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Lovol 1004-4 User Handbook Manual Download Page 85

                                                                                                                                                                                                                                                                                                                                               

 

 

III Installation and dismantlement of EGR valve and EGR cooler 

 

Dismantlement: 

1. Disconnect the inlet hose (3) and outlet hose (6). Pay attention not to let water splash onto the EGR valve (1) and 

electric elements. 

2. Loosen the bolts on the inlet and outlet of EGR cooler and then loosen the bolts on the cooler bracket (5). Finally 

remove the cooler (7) and its bracket. 

3. Keep the inlet and outlet of the EGR cooler downward; let remaining water inside the EGR cooler flow out. 

4. Disconnect the harness in the EGR valve and loosen the bolt connecting EGR valve and inlet elbow.   

 

Installation: 

1. Install the bracket of EGR cooler onto the exhaust pipe. Place the EGR cooler on the bracket and firmly connect 

the ends of the EGR cooler and the bracket and both the bolts of EGR pipe.   

2. Connect the hoses of the inlet and outlet of the EGR cooler. 

3.  Insert  the  EGR  valve  into  the  hole  on  the  inlet  elbow.  Firmly  connect  the  bolts  of  the  EGR  valve  and  the  inlet 

elbow. Connect the harness of the EGR valve. 

 

 

 

1 EGR Valve 

2 Inlet elbow       

3 inlet hose of EGR cooler 

4 outlet pipe of EGR cooler 

5 EGR cooler bracket               

6 Outlet hose of EGR cooler       

7 EGR cooler 

8 Inlet pipe of EGR cooler 

 

 

 

 

 

13.09 

 

Summary of Contents for 1004-4

Page 1: ...User s handbook World Power Inherits From leading Technology Lovol Phaser Series Lovol 1000 Series Part No T768050005 Tianjin Lovol Engines Co Ltd...

Page 2: ...DBOOK Lovol Phaser Series Lovol 1000 Series 3 4 and 6 cylinder diesel engines for industrial agricultural and vehicle use Tianjin Lovol Engines Co Ltd Jinwei Road Beichen District Tianjin China Postco...

Page 3: ...Lovol Phaser Series Lovol 1000 Series...

Page 4: ...EGR engine of Lovol Phaser Series Engine of Lovol 1000 Series...

Page 5: ...iews 2 Instruction for operation 3 Preventive maintenance 4 Engine fluids 5 Fault diagnosis 6 Engine preservation 7 Parts and service 8 General information 9 Fuel and injection Pump 10 Turbocharger 11...

Page 6: ...General information 1 Introduction 1 02 How to care for your engine 1 03 Safety precautions 1 04 Engine identification 1 05 Lifting device for engine 1 06 1 01...

Page 7: ...nd developed the classical power with European heritage and modern latest technology To ensure that you use the relevant information for your specific engine type refer to Engine identification on pag...

Page 8: ...ated in Preventive maintenance If the engine works in a very dusty environment or other adverse conditions certain maintenance intervals will have to be reduced Renew the filter elements and lubricati...

Page 9: ...able The battery fluid is dangerous to the skin and especially to the eyes Disconnect the battery terminals before a repair is made to the electrical system Only one person must control the engine Ens...

Page 10: ...of numbers and letters for example 1006 6TW 1006 6 cylinder engine 6 6 liter engine T Turbocharged TW Turbocharged but with an air to water intercooler to cool the induction air between the turbochar...

Page 11: ...ring lifting the engine During vertical lifting the lifting device shown in photo A is recommended which directly connect the sling ring A1 of the engine Don t lift the engine with single ring Before...

Page 12: ...Engine Views 2 Introduction 2 02 Location of engine parts 2 03 2 01...

Page 13: ...engine specification Location of engine parts Front and left side view of YB engine A 1 Filler cap for lubricating oil 2 Fuel filter 3 Lubricating oil cooler 4 Fuel injection pump 5 Lubricating oil d...

Page 14: ...of YB engine A 14 Induction manifold 15 Alternator 16 Lubricating oil filter 17 Fuel pump 18 Lubricating oil sump 19 Startermotor 20 Flywheel housing 21 Flywheel 22 Turbocharger 23 Exhaust manifold 2...

Page 15: ...g oil 2 Fuel filter 3 Lubricating oil cooler 4 Fuel injection pump 5 Lubricating oil dipstick 6 Drain plug for lubricating oil 7 Lubricating oil filter 8 Crankshaft pulley 9 Drive belt 10 Water pump 1...

Page 16: ...of YB engine A 15 Turbocharger 16 Exhaust manifold 17 Water tank 18 Generator 19 Bracket 20 Lubricating oil sump 21 Startermotor 22 Flywheel housing 23 Flywheel 24 Air filter 25 Rear lift bracket 26...

Page 17: ...Instruction for operation 3 How to start the engine 3 02 How to stop the engine 3 04 Adjustment of engine speed range 3 04 Running in 3 04 Turbocharged engines 3 04 Altitude 3 04 3 01...

Page 18: ...ions Diesel engines need a starting aid if they are to start in very cold conditions Normally your vehicle or your machine will be fitted with the correct equipment for your region of operation For th...

Page 19: ...tart a cold engine 1 If the engine is equipped with a manual stop control ensure that it is in the run position 2 Adjust the engine speed control to the maximum speed position 3 Turn the start key to...

Page 20: ...Adjustment of engine speed range The idle or maximum speed settings must not be changed by the engine operator because this can damage the engine or transmission The warranty of the engine can be aff...

Page 21: ...the detachable fuel filter 4 08 How to renew element s of the tank fuel filter 4 09 How to renew element s of the rapid detachable fuel filter 4 10 Atomiser fault 4 11 How to renew an atomizer 4 11 H...

Page 22: ...the equipment in which the engine is installed If necessary use the shorter periods When the operation of the engine must conform to the local regulations these periods and procedures may need to be a...

Page 23: ...y dusty conditions normal conditions Clean or renew the air filter element if this has not been indicated earlier Ensure that the turbocharger impeller and turbocharger compressor casing are cleaned 2...

Page 24: ...lter but on the cylinder body it must be drained and flushed For this disconnect the hoses C1 C2 on the top of the cooler and flush it by connecting to a tap C1 until clean water flow out of the inlet...

Page 25: ...s down the belt with the thumb at the centre of the longest free length and check the deflection B With moderate thumb pressure 45N 4 5 kgf the correct deflection of the belt is 10 mm If twin belts ar...

Page 26: ...el oil 2 Carefully wash all the sediment from the lift pump body 3 Clean the gauze strainer joint and cover 4 Assemble the lift pump Use a good joint and ensure that the lift pump body and the cover a...

Page 27: ...filter element has an internal thread B2 at the top is fastened to a threaded adaptor B1 in the filter head B A fuel filter with a quick release canister C has been introduced on certain engines Some...

Page 28: ...of each element 3 Lower the bottom cover of the filter 4 Remove the element A5 and discard it 5 Clean the inside surfaces of the filter head and of the cover 6 Renew the seals A2 and A6 and lightly lu...

Page 29: ...uitable container 3 Use a strap wrench or similar tool to loosen the filter canister and remove the canister 4 Ensure that the threaded adaptor B1 is secure in the filter head and that the inside of t...

Page 30: ...age of fuel can be avoided when loosing the clamp ring 3 Turn the sediment bowl A4 to the left and remove the bowl if one is fitted 4 Turn the clamp ring A2 to the left and remove the damp ring 5 Remo...

Page 31: ...ipe If necessary remove the pipe clamps 3 Remove the atomiser flange setscrews and remove the flange A2 the atomizer A6 and its seat washer A7 Remove the dust seal A5 and the spacer A4 and fit the spa...

Page 32: ...The low pressure fuel pipes are disconnected A part of the low pressure fuel system leaks during engine operation If air enters the fuel system it must be eliminated before the engine can be started T...

Page 33: ...e vent plug or the banjo connection bolt Remark If the drive cam of the fuel lift pump is at the point of maximum cam lift it will not be possible to operate the priming lever In this situation the cr...

Page 34: ...he recommended torque tension If there is a leakage from the union nut ensure that the pipe is correctly aligned with the atomiser inlet Do not tighten the atomiser union nut more as this can cause a...

Page 35: ...he connection Tighten the vent plug 2 Loosen the banjo connection bolt which is fitted on the top of the filter B1 and operate the lift pump until fuel free from air comes from the connection Tighten...

Page 36: ...s from the connection Tighten the union nut at the starting aid A wrench shall be put on the nut head of fuelled starting aid device to prevent the movement during tightening or loosing the union nut...

Page 37: ...in plug A3 and its O ring and drain the lubricating oil from the sump Ensure that the O ring is not damaged Fit the drain plug and its O ring and tighten the plug to 34 Nm 3 5 kgf m 3 Fill the sump to...

Page 38: ...ew canister Allow the oil enough time to pass through the filter element 5 Lubricate the top of the canister seal with clean engine lubricating oil 6 Fit the new canister and tighten it by hand only D...

Page 39: ...A3 if necessary 5 Check that the inside of the breath pipe is clean If the pipe is not clean release the flange setscrews and remove the pipe Wash the pipe with kerosene and dry it with low pressure a...

Page 40: ...A The wet type air cleaner must be drained at a suitable interval The container and element A1 must be cleaned with kerosene or with another suitable fluid Do not use gasoline Check that the seal A2 i...

Page 41: ...ion indicator C is fitted it will indicate precisely when the air filter element needs service This prevents the premature removal of the filter element which causes extra cost or late removal to the...

Page 42: ...360 degrees Three cylinders inlet exhaust exhaust inlet inlet exhaust 1 2 3 4 No of Cylinder and Valve 1 2 3 4 5 6 7 8 Valve I inlet valve E Exhaust valve I E E I I E E I I I I In n n nl l l le e e e...

Page 43: ...ylinder has just opened and the exhaust valve B7 of the same cylinder has not closed completely Check the clearances of the valves of number 1 cylinder and adjust them if it is necessary 2 Set the val...

Page 44: ...r 5 cylinder A9 and A10 3 Set the valves of number 4 cylinder A8 and A7 Then check adjust the clearances of the valves of number 3 cylinder A5 and A6 4 Set the valves of number 1 cylinder A1 and A2 Th...

Page 45: ...Fuel Lubricating oil and Coolant 5 Fuel specification 5 02 Lubricating oil specification 5 03 Coolant specification 5 05 5 01...

Page 46: ...to the lubricating oil change periods which may be necessary because of the standard of available fuel consult your nearest Lovol distributor The selection of diesel firstly should be based on the env...

Page 47: ...le For further details see Fuel specification on page 5 02 Specifications Engine type API CC SE API CC SE CCMC D4 CCMC D4 GB11123 CF GB11123 CD Naturally aspirated 1 Turbocharger Turbocharged 4 cylind...

Page 48: ...oncentrations of more than 50 of antifreeze must not be used because these can affect adversely the performance of the coolant 3 When frost protection is not necessary it is still an advantage to use...

Page 49: ...Fault diagnosis 6 Problems and possible causes 6 02 Code list of possible causes 6 03 6 01...

Page 50: ...34 36 37 38 39 40 42 43 44 63 Black exhaust smoke 11 13 15 17 19 21 22 34 36 37 38 39 40 42 43 44 61 63 Blue or white exhaust smoke 4 15 21 23 36 37 38 39 42 44 45 52 58 62 The pressure of the lubrica...

Page 51: ...31 Restriction in breather pipe 32 Insufficient coolant in system 33 Vacuum pipe leaks or fault in exhauster 34 Fault in fuel injection pump 35 Broken drive on fuel injection pump 36 Timing of fuel i...

Page 52: ...Engine preservation 7 Introduction 7 02 Procedure 7 02 7 01...

Page 53: ...seal the end of the pipe 9 Remove the air filter Then if necessary remove the pipe s installed between the air filter and induction manifold or turbocharger Seal the manifold or the turbocharger with...

Page 54: ...Parts and service 8 Introduction 8 02 Service literature 8 02 Training 8 02 8 01...

Page 55: ...e publications including Parts illustrators User s handbook Service handbook Handbook for after service of Lovol engine CD for service and maintenance or wall charts etc are available from your Lovol...

Page 56: ...Engine data 9 Engine data 9 02 9 01...

Page 57: ...ratio AA AC YA YC 16 5 1 AB AD YB YD 16 0 1 YD latest engine equipped with Fastram piston 17 25 1 AE YE 17 5 1 BA BB 17 5 1 Cubic capacity BA BB BC BD BE 3 litres AA AB AC AD AE 4 litres YA YB YC YD Y...

Page 58: ...o Fuel Injection Equipment and Its Air Discharge of Linear Pumps homemade 10 03 PB pump 10 05 Major Technical Data of PB Pump 10 06 Structure of PB Pump 10 06 Notices on Adjustment and Use of PB Pump...

Page 59: ...el is supplied in advance Otherwise the fuel supply is retarded 4 The fuel supply angles of various types of engines are listed below Engine type 110Ti 135Ti 160Ti 180Ti 210Ti 230Ti Pump type 7100 VE...

Page 60: ...lifted with the turning of the camshaft As a result the fuel pressure keeps increasing The high pressure fuel is pumped by the fuel pump and injected into the combustion chamber after flowing through...

Page 61: ...esult the moving parts might be choked So make sure there is no water in the fuel If there is carbon residual on the injector the engine performance will be affected So the fuel which can leave less c...

Page 62: ...The integral sealing is waterproof and dustproof 4 The rectangular drawbar of P pumps is applied 5 The pump body camshaft and bearings are specially reinforced to bear larger pressure 6 Moving parts...

Page 63: ...Structure of PB Pump 10 06...

Page 64: ...n will also occur 4 The plunger fuel outlet valve and nozzle coupling elements are of special accuracy which may be destroyed by any dust in the fuel Therefore the fuel filter and fuel tank should be...

Page 65: ...Structure of RSV Governor 10 08...

Page 66: ...d When adjusting the speed the torque generated by the pulling force of governor spring on the governor lever is equal to the torque of centrifugal force at the specified speed The stroke of governor...

Page 67: ...a coil current in the solenoid actuator The electronic actuator drives directly the high pressure fuel pump rack on the engine thus it can control the fuel delivery to the engine and thereby the speed...

Page 68: ...Turbocharger 11 The Use and Maintenance of the Turbocharger 11 02 Fault diagnosis of Turbocharged engine 11 04 11 01...

Page 69: ...ng lubricating oil Within 3 to 4 seconds after the engine is started the oil pressure at the turbocharger inlet should be about 69 kPa 0 7kgf cm2 3 When the engine is running with load the lubricating...

Page 70: ...people are not authorized to do so 2 it is strictly forbidden to use the outer pushing rod of the by pass valve actuator as a handle when moving the turbocharger otherwise the flexibility and durabili...

Page 71: ...to the manufacturer s recommendations Unsmooth air flow in the compressor inlet Remove the foreign substance or replace damaged parts if necessary Unsmooth air flow in the compressor outlet Remove the...

Page 72: ...return pipe of the turbocharger Remove the foreign substance or replace the exhaust pipe Unsmooth flow in the crankcase breather Remove foreign substance according to the Users Manual Dust or coke acc...

Page 73: ...ly the turbocharger is damaged The lubricating oil will be contaminated due to following factors a The oil filter does not fulfill requirements or low quality canister is used b The canister is broken...

Page 74: ...the exhaust manifolds during its installation and they enter the turbine with the exhaust gas Every foreign substance will influence the rotor dynamic balance causing the rotor to choke or rotating s...

Page 75: ...The Use and Maintenance of the Hydraulic Pump 10 08 12 01...

Page 76: ...e hydraulic oil should be changed for every 20000km running Meantime the oil should be checked frequently and the filter elements should be replaced periodically 1 3 The vacuum of the oil suction part...

Page 77: ...nciple of EGR induction system 13 02 Schematic diagram of EGR electric units 13 03 Introduction of ERG engine elements 13 05 Installation and dismantlement of EGR valve and EGR cooler 13 09 Fault disp...

Page 78: ...as However excess exhausted gas in mixed gas for combustion also can affect the ignition characteristics of mixed gas and thus affect the dynamic performance of engine especially when the engine is in...

Page 79: ...e diagram the total resistance can not be over 0 0034 ohm 2 The maximum voltage drop in coil circuit of the starting motor shall not be over 1 0v 3 If the key switch is in its preheating condition con...

Page 80: ...4 ECU Wiring principle diagram 13 04...

Page 81: ...speed acquire the signal at the W point of the little generator A Accelerator position sensor It is mounted an the fuel pump and the signal is acquired at the handle shaft Its figure and parameters a...

Page 82: ...3 07 ECU provides a position signal to EGR valve according to rotational speed position of throttle and signal of water temperature meanwhile EGR valve send a feedback signal to ECU then ECU will modi...

Page 83: ...current 1 5A Maximum allowable acceleration axial radial direction 30g Mass 0 7kg Feedback of position signal Available Position installation relative to perpendicular line Within 85 Temperature requi...

Page 84: ...et of the inner valve of valve must face downward as the lowest point The valve must be installed within the 85o relative to perpendicular direction See the figure Wrong installation EGR valve arrange...

Page 85: ...he harness in the EGR valve and loosen the bolt connecting EGR valve and inlet elbow Installation 1 Install the bracket of EGR cooler onto the exhaust pipe Place the EGR cooler on the bracket and firm...

Page 86: ...smallest grade number of priority This means that the fault indicator will display two short pulses and then a long pulse Meanwhile any other fault of the lower priority will not be displayed by the...

Page 87: ...Address Jinwei Road Beichen District Tianjin Postcode 300402 Seal Tel 0086 022 26992255 26996802 Service Tel 0086 022 86995886 FAX 0086 022 26993784 Homepage www lovolengines com...

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