FAW Jiefang Automotive 485 Operation & Maintenance Manual Download Page 1

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Summary of Contents for 485

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Page 2: ...tion machinery tractors combines electric generator sets etc This Manual describes main specification adjusting methods operation and maintenance requirements etc of 4DW series diesel engines Correctly using and maintaining the diesel engines are extremely important to both travel safety and their longer service life Users are kindly requested to read carefully this Manual and operate and maintain...

Page 3: ...Written by Zhai Yonghui Huang Qiwei Yang Xueming Reviewed by Wang Xinze Li Peiran Yao Zugen ...

Page 4: ...r should be 70 of full load This is very important to the reliability and after overhaul service life of the engine 4DW engines will bring you more economic effectiveness if you timely maintain them as per this Manual Contact phone numbers of our Works are as follows Sales Company 0510 85013436 fax Main engine dept 0510 85014990 8362 8363 Accessories dept 0510 85014990 8370 85010814 Service dept 0...

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Page 6: ...ing every 100h 15 III Maintenance after running every 500h 16 IV Storage 17 Chapter IV Structure 18 I Cylinder head 18 II Engine body 20 III Piston connecting rod 21 IV Crankshaft flywheel 23 V Camshaft 24 VI Gear system 25 VII Fuel speed governing system 26 VIII Lubricating system 31 IX Cooling system 33 X Electrical system 36 XI Oil pressure sensor water temperature sensitive plug 38 Chapter V A...

Page 7: ... vibration 45 VII Engine overheat 46 VIII Too much engine oil consumption 46 IX Speed increased greatly 46 X Engine stops by itself 46 XI Rough idle 47 XII Engine oil raised high 47 Annex Fit Clearance Table 48 ...

Page 8: ... I Right view of 4DW81 46 diesel engine 1 ...

Page 9: ... II Left view of 4DW81 46 diesel engine 2 ...

Page 10: ... III Front view of 4DW81 46 diesel engine 3 ...

Page 11: ... IV Vertical view of 4DW81 46 diesel engine 4 ...

Page 12: ... V Power output end of 4DW81 46 diesel engine 5 ...

Page 13: ... at full load g kW h 235 14 Consumption ratio of engine oil to fuel oil 0 8 15 Maximum smoke at full load Bosch 3 5 16 Free acceleration smoke Bosch 3 0 17 Crankshaft rotation direction viewing towards flywheel Anticlockwise 18 Lubrication mode Pressure lubrication splash lubrication 19 Starting mode By electricity 20 Overall dimensions excluding clutch housing L W H mm 696 492 650 21 Net weight k...

Page 14: ...0 28 0 33 mm Exhaust valve 0 28 0 33 mm T D C Intake valve opens Exhaust valve closes Exhaust valve opens Intake valve closes B D C Fig 1 Valve timing diagram 2 Fuel supply advance angle 16 1 before T D C 3 Temperature and pressure values of the engine 1 Exhaust temperature At 15 minute rated power 620 At one hour rated power 550 At 12 hour rated power 500 2 Engine oil temperature 95 3 Water out t...

Page 15: ...pressure when idling kPa no less than 98 4 Tightening torque for important bolts N m or kgf m 1 Bolts on connecting rod 60 70 6 7 2 Bolts on cylinder head 118 137 12 14 3 Bolts on main bearings 120 140 12 14 4 Bolts on flywheel 110 130 10 12 5 Starting bolts 110 130 10 12 5 Lube oil capacity L 7 8 ...

Page 16: ...III External characteristic curve of 4DW engines 1 External characteristic curve of 4DW81 46 B01 9 ...

Page 17: ...2 External characteristic curve of 4DW81 50 B05 37kW 3200 r min 10 ...

Page 18: ...ow freezing point should be used in winter Diesel oil brands should be selected basically as per ambient temperature conditions see Table 2 1 For example 35 diesel oil should be used for ambient temperature of 29 Table 2 1 Relations between diesel oil brands and suitable lowest temperature Diesel oil brand 10 0 10 20 35 Sulfur content 0 2 0 2 0 2 0 2 0 2 Cetane value 45 45 45 45 45 Freezing point ...

Page 19: ...hould be selected according to ambient temperature 3 Higher class one class higher than normal required class oil should be used when load is heavy or travel distance is long or where road condition is bad or in dusty regions 4 Recommended are CD15W40 and CD20W50 engine oil with several viscosities which not only have low temperature dynamic viscosity and low temperature boundary pumping performan...

Page 20: ...rs The coolant dedicated to Brand Xichai diesel engines which contains water distilled water or ion water additives and ethylene glycol can directly be add into the cooling system Its specific parameters and quality indexes as follows Item Coolant Brand 35 45 Color Blue Odor No peculiar Odor Freezing point 35 45 Boiling point 107 108 Influence on organic coatings No influence PH Value 7 5 11 Corro...

Page 21: ...ne to be idling and check if it is running normally and if any abnormal sound with special attention being given to whether the engine oil pressure is normal Then pull the speed governing handle little by little so that the engine speed reaches 1800 2000 r min thus the engine is warmed up with no load 5 When the ambient temperature is lower than 0 and it is difficult to start the engine perform ai...

Page 22: ... stain and dust pay special attention to the dry and clean condition of electrical equipment 8 For a new engine after running for 50h at light load it is necessary to change the engine oil including the oil in speed regulator of fuel injection pump and the element of engine oil filter and to clean the crankcase sump and engine oil filter 9 Eliminate the faults and abnormal phenomena if found any I...

Page 23: ...Maintenance after running for every 500h In addition to the instructions in Maintenance after running for every 100h followings should also be performed 1 Check injection pressure of fuel injector and observe atomization quality and if necessary clean and adjust it 2 Check fuel supply advance angle and if necessary adjust it 3 Check gas valve for its tightness and if found not complying with requi...

Page 24: ...ehydrated engine oil via gas way into each cylinder i e heat the engine oil to 110 120 until bubbles completely disappear and turn the crankshaft so that the oil will be uniformly and evenly applied on surfaces of valve cylinder jacket and piston etc Fit back the intake and exhaust pipes 4 Oil stain water trace and dust on outer surface of the engine should be wiped and cleaned Unpainted parts exc...

Page 25: ...terline of the cylinder head In the mounting hole of the injector there is a copper shim used for adjustment of the height from the protruding injector to the base plane of cylinder head and used for sealing When installing the fuel injector please evenly and tightly press the pressboard without any leakage It is important that when installing the pressboard the side with an inclination should fac...

Page 26: ...l increased and thus will influence the compression ratio Therefore the valve seat may necessarily be replaced if the deflected distance is increased to be 2mm or more Fig 3 Trimming of valve seat Fig 4 Deflection of valve The valve guide when assembled should be 12 5 13mm higher than the plane of cylinder cover It is necessary to often inspect the valve lash or clearance For its adjusting method ...

Page 27: ...assembling disassembling it the marks should be followed and incorrect direction is not allowed When assembling front main bearing cover it is important that it should be flushed with front end face of engine body and should not protrude otherwise the pressing of timing gear chamber will be influenced When removing the main bearing bushes for cleaning do not mistake the upper bush and lower bush b...

Page 28: ... rod bush and connecting rod sleeve etc Weight difference between assemblies of piston and connecting rod for same diesel engine should be no more than 25g and weight difference between assemblies of connecting rod should be no more than 15g 1 Piston Combustion chamber at the top of piston should be ω shape Skirt section is processed to be drum shape along height direction and ellipse shape along ...

Page 29: ...ing Fig 7 Measuring the end face gap of piston ring The piston rings should be removed and fitted back by special tools When fitting the rings opening of each ring should be staggered each other for 120 and should not be at the direction of piston pin During maintenance repair if the piston ring is found seized dead and cannot move it is possible to immerse the ring in diesel oil kerosene or gasol...

Page 30: ...on and connecting rod is fitted into or removed from cylinder jacket it is necessary to scrape completely the soot and oil dirt at upper part of the jacket Before it is fitted it is necessary to apply some clean use engine oil on cylinder jacket opening outer surface of the piston and the surfaces of piston ring rod bush and crankshaft rod journal etc Then place the guide sleeve onto the cylinder ...

Page 31: ...cker and valve controlling the intake and exhaust respectively At the front end of cam there is thrust flange At the front end of engine body is fitted camshaft thrust flange Length of the thrust flange is 0 08 0 25mm longer than the thrust plate controlling the axial playing of the shaft See Fig 8 1 Timing gear on camshaft 2 Thrust plate 3 Camshaft Fig 8 Camshaft timing gear thrust plate Each bea...

Page 32: ... system assembly 2 Mounting dismounting of the gears Mounting dismounting of the timing gear on crankshaft needs special tools Timing gear on camshaft can be pulled out by a gearwheel puller or be pushed up by a pressing machine Clearance fit is adopted between the timing idle gear and engine body be secured with bolts Mounting of gear of fuel injection pump Gear of fuel injection pump is fitted o...

Page 33: ... angle loosen the three nuts for the three openings Then if turn the fuel injection pump towards outside of engine body the fuel supply advance angle will decrease and vice versa 1 Fuel injection pump 2 Fuel injection pump s flanged packing 3 Fuel injection pump s pad 4 Fuel injection pump s coupling disc gasket 5 Gear chamber 6 Advancer Fig 10 Turning of fuel injection pump VII Fuel speed governi...

Page 34: ... transfer pump is driven by an eccentric gear on fuel injection pump camshaft The eccentric gear pushes the rod and the rod then pushes the piston pressing and transferring the fuel into the fuel chamber of fuel injection pump Inside the pipe fitting of fuel in pipe of fuel transfer pump is fitted a filter gauze used to filter the fuel During overhaul maintenance the filter gauze should be cleaned...

Page 35: ...isassembling assembling repairing or adjusting is really need it is necessary to keep clean Plunger couples and oil out valve couples etc are not allowed to be interchanged 4 Speed governor Speed governor is of whole course mechanical centrifugal type It consists of driving parts sliding disc sliding bush speed governing spring speed governing handling shaft etc See Fig 12 Speed sensitive element ...

Page 36: ... oil pump body when oil level appears in oil indication window of fuel injection pump oil level in the speed governor can also meet requirement for lubrication 5 Fuel injector Fuel injector is S series Fuel injector consists of injector body nozzle cap needle valve couple push rod pressure adjusting spring and pressure adjusting screw etc See Fig 13 The high pressure fuel oil pumped by fuel inject...

Page 37: ...1 Respirator and fuel filling port 2 High speed limiting screw 3 Idle speed limiting screw 4 Max fuel flow rate limiting screw 5 Sliding sleeve Fig 12 T7B Speed governor 30 ...

Page 38: ... seat bearing and rocker shaft bush etc while splash lubrication is used for cylinder jacket piston pin connecting rod bush cam and tappet and valve and valve guide etc Additionally rolling bearings used for water pump and generator etc will periodically be added grease for lubrication Oil stored in the crankcase sump will via engine oil collector pass through oil in pipe and then sucked into engi...

Page 39: ...ve guide 13 Camshaft and bush 14 Oil passages in engine body 15 Crankshaft and bearing Fig 14 Lubricating system schematic diagram 1 Engine oil pump The engine oil pump is of rotor type The rotor inside the pump is fixed on shaft with pin s The gear of the engine oil pump is driven by the driving gear of engine oil pump on the crankshaft On the engine oil pump body is fitted pressure limiting valv...

Page 40: ...m Cooling system is of forced circulation loop water cooling type Cooling system includes heat radiator water pump air fan thermostat and wind guide hood etc 1 Cooling water passage See Fig 15 1 Heat radiator 2 Thermostat 3 Air fan 4 Water pump 5 Water in pipe Fig 15 Cooling system Cooling water in heat radiator is pumped by the water pump into main water passage and directly enter into the cylind...

Page 41: ...ry hot or when water temperature is too high in summer the thermostat can be removed to increase the flow rate of cooling water and raise heat dissipation efficiency 2 Water pump The water pump is of centrifugal type Its water in chamber is at front end face of engine body The water pump is supported by two E60202 bearings Water seal is of ceramics graphite design Driven by crankshaft pulley fan b...

Page 42: ...water out pipe or when the water temperature is 70 or higher there is no water flowing out of water out pipe The faulted thermostat should be removed for inspection Heat the thermostat slowly in the water When water temperature reaches 70 valve on thermostat should open and when water temperature reaches 85 the valve should fully open If this requirement cannot be met then the thermostat should be...

Page 43: ...iesel engine when delivered does not have a storage battery in it When the engine is running it is necessary to give attention to the value of charging current If it is near 0 it indicates that the battery has fully been charged and the charging circuit can be turned off When measuring the electrolyte of battery metal rod is prohibited to be used to prevent it from reacting chemically with the ele...

Page 44: ...erator When installing the regulator it should be vertically placed with its two terminal posts downward and with its wiring being correct and reliable As regulator is a precise device its working clearance should not be arbitrarily adjusted For its inspection and adjustment it is possible to refer to Operation Manual for FT111 Regulator 4 Starting motor It is series excited d c motor The engageme...

Page 45: ...dental vibration can cause the contact relocate resulting in failure It is preferable that the resistance be measured when installing the sensor Resistance is 8 11Ω for Model 303 oil pressure sensor and 8Ωfor Model 306 water temperature sensitive plug If the resistance value is measured to be 0 it means that the sensor is directly connected and indicating needle of oil pressure gauge will go to th...

Page 46: ...linders as per foregoing procedure II Adjustment of fuel supply advance angle To ensure that the engine has most economical fuel consumption rate and good running performance fuel supply advance angle must be adjusted appropriately Correct fuel supply advance angle should be 16 1 before top dead center Adjusting procedure of fuel supply advance angle is as follows 1 Remove the air in fuel oil syst...

Page 47: ... times it is necessary to remove the fuel nozzle couple for a cleaning After inspection or grind perform test again 2 Adjust the pressure of fuel injection Remove the pressure adjusting screw cap s on the fuel injector and loosen or tighten the pressure adjusting screw s make the pressure of fuel injection to be 13 7MPa Then tighten the pressure adjusting screw cap s and perform re test 3 Watch th...

Page 48: ...ssible to adjust it by grinding it with clean kerosene When pair grinding them the needle valve should not collide with the valve body seat surface After the grinding carefully clean them with no dirt leftover 3 Protruding distance The distance between injector head end and the bottom plane of cylinder cover should be 3 0 25 mm Adjustment if necessary can be made with 0 2 mm copper shim IV Fuel in...

Page 49: ...lapped 4 Other causes 1 Air temperature too low oil viscosity too big 2 Water in combustion chamber or cylinder 1 Recharge it tighten the terminals repair wire post if necessary 2 Repair or replace the carbon brush 3 Turn the flywheel to another position If necessary inspect the installation of starting motor and eliminate the non parallelism between the axes of starting motor and gear ring 1 Fill...

Page 50: ...ace it 5 Replace it 6 Inspect adjust or replace it 7 Inspect it block it 1 Inspect and adjust it 2 Use engine oil with brand specified decrease is possible after the engine is warmed up 1 Clean and make it unclogged III Smoke emitted in exhaust gas 1 Black smoke emitted in exhaust gas 1 Oil injector is clogged with accumulated soot and needle valve is clogged 2 Load is too much 3 Fuel injecting is...

Page 51: ...ply advance angle is not correct 7 Oil supply rate for each cylinder is not uniform or even 8 Air filter not fluent or be clogged 9 Valve leaks gas 10 Compression pressure is not enough 11 Valve timing is not correct 12 Hole in oil injector leaks 13 Bolts on cylinder cover loosened 1 Clean or replace it 2 Inspect repair the injector or replace the oil nozzle couple 3 Adjust oil supply work detecti...

Page 52: ...d of crankshaft playing back and forth can be heard 1 Adjust the advance angle 2 Clean repair or replace the needle valve couple 3 Adjust valve clearance 4 Increase the valve clearance a little bigger correct the gap of connecting rod s bearing or replace the rod s bush 5 Replace cylinder cover gasket 6 Replace the spring push rod or tappet etc and adjust valve clearance 7 Depending wearing condit...

Page 53: ...l return hole on piston ring groove is clogged 3 Piston ring is stuck by glue gas ring if fitted with upper and lower faces being reversed too much wearing 4 Oil leaks on crankshaft front rear oil seal crankcase sump joint plane and side cover etc 5 Engine oil temperature or pressure is too high or evaporated and splashed 1 The oil the brand of which is specified in this Manual should be used 2 Re...

Page 54: ... moving clearance of fuel injection pump camshaft 4 Sleeve of sliding disc is jammed 1 Make the flow rate uniform repair or replace oil nozzle needle valve couple secure shifting fork screw 2 Replace them 3 Adjust it with copper shim 4 Clean repair or replace it XII Engine oil raised high 1 Cylinder jacket water seal ring is damaged 2 Cylinder jacket gasket leaks water 3 Cylinder cover or engine b...

Page 55: ...Annex Fit Clearance Table 48 ...

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