Dongfeng Chaoyang Diesel engine Co CYQD 32 Series CYQD32 Service Manual Download Page 41 | Manualshive

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41

To produce bush according to

connecting-rod small end wedge
plane, then remove burr.

4)Degree  of  parallelization  about
the  small  and  big  end  hole  of
con-rod

Limit

100:0.075

5)

Free

tension

of

connecting

—

rod shell

    If the shell is with sufficient free
tension,  when  installing  it,  the
finger  should  be  with  certain
strength.

If it loosed after installed, we

must replace shell.

15.Clearance

between

connecting-rod

shell

and

crankshaft

connecting-rod

journal
1) To make connecting-rod shell
enclose connecting-rod big end
hole,

and

tighten

stipulated

torque

according

to

the

requirement.

2) The big hole inner diameter
after installed shell
Nominal
inner
diameter

Φ

157

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Summary of Contents for CYQD 32 Series CYQD32

Page 1: ... Serve with whole heart Satisfaction accompanies the whole way Maintenance manual Model CYQD32 Series Diesel Engine Dongfeng Chaoyang Diesel engine Co LTD PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 2: ...ch deformation such as QD32 1B QD32EGR 1A QD32T 2A QD32Ti 1A The series diesel engine serial number which at the front of __ expresses essential configuration and performance which at the back of __ expresses equipping deformation In order to make diesel engine often keep good technology state and convenient for customer s maintenance and repairing So we wrote the manual especially Because the ser...

Page 3: ... requirement the configuration will continue to perfect So some contents may be unconformity future productions and please customers notice and take care of the new manual publishing PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 4: ...ntenance checking and adjusting V Basic parts disassemble and reassemble 1 Rocker arm shaft conjunction 2 Cylinder head and valves 3 Piston connection conjunction assembly VI Basic parts checking and maintenance VII Accessory parts disassembly and checking repairing and adjusting 1 Lubrication system 1 Pressure lubrication system abridged drawing 2 Piston cooling injection nozzle 3 Oil filter 4 Oi...

Page 5: ...5 3 Inlet preheating system 4 EGR system CYQD32EGR 5 Turbocharger charger CYQD32T CYQD32Ti PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 6: ...6 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 7: ...7 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 8: ...8 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 9: ...9 II Outside parts disassembly and assembly 1 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 10: ...10 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 11: ...amber cover oil sump high pressure fuel injection pump gear cover must be painted sealing glue the other parts don t need to be painted sealing glue 2 Inlet pipe When assembly inlet pipe to tighten screw bolt and nut according to the stipulated digital order and required torque 3 Exhaust pipe When assembly exhaust pipe to tighten nut according to the PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn...

Page 12: ...l order and required torque Note Different length screw bolts don t make wrong 5 Oil sump To tighten screw bolt according to the stipulated direction and required torque 6 Cylinder head cover To tighten screw bolt according to stipulated digital order and required torque PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 13: ...sembly and assembly cylinder block Seal gasket seal ring Tightening torque big N m Tighten torque matrix small N m To paint oil for lubrication To use seal glue which recommended PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 14: ... Inner parts disassembly and assembly cylinder head Seal gasket seal ring Tightening torque big N m Tighten torque matrix small N m To paint oil for lubrication PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 15: ...ert in the main bearing cover locating groove 2 The main bearing cover The arrow of the main bearing cover faced to the front of the engine The number on the top of arrow is position No the number on the bottom of arrowhead is batch No and model 3 Crankshaft thrust plate Oil grooves of upper and lower thrust plate faced to the sliding face of crankshaft The locating convex end of lower thrust plan...

Page 16: ... front or the inlet valve notch deviation the front end When install piston to make the ring compress with the special tools The big end bolt position side of connecting rod is matching No the other side is quality group No After connecting rod bolt was painted oil then assembly Torque N m 78 83 6 Idler shaft Oil hole faced to the top After inserted in gear and press plate then make bolt tighten P...

Page 17: ...ress plate chamfer faced to outside 9 Oil pump After filling some oil then assembly When assembly to tighten any bolt we must rotate gear and don t have inhibition 10 Flywheel case After bolt was painted oil then assemble Torque N m 60 70 11 Flywheel To make oil pain on thread of the bolt and the head end then to tighten according to the stipulated digital order and required torque Torque N m 167 ...

Page 18: ... the cylinder block link surface 14 Cylinder head To make oil paint on the thread of the bolt and the head then tighten by three steps according to the drawing digital order and torque 15 Rocker arm shaft conjunction To tighten bolt and nut according to the stipulated digital order 16 Valve clearance To adjust the valve clearance with QD290 CN 101 valve clearance gauge Cooling valve clearance Inle...

Page 19: ...and CYQD32T CYQD32Ti is justification with the top calibration mark and make 1 4 cylinder piston lie to T D C To shake the first cylinder inlet and exhaust valve rocker arm with hands if the both exist clearance it showed the first cylinder piston lies to T D C of the compress stroke If the rocker arm have no clearance so it existed clearance between the fourth inlet valve and exhaust valve rocker...

Page 20: ...t filter element clean or replace fuel filter element dismounting see fuel filter resolution and reassembly if necessary replace every seal parts 3 Injector Checking To check injection oil pressure with injector test device Standard starting injection pressure kPa 9800 Adjusting To observe and adjust injection fuel with injector test device PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 21: ...cating light is on we will carry out Without filter element indicating light regularly carry out according to the practice To wash filter element When the filter element was stained with oil smoking dilute with water important filter element abstergent detergent then put filter element into about twenty minutes then take it out and wash it with water then blow it dry in the well ventilated air pla...

Page 22: ...22 5 Fan water pump belt and air compressor belt To add 39 N strength to the belt single one the deflection is 10 15mm PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 23: ...23 V Basic parts disassembly and reassembly PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 24: ...24 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 25: ...ools 2 Inlet exhaust valve Because the heads of inlet and exhaust valves are different don t make wrong 3 Split collets and valve spring seat To disassembly and reassembly split collets and valve spring seat with 6102 29 03 disassembly valve tools 4 After installing split Collets to beat valve lever end with plastic hammer softly PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 26: ...26 3 Piston connecting rod assembly PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 27: ...body 2 Check ring To disassembly and reassembly check ring with special tools or clippers 3 Piston ring To disassembly and reassembly piston ring with special tools Don t make every ring install wrong The first ring with the mark side faced up The second ring inscribe groove faced up oil ring bush spring interface be put the opposite of ring body opening rotate smoothly and no inhibition PDF 文件使用 ...

Page 28: ...over limit value we must replace seat ring When disassembly valve seat ring mustn t heat otherwise will make bottom hole deformation When replace it inlet valve seat ring don t enlarge bottom hole 2 To insert valve seat ring To completely clean out metal oxide and deposit carbon on valve seat ring hole surface of cylinder head then press seat ring by pressure To cut down valve seat with 90 reamer ...

Page 29: ...acting ring should not intermit the width is 1 2 mm To install valve spring and fill kerosene into inlet and exhaust passage and ensure it will not leak lasting for two minutes If existing problem we should hinge valve seat ring again and grind valve and seat ring with abradant 4 To replace and maintenance valve seat ring If the exhaust valve sinkage is too big we must be reference left drawing ac...

Page 30: ...oning angle and head thickness Valve seal coning angle 90 Valve head thickness Standard Limit 1 5 1 0 2 Valve lever diameter 3 Valve guide inner diameter 4 Clearance between valve lever and guide PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 31: ...linder head gasket d Φ100 4 a When only replacing the cylinder head gasket must be the same with the cylinder head gasket group b When replacing or maintenance cylinder block cylinder head piston connecting rod and crank shaft choose cylinder head gasket according to the following 1 To measure piston protruding height i To measure two points on T D C piston top see drawing ii Average value for two...

Page 32: ...32 2 To choose qualified cylinder gasket According to max protruding height of piston in four cylinders PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 33: ...ny kinds of wear damage and other abnormal phenomenon 2 Tappet diameter Standard Limit Φ 25 960 Φ 25 970 Φ 26 93 3 Tappet hole inner diameter Standard Limit Φ 26 00 Φ 26 033 Φ 26 07 4 Clearance between tappet and tappet hole Standard Limit 0 03 0 013 0 20 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 34: ...0 3 9 Rocker arm conjunction 1 To check all disassembly parts to see if there is any wear damage and the other abnormal phenomenon 2 Rocker arm shaft diameter 3 Rocker arm conjunction inner diameter 4 Clearance between rocker arm and rocker arm shaft PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 35: ...al phenomenon 2 Camshaft axial clearance Standard Limit 0 08 0 28 0 4 There is abnormal phenomenon or side clearance is too big we should replace gear 4 Camshaft journal Standard Limit 50 0 079 0 60 55 6 5 Camshaft bush bearing inner diameter Standard 50 50 030 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 36: ... camshaft bush To replace camshaft bush with special blanking tool and hammer When installing bush we must make oil hole on the bush aim at oil hole on cylinder block among them the front bush has two oil holes and the other bush has only one hole Note After semi finished goods bush was press in need to manufacture again in the same time we should ensure the center to center between the hole and i...

Page 37: ... shaft outside diameter Standard Limit Φ41 959 Φ41 975 Φ41 85 12 Final manufacture cylinder hole according to the following dimension producing group Cylinder hole wear limit value 0 20 X Y standard value 0 020 A B standard value 0 020 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 38: ... Piston piston pin and piston ring 1 Piston diameter Measure position Diesel engine stroke S The distance from measure point to the top a 102 54 8 Diameter dimension group 2 Clearance between piston and cylinder PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 39: ...nd ring groove 4 Clearance of the piston ring opening 5 Clearance between piston pin and pin hole 33 0 07 0 Piston hole inner diameter Φ33 005 0 003 0 005 Clearance after assembled by group PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 40: ...l end hole of con rod Standard limit 0 025 0 045 0 15 2 Change about small end bushing of con rod Extrude bushing of small end by technology bar and compressor press in by technology bar and compressor or hammer pay attention to the justification of oil hole 3 Machine of small end bushing hole After bushing was installed ream hole by reamer the center distance is 157 0 025 Standard hole diameter 3...

Page 41: ...ension when installing it the finger should be with certain strength If it loosed after installed we must replace shell 15 Clearance between connecting rod shell and crankshaft connecting rod journal 1 To make connecting rod shell enclose connecting rod big end hole and tighten stipulated torque according to the requirement 2 The big hole inner diameter after installed shell Nominal inner diameter...

Page 42: ... If the shell is with sufficient free tension when installing it the finger should be with certain strength If it loosed after installed we must replace shell 2 To make the main bearing bush enclose the main bearing hole of cylinder block and tighten stipulated torque according to the requirement 3 The main bearing hole inner diameter after installed the main bearing shell Nominal inner diameter Φ...

Page 43: ...haft main journal Standard Φ 70 907 Φ 70 920 5 Clearance Standard Limit First 0 024 0 044 0 10 2nd 5th 0 024 0 056 0 10 6 Axial clearance of crankshaft Standard Limit 0 06 0 25 0 40 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 44: ...ecreasing dimension allowing 0 5 and 1 0 two shift Round corner radius for the main journal and connecting rod journal separating R3 0 2 and R3 5 0 2 2 Dimension of thickened shell Dimension of thicken shell allowing two shift Dimension of thickened shell 0 25 and 0 5 19 Crankshaft gear 1 Clearance of crankshaft gear Standard Limit 0 05 0 20 0 35 If we found the crankshaft gear exist wear abnormal...

Page 45: ...ing installing plane faced to flywheel 21 To replace the front and the rear oil seal of the crankshaft 1 The rear oil seal is installed rear oil seal seat and pried with screw driver pay attention not to damage installing hole of the rear oil seal To install it with blanking tool and hammer 2 The front oil seal is installed gear chamber cover and pried with screw driver pay attention not to damage...

Page 46: ...46 VII Accessory parts disassembly and checking repairing and adjusting 1 Lubrication system PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 47: ...ving smoothly 2 To ensure nozzle unobstructed if necessary we may clean it with metal wire When installing nozzle ensure nozzle justification with the main oil gallery of cylinder block Nozzle bolt tightening torque 29 39 N m CYQD32series diesel engine Dimension D mm 17 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 48: ...g overflow valve steel ball to see if it is flexible and if it is fracture If it damaged we must replace a new overflow valve 2 Oil pump by pass 1 To check equalizer valve unit if it is wear or damaged If it is damaged we should replace new equalizer valve PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 49: ... 2 When slide valve is smeared by oil checking if slide valve can move freely in the valve hole If it can t move we must repair and replace it 4 Oil cooler PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 50: ... valve To check overflow valve motion by pushing overflow valve steel ball if it is flexible and if it is fracture If it is damaged we must replace new overflow valve PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 51: ... oil checking if slide valve can move freely in the valve hole If it can t move we must repair and replace it To check all disassembly parts to see if it is wear damaged or other abnormal phenomenon especially whether cooler core is block or not If necessary we must repair or replace it By pass opening pressure 300kPa PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 52: ...e crankshaft clockwise until the first cylinder piston reached T D C 4 Dial gauge reading CYQD32 0 416 0 020 CYQD32GR 0 468 0 020 CYQD32T 0 527 0 020 CYQD32Ti 0 736 0 020 5 If reading is not in above scope we must adjust it as follows A if reading is smaller than requirement we should rotate pump anticlockwise B if reading is bigger than requirement we should rotate pump clockwise until it meets t...

Page 53: ... To accelerate idling and read rotation speed meter reading Max idling 4700 100rpm 4 If reading is smaller than standard value we should adjust bolt to rotate anticlockwise 1 2 circles then idling making the throttle reach the max and watching the reading 5 After adjusting if it is still low we will continue adjust according to above requirements until it met the requirements 6 After adjusting tig...

Page 54: ...54 Injection oil amount adjusting data form PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 55: ... bright showed that cooling temperature now is lower than the device setting value 5 1 system will preheat automatic After prophase preheating finished prophase preheating time is 20 seconds when preheating indicating light blink 1 2Hz tact then may start engine if preheating indicating light blinked in beginning 10 2 seconds can t still start engine electric device will automatically cut off circ...

Page 56: ...eck circuit or change electric plug and overflow valve ect by it but electric controlling device still continue to work Quickly blinking is 2 5Hz tact 5 We strong suggested during colder weather in order to protect your engine and your benefit you may not start engine until you must wait for prophase preheating finished after preheating indicating light blink 6 Please pay attention to use after he...

Page 57: ...pply vacuum with manual vacuum pump EGR valve membrane should be raised or we must replace EGR controlling valve Air throttle To give air throttle supply vacuum with manual vacuum pump throttle should be closed or we must replace EGR controlling valve PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

Page 58: ... is oil which lubricated rotator if exhaust air without abnormal white smoking it belongs to the normal every parts outside checking 1 With visual checking if it existed chappy interference damage deformation and if it existed leakage air and leakage oil 2 To rotate rotator with hand to check if it rotates flexibly and check rotator clearance between axial and rotating direction PDF 文件使用 pdfFactor...

Page 59: ...sassembly turbine case Note When disassembly pay attention to vane have no interference Checking after disassembly The vane has not bending chappy and damage Vane and case have not interference No carbon and oil abnormal adhereing Note If we found quality of middle body is not good we must replace it Cleaning after disassembly To clean carbon and contamination in all kinds of spare parts conjuncti...

Page 60: ...60 PDF 文件使用 pdfFactory Pro 试用版本创建 www fineprint cn ...

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