form a lubricating oil film, obtaining a poor
lubricating condition.

Connecting rod:
It transmits the force from the piston to the
crankshaft, and converts the reciprocating motion of
the piston into the rotary motion of the crankshaft.

Connecting rod bearing:

It is designed to protect the connecting rod
journal and connecting rod big end hole.

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3. Lubricating System

During operation of the engine, the lubricating sys-

tem is functioned to continuously deliver abundant
clean lubricating oil to friction surfaces of all driv-
ing parts, form an oil film between the friction sur-
faces to realize fluid friction, decrease friction re-
sistance, reduce power consumption and lighten
wear, improving engine operating reliability and
durability.

Lubrication manner:
Pressurization, splash lubrication

The lubricating system is composed of:

Oil pump
Oil filter
Oil cooler
Oil sump A
Suction filter
Lubricating oil pipeline

A-Gear train B
B-Idler shaft
C-Oil pump
D-Engine oil suction filter
C F
E-Oil sump
F-Oil filter E
D
Function of lubricating oil:
Lubrication---Reduce wear between parts by use of
the oil film
Sealing---Prevent gas leakage by use of the oil film
Cooling---Absorb heat
Clean and Rust cleaning---Remove the metal filings,
inclusions and acidic substances.
Vibration damping---Damp the vibration by use of
the oil film

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4. Fuel supply system

4.1 Theoretical information

System function: The fuel system is mainly

used to deliver the fuel into the high pressure fuel
pump from the fuel tank and via diesel filter and
pipeline with help of the fuel delivery pump, and
then the fuel is pumped from the high pressure
pump, flows through the high pressure fuel pipe,
and is injected to the cylinder by the fuel injector (at
pressure of 21MPa), as well as used for compres-
sion and combustion. The excessive fuel flows back
to the fuel tank via the fuel return pipe of the fuel
injector.

4.2 Fuel injector

Operating principle:

The high pressure fuel pump delivers the high

pressure diesel to the lower end of the needle valve
body through the fuel inlet pipe fitting F and
oblique fuel pipe, and then the diesel is applied to
the pressure-bearing conical surface of the needle A
valve. When the pressure exceeds the pre-tightening
B
force of the high pressure spring D, the needle valve
is raised, the high pressure diesel in the annular fuel CD
chamber of the needle valve body is atomized and
injected at high speed from the gap formed by the E
F
needle valve and needle valve body. When the fuel
injection pump stops fuel delivery, the pressure in
the annular fuel chamber is reduced, and under ac-
tion of the high pressure spring, the needle valve is
G
dropped into the valve body to stop fuel injection.
H
A-Fuel return pipe fitting I
B-Injector cap J
C-High pressure screw
K
D-Pressure spring
E-Fuel injector body
F-Fuel inlet pipe fitting
F-Push rod
H-Steel ball
I-Needle valve
J- Fixing thread insert
K-Needle valve body

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5. Cooling system

Function: The lubricant nipple of the water pump should

The engine can be kept within an appropriate be injected with grease on a regular basis. Usually,
temperature range in all conditions. the grease should be replenished every about 200
operating hours for the diesel engine. The lubricat-
Cooling method:
ing grease is #4 calcium base lubricating grease.
The engine is cooled by means of closed-type
The lubricating grease level should not be too high,
positive water circulating, namely that the pressure
but about 1/3～1/2 of the bearing chamber. Exces-
of the coolant can be built up by the water pump to
sive grease will get the bearing overheated.
compel the coolant circulation in the engine.
3. Thermostat:
Composition:
The thermostat is a bellows single-valve type,
It is composed of water pump, radiator, cooling
which is installed in the thermostat housing at the
fan, thermostat, water make-up barrier, engine body,
water outlet at the front end of the cylinder head. It
cylinder liner, cylinder head and other attachments
contains a temperature sensitive fluid to automati-
and etc.
cally control opening and closing of the valve. Its
1. Cooling water line: model is 155B.
During operation of the diesel engine, the When the temperature of the cooling water for
crankshaft pulley is operated through driving the the diesel engine does not reach 70℃, the thermo-
water pump by the belt, so as to pressurize the stat valve remains closed, and the cooling water
cooling water into the water chamber of the engine undergoes the small circulation in the engine; when
body and cool down the cylinder liner, block and the temperature of the cooling water for the diesel
head, and then enter the thermostat. When the outlet engine exceeds 70℃, the thermostat valve is open,
water temperature is lower than 70℃, the thermo- the cooling water circulates in the big circuit; and
stat is closed, and the cooling water flows back to when the water temperature exceeds 85 ℃ , the
the inlet water chamber via the bottom of the cylin- thermostat valve is fully open.
der head and corresponding small water pore on the
engine body, and then enter the water pump and Attention: If the water temperature is failed to
realize small circulation in the engine. When the reach 70℃ and there is water flowing from the
outlet water temperature is higher than 70℃-80℃, water pipe after the diesel engine is cold-started, or
the thermostat is fully open, and at this moment, the when the water temperature of the diesel engine
cooling water flows into the upper water chamber exceeds 70℃, no water flows out from the water
of the water tank via the thermostat, and to the low- outlet pipe. This indicates that the thermostat has
er water chamber along the flattened brass pipe. In been malfunctioned, and should be removed for
this process, the cooling water is cooled by the air inspection.
sucked or exhausted by the fan, realizing the big Do not remove the thermostat at will because
circulation. According to different applications, the excessively low cooling water temperature is un-
fan can adopt induced draft or exhaust type. beneficial to normal startup and operation of the
2. Water pump diesel engine.
The diesel engine adopts centrifugal water
pump. When the water seal is worn and much water
is dropped from the drain hole at lower part of the
water pump body, it is required to change the water
seal, and blockage of the drain hole is not allowed,
otherwise, the water will enter the bearing, making
the bearing worn. If the water leakage is serious, an
abnormal sound is produced during operation of the
bearing, and it is required to change the bearing.

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6. Electric system

6.1 Introductions for starter

6.1.1 Structural principle of the starter

C D E
B F
G I
A
H J
K L
M

S
R Q

AA P

N N
Y

X W T
O

V U

A-One-way clutch B-Fork seat C-Fork shaft D-Fork E-Hold-down ring F-Gasket G-Water proof
rubber sleeve H-Rubber gasket I-Electromagnetic switch J-Armature assembly K-Stator assembly
L-Carbon brush holder assembly M-Rear cover N-Water proof rubber washer O-Planetary gear ring
cover P-Rubber gasket Q-Planetary gear ring R-Ball S-Planetary gear T-Planet gear shaft
U-Rubber gasket with male and female face V-Internal friction plate W-Bearing X-Vibration damper
Y-External friction plate Z-Planet gear shaft circlip AA-Front end cover

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6.1.2 Use and maintenance of the starter

1. Precautions for use of the starter

◆Frequently inspect connecting condition of in-
dividual parts and tightness of the cables.
◆Remove oxides on the cables and terminals,
clean the dust and oil stains deposited on the exter-
nal of the starter.
◆The starter should be preheated for 10-15 se-
conds during startup in cold season.
◆The starter can be operated for a short time,
and every time the startup time cannot exceed 5
seconds. If the starter cannot be started once, it
should be re-started after 45-60 seconds
◆After startup of the engine, it is required to
immediately release the starter switch, preventing
wear of the starter.

2. Maintenance after the starter is put into service

for one year:
◆Remove oil stains and contaminants in the
starter and at individual interfaces.
◆ Inspect whether the commutator surface is
smooth and clean, the brush is jammed in the brush
holder, the brush contacts the commutator well, and
brush height (the height cannot be less than 10mm
for QD1536S starter) is sufficient. If the commuta-
tor surface is slightly burned, it can be polished by a
No. "00" sandpaper. If it is burned seriously and the
out-of-circularity is more than 0.08mm, it has to be
re-machined, and polished by a No. "00" sandpaper.
◆Inspect the pressure of the brush return spring
(to be measured by a spring balance); the pressure
exerted by the return spring of the QD1536S stator
to the brush should be within 1.2-1.5kg, otherwise it
should be adjusted or changed.
◆Use a hair brush or rag to remove oil sludge
and dust on the stator、rotor and other parts again.
During installation, the helical spline of the rotor,
bearing bushings and bearing pores should be ap-
plied with lithium base lubricating grease.
◆Inspect working condition of the excitation
winding.
◆Inspect locking capability of the isolator.
◆Inspect condition of the contact plate and sta-
tionary contact of the electromagnetic switch; if it is
burned or has black spot, it should be ground to
flush by using a No. "00" sandpaper.

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6.2 Structural principle of the alternator

Introductions for the alternator
The alternator is a three-phase alternator. Its prin- 2. Construction of the alternator-Stator as-
ciple is to convert the mechanical energy into sembly
electric energy through the rotating magnetic field. Function of the stator components: To produce a
Then, it delivers electric power to electric equip- three-phase alternating current.
ments by means of direct current after being recti- Composition of the stator components: The
fied by the diode, and charges the battery simul- stator is composed of stator core and winding.
taneously. The stator core is superposed by silicon steel
The alternator used by the tractor is a silicon rec- sheets with grooved inner circle, and the cable
tification alternator, which is composed of an al- for the stator winding is placed in the groove of
ternator and silicon rectifier, and is able to gener- the core. For the stator with a three-phase wind-
ate a three-phase alternating current. ing, the three-phase winding must be wound as
Winding the stator coil: The electromotive force per requirements to obtain a three-phase elec-
produced by the three-phase winding, it should be tromotive force with same frequency, equal
a symmetrical electromotive force, namely the magnitude and phase difference of 120 degree.
electromotive force at each phase is equal and The stator winding has three phases, which is
potential difference is 120°electrical degree. connected by star connection scheme or delta
Connection of the stator coil: It is connected by (big power) connection scheme.
star connection scheme or delta connection
scheme. The stator coil used in the alternator of
the tractor is connected by star connection
scheme.

1. Construction of the alternator-Rotor assem-

bly
Function: To build a magnetic field.
Composition: It is composed of two claw poles,
(rotor coil) excitation winding, shaft and slip
ring and etc.
Generation of a magnetic field: When the brush
Magnetic line distribution of rotor field and
transmits the direct current to two collector rings, principle of magnetic field circuit
a direct current flows through the magnetic field a. Magnetic line distribution of the magnetic
winding, and an axial magnetic flux is generated field.
to get one claw pole magnetized to pole N, and b. Principle of magnetic field
1, 5 Brush; 2, 4 Slip ring; 3 Excitation wind-
the other claw pole magnetized to pole S, so that
ing; 6 Ignition switch(lock); 7 Battery
six pairs of magnetic poles intersected are
formed. When the rotor rotates, a rotating mag-
netic field is formed.
For magnetic line distribution of the magnetic
field and excitation circuit, see the figure on
right hand.

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whose negative brush (e) of the field winding is

3. Construction of the alternator--Silicon recti-
directly grounded to the alternator (directly con-
fier nected with the housing)
Function of the rectifier: Converts the three-phase Externally grounded alternator: It is an alternator
alternating current of the stator winding into direct whose two brushes of the field winding are insu-
lated from the housing.
current.
The negative pole (negative brush) of the field
Composition of the rectifier of 6-diode alternator:
winding for the externally grounded alternator is
The three-phase full-wave bridge rectifier
circuit is formed by 6 pieces of silicon rectifier connected to the regulator, and then grounded.
diodes. The 6 silicon rectifier diodes are pressed
(or soldered) onto two boards insulated from each
other, respectively, of which one board is acted as
a positive board (with output terminal bolts), and
the other one is acted as a negative board and di-
rectly connected with (grounded to) the alternator
housing. Also, the rear end cover of the alternator
is acted as the negative board.
For the three diodes pressed onto the
heat-dissipating plate, their leads are the posi-
tive-positive tubes of the diode.
For the three diodes pressed onto the rear end
cover, their leads are the negative-negative tubes
of the diode.
The heat dissipating plate must be insulated from
Grounding pattern of the alternator
the rear end cover, and fixed onto the rear end
a. Internally grounded alternator.
cover with bolts to act as terminals for the live
b. Externally grounded alternator
cable of the alternator, which is marked as "b"
("a", "+" or "armature").
4. Construction of the alternator--Front and

rear end covers

The rear end cover is installed with a brush holder
and a brush.
Composition of the brush components: It is com-
posed of a brush, brush holder and brush spring.
Function of the brush: The power supply is con-
ducted into the excitation winding via the slip ring.
The two brushes are installed in the holes on the
brush holder, respectively, and left contact with
the slip ring with help of the spring pressure.
The brushes should contact the slip rings well; if
not, the power generation of the alternator is in-
sufficient due to excessively small field current.
The externally-mounted brush holder can be dis-
mantled and replaced outside the alternator, and is
easy to maintain.
Ground connection type of the field winding and
corresponding brush connection scheme: Inter-
nally grounded type or externally grounded type
Internally grounded alternator: It is an alternator

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Working principle of the three-phase alterna- winding), the negative tube at the phase with
tor minimum voltage breaks over at certain instant,
but there are two closed tubes at the same time, of
1. Power generation principle which one is a positive tube, the other one is neg-
Electromagnetic induction phenomenon: ative tube.
A voltage is produced in case of relative motion The diodes in the three-phase bridge rectifier cir-
between the conductor and field. The voltage cuit breaks over in sequence and in a cyclic man-
strength of the conductor depends on the magnetic ner, so that a stable pulsating direct current volt-
age is obtained at both ends of the load "rl". The
field intensity, speed of cutting the magnetic field average DC voltage output by the alternator is as
by the conductor, and number of conductors pass- follows: u=1.35ul=2.34u&U</P<p></P<p>.
ing through the field. 3. Voltage to neutral
Structural characteristics of the alternator: Concept of voltage to neutral
The live coil is wound onto the rotating core to When the stator winding is connected by star
produce a rotating magnetic field, and the connection scheme, the common junction point of
three-phase winding cuts the magnetic line to
produce a three-phase alternating current. the three-phase winding is called a neutral point,
Basic principle of the three-phase alternator: and a conductor is led from the neutral point of
When the magnet with field winding rotates, the the three-phase winding to the outside of the al-
magnetic flux passing through the cores varies, so ternator, and marked as "n".
The voltage "un" between the neutral point to the
an electromotive force is produced in the alternator housing (ground) is called the voltage to
three-phase winding; however, due to existence of neutral, which is a DC voltage obtained through
time difference in magnetic flux variation between rectification by three negative diodes (namely
the windings at individual phases, the electromo- three-phase semi-wave rectification).
tive forces produced also exhibits a time differ- The voltage to neutral is half of the output voltage
of the alternator.
ence, so as to obtain a three-phase alternating
Usage of the voltage to neutral
current.
a. The voltage to neutral is usually used to control
2. Rectification principle
relays for applications (such as field relay, charg-
In the three-phase winding of the stator for the
ing indicator relay and etc.);
alternator, the magnetic induction produces an
b. Increase the power output (The eight-diode al-
alternating current. The alternating current is
ternator improves the alternator power output by
converted into a direct current by the three-phase
use of the voltage to neutral).
rectifier bridge rectifier circuit formed by six di-
4. Excitation method of the alternator
odes (by use of unilateral conductivity of the di- Except that the permanent-magnet alternator does
ode). not require excitation, other alternators require
The diode shows unilateral conductivity. When a excitation because their magnetic fields are elec-
forward voltage is applied to the diode, the diode tromagnetic fields. that's to say, the field is pro-
breaks over, and when a reverse voltage is applied duced only when the field winding is energized.
to the diode, the diode is cut off. The diode breaks The process in which the electricity is delivered to
over by following principle: the field winding to form a magnetic field is
When the negative ends of three diodes are con- called excitation. The alternator can be excited by
nected, the diode with maximum potential at the means of separate excitation and self-excitation.
positive end breaks over; Separate excitation
When the positive ends of three diodes are con- Due to weak remanence of the alternator rotor, the
nected, the diode with minimum potential at the alternator can be self-excited only when it rotates
negative end breaks over; at higher speed.
For the three positive tubes (d1, d3 and d5 are During startup of the engine, the battery should
connected with the beginning end of the stator deliver field current to the alternator to produce
winding), the positive tube at the phase with magnet, so as to improve the field intensity and
maximum voltage breaks over at certain instant. enable the alternator to generate electricity. This
For the three negative tubes (d2, d4 and d6 are kind of excitation means by which the battery de-
connected with the beginning end of the stator
livers current to the field is called separate excita-

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tion power generation. This is the main cause that

the alternator has excellent low-rate charging per-
formance. Usually, the separate excitation is
switched to self-excitation after the alternator
speed is up to 1000r/min.
Self-excitation
As the alternator speed increases, the electromo-
tive force of the alternator gradually increases and
can be output (usually at the time when the engine
speed is up to idling speed). When the output
voltage "ub" of the alternator is more than the
battery voltage, the alternator can supply electric-
ity; and when the alternator can deliver electricity,
it can supply electricity produced by itself to its
field winding for electricity generation. So, this
method by which the alternator delivers electricity
to the field is called self-excitation.
Excitation process of the alternator (the sepa-
rate excitation occurs before the self-excitation)
When the engine speed reaches normal idling
speed, the output voltage of the alternator is nor-
mally 1～2v higher than the battery voltage, so as
to charge the battery; at this moment, the alterna-
tor starts self-excitation power generation.
Excitation circuit of the alternator (see the
right figure)
Excitation circuit with excitation di-
ode-Nine-diode alternator Circuit characteris-
tics:
Two full-wave rectification circuits are formed by
9 rectifier diodes. Among them, the three-phase
full-wave bridge rectifier circuit formed by 6 big
power rectifier diodes is designed to deliver elec-
tricity to the external loads, and the three-phase
full-wave bridge rectifier circuit by three small
power diodes and three big power negative diodes
is designed to deliver electricity to the alternator
field. So, these three small power diodes are
called excitation diode. The charging circuit is
usually installed with a charging indicator lamp,
which cannot only indicate operating condition of
the charging system through controlling the
charging indicator lamp, but also can prevent de-
livery of electricity by the battery to the excitation
winding through the regulator for a long period
due to the reason that the operator forgets turning
off the ignition switch.

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Operating principle: volume, high reliability, long service life and

a. Non-charging state: With the power switch small radio interference and etc., it acts as an ex-
turned on, the excitation current flows as follows:
battery +--k---charging indicator lamp-regulator ternal regulator, which is widely substituted for
(live terminal--contact--"field" termi- the electromagnetic vibration regulator.
nal)--excitation winding--ground strap--battery "-". Integrated circuit type regulator: It is fab-
(Separate excitation, indicator lamp On) see the ricated by use of semi-conductor technique or
figure.
b. Charging state: With the alternator operated, it lamina technique and encapsulating the transistor,
voltage rises at output end of the three excitation resistor, capacitor and other components onto a
diodes as the speed increases, and the charging silicon or insulator substrate as per circuit re-
indicator lamp brightness gets weaker; when the quirements. It features high reliability and integra-
alternator voltage is up to the battery charging tion degree, which is usually installed in the al-
voltage, the alternator is switched to
self-excitation mode, and the indicator lamp is off. ternator as a built-in regulator.
On one hand, after rectification by d1-d6 diodes, a
DC current voltage is output to the battery for
charging; on other hand, after rectification by d7,
d8 and d9 excitation diodes, and d2, d4 and d6
negative diodes, the excitation circuit is energized.
Function of the charging indicator lamp:
a. The indicator lamp gets on if the operator for-
gets turning off the power switch;
b. The indicator lamp gets off when the alternator
is operated normally;
c. The indicator lamp gets on due to voltage rise at
both ends of the indicator lamp when the alterna-
tor speed decreases or is failed.
Conclusion: The functions of the charging indica-
tor lamp are as follows:
a. Remind the driver of turning off the power
switch in time;
b. Indicate operating state of the alternator.
Voltage regulator
The regulator can be categorized into fol-
lowing types in terms of structural pattern: elec-
tromagnetic vibration type regulator, transistor
regulator and integrated circuit type regulator.
Electromagnetic vibration type regulator:
The make/break of the electromagnetic contact is
controlled by the voltage magnitude of the alter-
nator, so as to control current intensity of the field
coil and change magnitude of the voltage output
from the alternator, enabling the voltage to be kept
within limit at high speed of the alternator and not
to increase as the speed increases.
Transistor regulator: The excitation current
is switched on and off by use of the transistor to
output a constant voltage. Compared to the elec-
tromagnetic vibration type regulator, the transistor
regulator boasts a better regulating performance,
without provision of the electric magnet with
complicated structure and slow action, of contact
liable to be burned. Due to light weight, small

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Chapter 3 Inspection and adjustment

1. Inspecting valve clearance (mm)

Cause: taken account of.
The compressive force of the cylinder is insufficient, 1. The piston ring is deposited with carbon, jammed
and there is black smoke and abnormal sound dur- or worn.
ing exhausting. 2. The cylinder head gasket is air-leaked.
Equipment:
Open-end spanner, flat-tip screw driver, and feeler
gauge
Test steps and adjustment: 7
1. Dismantle the cylinder head cover, and inspect
and tighten the hold-down nut for the rocker arm
seat.
2. Turn the crankshaft to the position where the pis-
tons of the 1st cylinder and 4th cylinder are placed
at the upper dead point (the "0" scale line on the
crankshaft pulley is aligned with the pointer on the
timing gear chamber cover at this moment; among 1-Feeler gauge
them, if the intake valve and exhaust valve of one 2-Rocker arm
cylinder must be closed simultaneously, the piston 3-Adjusting screw
of this cylinder is placed at the upper dead point in 4-Locknut
the compression stroke). 5-Push rod
3. Release the locknut, and use a screwdriver to turn 6-Valve spring
the adjusting screw, as well as insert the feeler
7-Valve clearance
gauge into the intake valve and exhaust valve of the
1st cylinder, intake valve of the 2nd cylinder and
exhaust valve of the 3rd cylinder to inspect and ad-
just the clearance, so that the cold clearance is kept
within 0.30～0.35mm.
4. During adjustment, the valve should be tightened
by such means that the valve push rod can be turned
evenly by fingers. After being adjusted properly, it
is required to tighten the locknut firmly to prevent
looseness during operation.
5. According to the operating sequence of the
cylinders (the cylinders are operated in such se-
quence of 1-3-2 for the three-cylinder engine, and
1-3-4-2 for the four-cylinder engine), rotate the
crankshaft by one turn (namely 360°), and inspect
and adjust clearance of the remaining valves by the
method above (note that the valve clearance cannot
be adjusted by turning the crankshaft in reverse di-
rection).
Specification:
Intake valve clearance (cold state): 0.20-0.25 mm
Exhaust valve clearance (cold state): 0.25-0.30 mm
Test results:
If the problem remains unresolved after being ad-
justed as per requirements, other causes should be

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2. Inspecting cylinder pressure

Cause:
It is used to inspect whether there is white
smoke resulting from insufficient compressive force
of the cylinder.

Equipment:
Pressure tester, open-end spanner

Connection:

The sensor is inserted into the glow plug hole,

and then a pressure tester is connected.

Testing steps:

1. Connect the pressure tester in the 1st cylinder,

and turn the crankshaft, as well as observe the
change in reading of the pressure tester;
2. After testing the 1st cylinder, inspect pressure of
the remaining cylinders by the same steps above in
sequence.

Specification
Pressure value: 2400 kPa±175 KPa

Test results:
In case of out of specification results, it is required
to take account of following factors:
1. Air leakage of the valve
2. The valve spring is broken.
3. Wrong valve clearance
4. Carbon deposit, blockage or wear of the
piston ring.
5. Air leakage of the cylinder head gasket.

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3. Inspecting the engine oil pressure

Cause:
To confirm whether the bearing or lubricating system component is worn.

Equipment:
Pressure indicator assembly
Hose assembly
Temperature indicator

Connection:
1. Dismantle the engine oil pressure sensor
Note: The thread is taper pipe thread 1/8, and it is
required that the pressure range is (0—700)kPa ((0
—6.9) bar or (0—100) psi) for special fittings and
hose connections.
2. Connect the pressure indicator assembly and hose
assembly

Important notice : if the pressure reading is low-

er than 72 kPa (0.72 bar or 10.5 psi), the engine
flames out.

3. Install the temperature indicator at the engine oil

filter element.

Note: When the engine and oil pressure indicator

are operated in an endurable extreme conditions, the
reading of the oil pressure indicator is up to 582kPa
(5.82 bar or 85 psi). This does not result in damage
to the engine.

4. Enable the engine to be operated for about 5

minutes, so that the engine oil temperature reaches
the specified value; after that, measure the engine
oil pressure.

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Specification
Engine oil temperature (engine speed of 825rpm) 93°C (220F)
Engine oil temperature (engine speed of 2500rpm) 105°C (220F)
Minimum pressure of the engine oil (engine speed of 825rpm) 100 kPa (1 bar or 15 psi)
Minimum pressure of the engine oil (engine speed of 2500rpm) 277—483 kPa (2.77—4.83 bar
or 40—70 psi)

Test results:
1. If the oil pressure value is not within technical
parameters, inspect whether the oil pressure regu-
lating valve is damaged, the spring is broken or
ruptured. (Carry out maintenance activities by
making reference to the Chapter 4 of this Part as
required.

A-Temperature indicator

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4. Inspecting fuel injection pump timing

Cause:
High fuel consumption rate, poor power perfor-
mance and black smoke.

Equipment:
Special socket or open-end spanner

Testing steps:
1. Remove the air in the fuel system, enable the
crankshaft to be reciprocated to get the oil injection
pump fully filled with diesel fuel, and dismantle the
1st high pressure oil hose to blow out the residual
oil in the fitting hole of the oil valve seat; after that,
slowly turn the crankshaft in forward direction, and
pay a close attention to oil level in the fitting hole;
stop turning the crankshaft immediately when the
oil level fluctuates.

2. Check whether scale on the flywheel scale line

aligned with the marking scale line on the flywheel
cover meets the specified optimal value.

3. If the fuel supply advance angle is too big or

small, it is possible to release the three nuts on the
triangle flange of the oil injection pump. Turning
the fuel injection pump outward can get the fuel
supply advance angle increased, and turning inward
can get the advance angle decreased. Tighten the
three nuts on the mounting flange, and then inspect
the fuel advance angle until it meets the require-
ments.

Specification:
(KM385BT/4L22BT) Fuel supply advance angle:
16°±1°
(KM385T/4L22T) Fuel supply advance angle:
10°±1°

Test results:
If the timing of the fuel injector has no prob-
lem, it is possible to take account of other factors.

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5. Calibration of the fuel injection pump

Cause:
The fuel supply to the individual cylinders is
non-uniform, and the fuel injection pressure is in-
sufficient.

Equipment:
Fuel pump test bench

Testing steps:
1. Install the fuel injection pump onto the test
bench, connect the standard fuel injector, and then
turn the fuel pump to pump fuel.
2. If fuel delivery unevenness of cylinders is
too serious, it is possible to turn the plunger to ad-
just the fuel delivery.
3. Turning the plunger in clockwise direction
can make the fuel quantity decreased, and increases
in counterclockwise direction until the delivery un-
evenness of cylinders reaches the specified re-
quirement.

Specification:
Delivery unevenness of cylinders: Nominal:
10%; Calibration: 10%; Idling speed: 30%.

Test results:
If the delivery unevenness of cylinders has no
problem, it is possible to take account of other fac-
tors.

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6. Inspecting atomization by the fuel injector

Cause:
Black smoke from the diesel engine, insufficient
power, increase in fuel consumption and other trou-
bles.

Equipment:
Pressure tester, open-end spanner , fuel injector test
bench

Test steps and adjustment:

1. Get the fuel pressure increased to 10.78Mpa by

turning the pump manually, and then slowly pump
the fuel, so as to make the pressure increased to the
nominal fuel injection pressure, and then observe
whether there is oil dripping or leakage from the
fuel injection nozzle orifice; if there is still fuel
dripping after being tested for many times, it is re-
quired to dismantle the fuel injection nozzle, and
clean, inspect, grind or replace it, and then re-test it
again.
2. Adjust the fuel injection pressure, remove the
fuel injector adjusting screw cap, and unscrew or
tighten the pressure adjusting screw, so as to enable
the fuel injection pressure to meet the nominal val-
ue, and then tighten the pressure adjusting screw
cap, and re-test it.
3. Observe the fuel atomization quality, and carry
out atomization test at a rate of about one time per
second; the fuel spray should be fine and even at-
omized fuel, without visible splashed fuel, partial
density unevenness or single-side fuel injection;
when the fuel is cut off, there is an obvious clear
sound.

Specification
Fuel injection pressure value: 24-25MPa

Test results:
If failed to reach the fuel injection pressure, the
fuel injector nozzle has to be cleaned, ground, or
replaced with a new one.

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Chapter 4 Fault analysis and troubleshooting

1. White smoke

Inspection po-
Steps Fault causes Troubleshooting
sition
The possible cause is that the
fuel injector pressure is lower
Repair or change the fuel injector (Re-
1 Fuel injector than 23MPa, the fuel is atom-
fer to Section 3, Chapter 6, Part II)
ized poorly, or there is fuel
leakage.
Water tempera- The cooling water temperature
2 Increase the coolant temperature.
ture is too low.
The cylinder gasket, cylinder Replace (Refer to Section 3, Chapter 2,
3 Cylinder
head or block is damaged. Part II)
Remove the water contained in the fuel
4 Fuel The fuel contains water.
in time or change the fuel.

2. Blue smoke

Inspection
Steps Fault causes Troubleshooting
position
The piston ring is worn excessively, or
the elasticity of the piston ring is insuf-
Change the piston ring (Refer to
1 Piston ring ficient due to carbon deposit, resulting
Section 4, Chapter 2, Part II)
in ingression of the engine oil into the
combustion chamber.
The engine oil level is declined
2 Engine oil The engine oil level is too high.
within the specified range.
The gaseous ring is installed in a reverse
direction or the open ends are scattered
Re-install the gas ring (Refer to
3 Gaseous ring by less than 180°, resulting in ingres-
Section 3, Chapter 2, Part II)
sion of engine oil into the combustion
chamber.

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3. Black smoke or grey smoke

Inspection
Steps Fault causes Troubleshooting
position
The fuel injector or the injector nozzle
is damaged or blocked, resulting in poor Repair or replace (Refer to Sec-
1 Fuel injector
atomization and insufficient combus- tion 6, Chapter 3 of this Part)
tion.
1. The fuel injection is too late, and par-
1. Adjust the fuel supply advance
tial fuel is combusted in the exhaust
angle to 16°±1°(Refer to Section
Fuel injection process.
2 4, Chapter 3 of this Part)
pump 2. The fuel supplied by the fuel injec-
2. Calibrate the pump (Refer to
tion pump is insufficient, causing une-
Section 4, Chapter 3 of this Part)
venness of the combustion power.
1. The valve is not sealed tightly, re-
sulting in low compression ratio of cyl- Grind the valve or adjust the valve
3 Valve inders. clearance (Refer to Section 1,
2. The valve is open slowly, and the Chapter 3 of this Part)
engine is operated roughly.
The air filter is blocked, and the air in- Clean the air filter or change the
4 Air filter
take quantity is insufficient. filter element.
Reduce the load within specified
5 Overload Overload operation
range.

4. Insufficient compression pressure of cylinders

Inspection
Steps Fault causes Troubleshooting
position
Intake and Grind the valve (Refer to Section
1 exhaust The valves are not sealed tightly. 4, Chapter 1, Part II) or adjust the
valves valve clearance.
Replace (Refer to Section 3,
2 Valve spring The valve spring is broken.
Chapter 6, Part II)
Valve clear- Adjust (Refer to Section 1, Chap-
3 The valve clearance is inappropriate.
ance ter 3 of this Part)
Clean the carbon deposit or re-
Carbon deposit, jamming or serious
4 Piston ring place it with new one (Refer to
wear of the piston ring
Section 4, Chapter 2, Part II)
Cylinder head Tighten the bolts to 135-150N.m
The cylinder head bolts are loosened or
5 Cylinder head or replace it with a new cylinder
gasket the cylinder head gasket is damaged.
head gasket.

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5. Air intake obstructed

Inspection
Steps Fault causes Troubleshooting
position
The filter element is damaged, and the Replace the filter element or clean
1 Air filter
air filter is blocked. the air filter.
Air intake
2 The air intake pipeline is blocked. Clean the air intake pipeline.
pipeline

6. Black smoke

Inspection
Steps Fault causes Troubleshooting
position
Reduce the load within specified
1 Load Overload operation
range.
The plunger spring of the fuel injection Replace or repair the fuel injection
Fuel injection
2 pump is broken, or fuel delivery error of pump (Refer to Section 5, Chapter
pump
cylinders exceeds the specified range. 3 of this Part)
Valve clear- Adjustment (Refer to Section 1,
3 The valve clearance is inappropriate.
ance Chapter 3 of this Part)
Replace the spring or grind the
The valve spring is loosened or the
4 Valve valve (Refer to Section 4, Chapter
valve is not sealed tightly.
1, Part II)
Fuel supply The fuel supply advance angle is insuf- Adjustment (Refer to Section 1,
5
advance angle ficient. Chapter 3 of this Part)
Air intake The air filter element or air intake pipe-
6 Replace or clean
system line is blocked.
The fuel is atomized poorly, and there is
Repair or replace (Refer to Sec-
7 Fuel injector fuel leakage from the fuel injector noz-
tion 6, Chapter 3 of this Part)
zle.

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7. Abnormal sound from the diesel engine

Inspection
Steps Fault causes Troubleshooting
position
The fuel supply advance angle is too
Fuel supply Adjust the fuel supply advance
1 big, and there is rhythmic metallic
advance angle angle to 16°±1°
knocking sound.
The fuel drips from fuel injector or the Repair or replace (Refer to Sec-
2 Fuel injector
needle valve is stuck. tion 6, Chapter 3 of this Part)
The valve clearance is too big, and there Adjustment (Refer to Section 1,
3 Valve
is clear and rhythmic knocking. Chapter 3 of this Part)
Adjustment (Refer to Section 1,
4 Piston The piston is in contact with the valve.
Chapter 3 of this Part)
The cylinder head thickness is insuffi-
Cylinder head
5 cient, and the piston contacts the cylin- Change the cylinder head gasket.
gasket
der head.
Valve spring, The valve spring is broken, the valve
valve push push rod is bent, and the valve tappet is Change the damaged part (Refer
6
rod, and valve worn, resulting in a slight knocking to Chapter 1, Part II)
tappet from the valve mechanism.
The clearance between piston and cyl- Repair or change the piston, cyl-
Piston and inder liner is too big, but such sound is inder liner, piston ring and piston
7
cylinder liner weakened as the diesel engine tempera- pin (Refer to Chapter 1 and Chap-
ture rises. ter 2, Part II).
The connecting rod bearing shell clear-
Connecting Change the connecting rod bear-
ance is too big. When the speed de-
8 rod bearing ing shell bushing (Refer to Chap-
creases suddenly, a heavy and strong
shell ter 2, Part II).
whomp can be heard.
The clearance between connecting rod
Connecting Change the connecting rod and
bushing and piston pin is too big. Such
9 rod bushing piston pin bush (Refer to Chapter
sound is slightly sharp, especially clear
and piston pin 2, Part II)
during idling.
The wear of the crankshaft thrust plate
will lead to excessive axial clearance,
Crankshaft and it is possible to hear knocking pro-
10 Change the thrust plate
thrust plate duced from forward and backward
movement of the crankshaft during
idling.

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8. The engine cannot be operated normally or flames out frequently

Inspection
Steps Fault causes Troubleshooting
position
The air passage is obstructed, resulting
1 Fuel tank cap in negative pressure built up in the fuel Clean or replace
tank.
The diesel grade is wrong or the fuel
2 Fuel tank Change or replenish the fuel
quantity is insufficient.
Air filter ele- The filter element is contaminated or
3 Clean or replace the filter element
ment blocked.
4 Fuel filter The filter is blocked. Replace
Sediment
5 The sediment bowl is off. Turn on the sediment bowl switch.
bowl
Intake and
The intake and exhaust valve clearance Adjustment (Refer to Section 1,
6 exhaust
is inappropriate. Chapter 3 of this Part)
valves
Repair or replace (Refer to Sec-
7 Fuel injector Poor atomization
tion 6, Chapter 3 of this Part)
Piston, cylin-
Replace the piston, cylinder liner,
der liner, pis- The piston, cylinder liner, piston ring
8 piston ring and piston pin (Refer
ton ring and and piston pin are worn seriously
to Chapter 1 and 2 of Part II)
piston pin

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9. Low power

Inspection
Steps Fault causes Troubleshooting
position
Diesel filter or The fuel inlet/outlet pipe or strainer
1 Clean or replace
fuel pump is blocked.
The fuel injector is damaged or
blocked, the fuel injector pressure is Repair or replace (Refer to Section 6,
2 Fuel injector
inappropriate or the atomization is Chapter 3 of this Part)
poor.
1. The plunger and barrel assembly of
the fuel injection pump is worn exces-
sively;
Fuel injection The fuel injection pump does not 2. The governor spring is deformed or
3
pump operate smoothly. loosened;
3. For abnormal operation of the fuel
injection pump, refer to Chapter 3 of
this Part to maintain the pump.
4 Fuel system Ingression of air into the fuel system Remove the air in the fuel pipeline.
Fuel supply The fuel supply advance angle is Adjust the fuel supply advance angle
5
advance angle insufficient. to 16°±1°
Adjust the delivery unevenness of cyl-
Fuel delivery The fuel delivery error of cylinders is
6 inders to specified range: Nominal:
quantity out of specification.
10%; Calibrated: 10%; Idling: 30%.
Intake pipe
7 The air intake is not smooth. Clean or replace the filter element
Air filter
The intake and exhaust valve clear- Adjust (Refer to Section 1, Chapter 3
8 Valve
ance is inappropriate. of this Part)
Change the worn parts as required, and
adjust the valve timing:
Intake valve open Before upper dead
point 12±3°
The valve mechanism parts are worn Intake valve closed After lower dead
9 Valve timing
seriously. point 38±3°
Exhaust valve open Before lower dead
point 50±3°
Exhaust valve closed After upper dead
point 14±3°
There is air leakage from the sealing
Fuel injector Remove the carbon deposit or tighten
10 surface between the seat and cylinder
seat the set bolts.
head.
Cylinder head The cylinder head bolts are loosened; The tightening torque for the cylinder
11 Cylinder head There is air leakage from the cylin- head bolts is (145～155)N.m;
gasket der head gasket. Change the cylinder head gasket.
Clean the carbon deposit or replace it
The piston ring is deposited with
12 Piston ring with new one (Refer to Section 4,
carbon, jammed or worn.
Chapter 2, Part II)

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10. The engine oil is mixed with water

Inspection
Steps Fault causes Troubleshooting
position
Cylinder liner, The cylinder liner or sealing ring is
1 Replace
sealing ring damaged.
Cylinder head
2 The cylinder head gasket is damaged. Replace
gasket
3 Cylinder head The cylinder head is damaged. Replace
Cylinder
4 The cylinder block is damaged. Replace
block

11. Abrupt increase in speed

Inspection
Steps Fault causes Troubleshooting
position
The speed regulator is failed, and the tie
Speed regula- Repair or replace (Refer to Sec-
1 rod is stuck at the big fuel quantity posi-
tor tion 5, Chapter 3 of this Part)
tion, resulting in galloping.
Speed regula-
The Speed regulator sliding disk bush- Repair or replace (Refer to Sec-
2 tor sliding
ing is stuck. tion 5, Chapter 3 of this Part)
disk bushing
Reduce the engine oil quantity to
specified range or change the pis-
Serious ingression of engine oil into the
3 Engine oil ton, cylinder liner, piston ring and
combustion chamber.
piston pin (Refer to the Chapter 1
and 2, Part II)

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12. Erratic operation

Inspection
Steps Fault causes Troubleshooting
position
Repair or replace (Refer to Sec-
1 Fuel injector The fuel drips from the fuel injector.
tion 6, Chapter 3 of this Part)
The clearance between the fork and ad-
Fork and ad- Replace (Refer to Section 5,
2 justing arm is too big; the steel ball and
justing arm Chapter 3 of this Part)
sliding disk are worn and dented.
Repair the fuel delivery uneven-
The fuel delivery of cylinders is uneven,
Fuel injection ness of cylinders to specified
3 and the axial clearance of the fuel in-
pump range (Nominal: 10%, Calibrated:
jector camshaft is too big.
10%; Idling: 30%)
Sliding disk Repair or replace (Refer to Sec-
4 The sliding disk bushing is jammed.
bushing tion 5, Chapter 3 of this Part)

13. Engine overheat

Inspection
Steps Fault causes Troubleshooting
position
Fill cooling water until the cooling
The water quantity is insufficient or water level is over 5mm below the
1 Cooling water
there is air in the water pipe. sealing surface of the radiator
cover, or remove the air.
Radiator and The scale deposit on the water tank and Clean the cooling system with
2
water pipe water passage is too much. cleaning solution.
Change the water pump or adjust
the belt tension (Through applying
Water pump
There is water leakage from the water a force about 98N to the middle
3 assembly or
pump or the fan belt is loosened. part of the belt, the sag is (7-9)
fan belt
mm for a new belt, and (11-13)
mm for a used belt).
The thermostat cannot be actuated nor-
4 Thermostat Replace the thermostat
mally.

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14. Abnormal coolant temperature

Inspection
Steps Fault causes Troubleshooting
position
It is operated within normal load
1 Overload Overload operating time is too long.
range.
Adjust the valve timing:
Intake valve open Before upper dead
point 12±3°
Intake valve closed After lower dead
The valve timing is not within speci-
2 Valve timing point 38±3°
fied range.
Exhaust valve open Before lower
dead point 50±3°
Exhaust valve closed After upper dead
point 14±3°
Fuel supply The fuel supply advance angle is in- Adjust the fuel supply advance angle
3
advance angle sufficient. within 16°±1°
Fill cooling water until the cooling
The water quantity is insufficient or water level is over 5mm below the
4 Cooling water
there is air in the water pipe. sealing surface of the radiator cover,
or remove the air.
The scale deposit on the water tank
5 Water tank Clean the water tank
and water passage is too much.
Change the water pump or adjust the
belt tension (Through applying a force
There is water leakage from the water
6 Water pump about 98N to the middle part of the
pump or the fan belt is loosened.
belt, the sag is (7-9) mm for a new
belt, and (11-13) mm for a used belt).
The thermostat cannot be actuated
7 Thermostat Replace the thermostat
normally.
The engine oil is insufficient or ex-
cessive, the engine oil pressure is too Fill engine oil above grade CD to the
8 Engine oil
low, the engine oil is thinned or dete- specified level (5L-6L) as required.
riorated, or a wrong oil grade is used.
The piston ring is air-leaked, the pis-
Piston ring
ton and cylinder liner are worn ex-
9 and cylinder Replace it with a new one.
cessively, and the gas goes into the
liner
crankcase.

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15. No engine oil pressure or low pressure

Inspection
Steps Fault causes Troubleshooting
position
Fill engine oil above grade CD to
1 Engine oil The engine oil level is too high or low. the specified level (5L-6L) as re-
quired.
Engine oil The oil line is blocked or subject to oil
2 Clean or repair
pipeline leakage.
3 Oil filter The filter is blocked. Clean or replace
Oil pressure The indication value is not consistent Change the engine oil pressure
4
gauge with the actual pressure. indicator or oil sensor.
Clean or replace it (Refer to Sec-
5 Oil pump It is blocked or aged.
tion 4, Chapter 4, Part II)
Engine oil Change the safety valve or adjust
6 pump safety Failure or damage the opening pressure of the safety
valve valve to 600KPa
Engine oil
7 The gasket is damaged. Replace
pump gasket
8 Oil passage The oil passage is blocked. Cleaning

16. The engine oil pressure is too high

Inspection
Steps Fault causes Troubleshooting
position
Engine oil Repair the opening pressure of the
The engine oil line is blocked or the
1 pump safety
valve opening pressure is too high. safety valve to 600KPa.
Any kind of engine with appropri-
Engine oil
2 The engine oil grade is inappropriate. ate viscosity oil is selected as per
viscosity
environmental temperature.

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17. The engine oil temperature is too high

Inspection
Steps Fault causes Troubleshooting
position
Fill engine oil with appropriate
The engine oil level is too low or the oil viscosity and above grade CD to
1 Engine oil
grade is inappropriate. the specified level (5L-6L) as per
the environmental temperature.
Refer to the troubleshooting for
Engine oil The oil pressure is not within (200-400)
2 the fault of “No engine oil pres-
pressure value KPa
sure or low pressure”.
Piston, cylin-
The piston ring is air-leaked, the piston Change the piston, cylinder liner,
der liner, pis-
3 and cylinder liner are worn excessively, piston ring and piston pin (Refer
ton ring and
and the gas goes into the crankcase. to the Chapter 1 and 2, Part II)
piston pin

18. High engine oil consumption

Inspection
Steps Fault causes Troubleshooting
position
Select a kind of engine oil with
appropriate viscosity and above
1 Engine oil The engine oil grade is inappropriate.
grade CD as per the environment
temperature.
The piston and cylinder liner are worn ex- Repair the piston ring, piston and
Piston, cylin-
2 cessively, and the engine oil goes into the cylinder liner (Refer to Section 4,
der liner
cylinders to cause oil consumption. Chapter 2, Part II).
The gas ring is installed in a reverse manner,
Re-install or replace (Refer to
3 Piston ring and worn excessively, and the oil goes into
Section 4, Chapter 2, Part II)
the combustion chamber.
The front oil seal or rear oil seal of the
4 Oil seal crankshaft is damaged, and subject to oil Replace
leakage.
Gaskets of the There is oil leakage from the mating faces of
5 Replace
whole engine the oil pan, gear chamber and etc.

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 MAINTENANCE MANUAL OF ENGINE

19. Low starter speed

Inspection
Steps Fault causes Troubleshooting
position
1 Battery The battery electricity is at low level. Charging

2 Starter The contact is poor or aged. Clean or replace

The starter motor gear cannot be en- Adjust installation position of the
3 Starter
gaged with gear ring normally. starter

20. Cannot be started or be started difficultly

Inspection po-
Steps Fault causes Troubleshooting
sition
The air passage is obstructed, re-
1 Fuel tank cap sulting in negative pressure built up Clean or replace
in the fuel tank.
The fuel grade is not matched with Select an appropriate fuel type based
2 Fuel
the engine. on the environmental temperature.
3 Sediment bowl The sediment bowl switch is off. Turn on the switch
There is air entrapped in the pipe-
4 Fuel pipeline Release the air or clean the pipeline.
line or the pipeline is blocked.
The battery is damaged or the bat-
5 Battery Replace or charge
tery electricity is insufficient.
6 Fuel filter The filter is blocked. Clean or replace
The engine speed is less than
Repair (Section 6, Chapter 2 of this
7 Starter 90rpm/min at the instant when the
Part)
engine is started.
Fill engine oil with appropriate vis-
The engine oil is dirty, and the vis-
cosity and above grade CD to the
8 Engine oil cosity does not meet the require-
specified level (5L-6L) as per the
ment.
environmental temperature.
The fuel injector nozzle is dirty or Clean or replace (Refer to Section 6,
9 Fuel injector
blocked, and oil dripping occurs. Chapter 3 of this Part)
The fuel injection pump timing is Calibrate the pump or replace it
Fuel injection
10 wrong, or the fuel injection pump is (Refer to Section 5, Chapter 3 of this
pump
damaged. Part)
Intake and ex- The intake and exhaust valve Adjust (Refer to Section 1, Chapter 3
11
haust valves clearance is inappropriate. of this Part)
The piston, cylinder liner, piston
Piston, cylinder Change the piston, cylinder liner,
ring and piston pin are worn seri-
12 liner, piston ring piston ring and piston pin (Refer to
and piston pin ously, and a cylinder pressure of
the Chapter 1 and 2, Part II)
2400 kPa is kept.

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 MAINTENANCE MANUAL OF ENGINE

21. The diesel engine is started difficultly

Inspection
Steps Fault causes Troubleshooting
position
1 Fuel tank The fuel quantity is insufficient. Add fuel
Sediment
2 The sediment bowl switch is off. Turn on the switch
bowl
1. There is air or water in the fuel sys- 1. Release the air or water, or re-
tem; place the diesel.
3 Fuel system
2. There is fuel leakage from the low 2. Fasten the connection or replace
pressure fuel line connection. it with a new one.
Fuel line or Clean the pipeline, or replace the
4 The fuel line or filter is blocked.
filter filter element.
Fuel delivery The fuel delivery pump or fuel injec-
Overhaul the fuel delivery pump,
pump, fuel tion pump cannot deliver fuel or the
5 fuel injection pump or adjust the
injection fuel supply advance angle is inappro-
fuel supply advance angle.
pump priate.
The atomization effect obtained by the Repair or replace (Refer to Section
6 Fuel injector
fuel injector is poor. 6, Chapter 3 of this Part)
The fuel delivery valve, or plunger and
Fuel injection Grind or change it (Refer to Section
7 barrel assembly of the fuel injection
pump 5, Chapter 3 of this Part)
pump is worn.

148
LOVOL HEAVY INDUSTRY CO,. LTD.

Add: NO.192 Beihai S.Rd., Fangzi District, Weifang, Shandong,China.

Zip code:261206
Website:www.fotonlovol.com
Specifications and designs are subject tochange without prior notice.

Machines shown may include optional parts.