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MAINTENANCE MANUAL OF ENGINE

5. Dismantling/installing the starter

5.1 Dismantling the starter

1. Dismantle the starter bolt A

A-Set bolt
B-Starter assembly

Attention: Hold the starter by hands during disman-
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

Summary of Contents for KM/4L22

Page 1: ...KM 4L22 Diesel Engines MAINTENANCE MANUAL THE PEOPLE S REPUBLIC OF CHINA LOVOL HEAVY INDUSTRY CO LTD...

Page 2: ...rite 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 m...

Page 3: ...ional 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...

Page 4: ...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 Inspectio...

Page 5: ...3 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...

Page 6: ......

Page 7: ...g 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 th...

Page 8: ...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 e...

Page 9: ...2350 2400 2350 Maximum torque speed N m r min 86 1650 108 1750 124 1650 Fuel Consumption Rate under Rated Working Con dition g k W h 278 276 278 Oil Consumption Rate un der Rated Working Condi tion 2...

Page 10: ...Minimum steady speed at no load rpm 850 850 850 11 Minimum fuel consumption at max imum opening of valve g kW h 248 248 248 12 Ratio of engine oil consumption to fuel consumption 0 8 13 Ratio of maxim...

Page 11: ...f plunger of fuel injection pump 8 Needle valve set of fuel injector ZCK154S425 Accessory Classification Starter Model QD1315A or QD138C Power 2 5KW Voltage 12V Accessory Classification Alternator Mod...

Page 12: ...Torque Remarks N m 1 Bolts cylinder head 135 150N m 2 Long bolts rocker arm shaft base 21 25N m 3 Bolts connecting rod 50 60N m 4 Bolts main bearing cap 115 130N m 5 Bolts connecting water pump to cy...

Page 13: ...ANUAL OF ENGINE 7 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...

Page 14: ...MAINTENANCE MANUAL OF ENGINE 8 6 2 Right side of engine A Cylinder head cover B Breather C Alternator D Starter A B C D...

Page 15: ...d 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...

Page 16: ...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...

Page 17: ...isable 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 Attention 1 Select a proper engine oil desig...

Page 18: ...ion 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...

Page 19: ...anufacturer 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 custom...

Page 20: ...eplate 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 nam...

Page 21: ...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 Position of alt...

Page 22: ...tarter 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 Position of starte...

Page 23: ...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 Position of air com...

Page 24: ...figuration 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...

Page 25: ...MAINTENANCE MANUAL OF ENGINE 19 2 Configuration optional Optional air compressor assembly A Air compressor A...

Page 26: ...ents and tools Note Special tools Adjustable torque wrench 2 Torque and data 2 1 Torque requirements Item Measurement Unit Parameters Remarks Bolts cylinder head Torque 135 150N m Bolts main bearing c...

Page 27: ...guide 0 025 0 069 mm Maximum clearance between valve stem and guide 0 069 mm Diameter of valve head 35 0 15 mm Valve face angle 120 20 Full length 117 0 1 mm Sealing manner Rubber seal ring mounted t...

Page 28: ...Outer diameter 16 0 016 0 034 mm Rocker arm and bushing Diameter of bushing installation hole 20 0 021 0 mm Outside diameter of bushing 20 0 068 0 035 mm Interference of bushing with rocker arm 0 068...

Page 29: ...1 Dismantling the cylinder head cover 1 Dismantle the nut A and gasket set B from the cylinder head cover C Loosen the cylinder head cover A Nut cylinder head cover B Gasket set C Cylinder head cover...

Page 30: ...ssembly 1 Dismantle the bolt A for fixing rocker arm shaft A Bolt for fixing rocker arm shaft 2 Dismantle the rocker arm shaft assembly A A Rocker arm shaft assembly 3 Dismantle the push rod A A Push...

Page 31: ...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 Secti...

Page 32: ...Bolt for fixing cylinder head Attention Loosen the bolts in the diagonal se quence This is to ensure that pressures applied to the cylin der head and its gasket are uniform to avoid dis placement and...

Page 33: ...ylinder 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 c...

Page 34: ...tion 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 con...

Page 35: ...m 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 s...

Page 36: ...e 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 sp...

Page 37: ...lubricating oil to the valve tappet A Valve tappet 3 Check the installation hole A A Installation hole 4 Install the valve tappet A Valve tappet The valve tappet shall be installed so that it can slow...

Page 38: ...e 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 2...

Page 39: ...marks made when removing them Install the intake valve seat G intake valve guide F valve stem oil seal assembly E inner spring D outer spring C upper valve spring retainer A and valve split cone B one...

Page 40: ...n 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 Att...

Page 41: ...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...

Page 42: ...with a magnetic stand 3 Raise the valve head by 15mm Move the probe of dial indicator so that it just comes into contact with the valve head fringe Zero the dial indicator Radially moves the valve he...

Page 43: ...nder head gasket A A Cylinder head gasket 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...

Page 44: ...e tighten them in the specified sequence A Bolt for cylinder head 4 Tighten the bolts A again in the specified se quence to the specified torque A Bolt tightening diagram Torque 135 to 150N m Attentio...

Page 45: ...UAL OF ENGINE 39 4 7 Installing the rocker arm assembly Check the push rod for deformation If any replace it with a new one 1 Install the push rod A A Push rod 2 Install the rocker arm shaft A A Rocke...

Page 46: ...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 th...

Page 47: ...ting 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...

Page 48: ...d 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 Cylinder head cover 2 T...

Page 49: ...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 sp...

Page 50: ...bearing shell 0 04 0 101 mm Piston pin naturally aspirated engine Type Full floating Outer diameter 280 0 006 mm Clearance fit in piston axle sleeve 0 0045 0 0105 mm Small end bushing naturally aspira...

Page 51: ...s 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 6 Dismantle the connecting rod cap A and con n...

Page 52: ...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...

Page 53: ...MAINTENANCE MANUAL OF ENGINE 47 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...

Page 54: ...t 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 as...

Page 55: ...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 bott...

Page 56: ...rod bushing E 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...

Page 57: ...ing 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 Wh...

Page 58: ...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 han...

Page 59: ...ter 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 clea...

Page 60: ...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...

Page 61: ...ain 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 c...

Page 62: ...amber 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 cannot be directly used for knocking...

Page 63: ...ng 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 Ope...

Page 64: ...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 gaseo...

Page 65: ...g 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...

Page 66: ...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...

Page 67: ...ng rod the direction shall not be reserve Pay attention to the marking on piston and connecting rod body to as semble by marking direction The clearance between small end bushing of con necting rod an...

Page 68: ...er 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...

Page 69: ...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 connec...

Page 70: ...nts and tools Note Special tools 16 19 open wrench 8 socket wrench 13 socket wrench Digital torque wrench 2 Torque requirements Item Measurement Unit Parameters Remarks Bolts connecting water pump to...

Page 71: ...5 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 Attaching...

Page 72: ...MAINTENANCE MANUAL OF ENGINE 66 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 A...

Page 73: ...MAINTENANCE MANUAL OF ENGINE 67 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 A A A...

Page 74: ...MANUAL OF ENGINE 68 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 as...

Page 75: ...ssembling 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 2 Dismantle bolt B take out fan A fan gasket...

Page 76: ...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...

Page 77: ...aring hole it is generally 0 02 0 02 mm it is allowed to be 0 02 0 044 mm for overhaul After installation water pump impeller shall be generally 0 1 0 5 mm higher than pump shaft After water pump is i...

Page 78: ...MANUAL OF ENGINE 72 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...

Page 79: ...ENGINE 73 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 f...

Page 80: ...ENANCE MANUAL OF ENGINE 74 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 98...

Page 81: ...ing System 1 Maintenance equipments and tools Note Introductions for special tools Open end wrench or offset ring wrench 2 Torque requirements Item Measurement Unit Parameters Remarks The engine oil p...

Page 82: ...ts 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...

Page 83: ...he oil pan parts 1 Install the oil pan gasket A A Oil pan gasket Attention Install a new oil pan gasket 2 Install the oil pump parts see Section 4 2 in this chapter 3 Install the oil pan A Oil pan 4 T...

Page 84: ...NANCE MANUAL OF ENGINE 78 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 pa...

Page 85: ...MAINTENANCE MANUAL OF ENGINE 79 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 A A...

Page 86: ...80 Chapter 5 Electric system 1 Maintenance equipments and tools Introductions for special tools Sleeve 2 Torque requirements Item Measurement Unit Parameters Remarks Connection between the starter and...

Page 87: ...ternator 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 b...

Page 88: ...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 b...

Page 89: ...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...

Page 90: ...ntling the starter 1 Dismantle the starter bolt A A Set bolt B Starter assembly Attention Hold the starter by hands during disman tling and pay attention to personal safety 5 2 Installing the starter...

Page 91: ...6 Fuel supply system 1 Maintenance equipments and tools Note Introductions for special tools Sleeve 2 Torque requirements Item Measurement Unit Parameters Remarks Connection between the fuel injection...

Page 92: ...part A and the fuel pipe B from the fuel filter to the fuel injection pump A Fuel return pipe part B Fuel pipe from the fuel filter to the fuel injection pump 2 Dismantle the high pressure fuel pipe...

Page 93: ...Dismantle the bolt and remove the fuel pipe A from the fuel filter to the fuel injection pump A Hollow bolt B Fuel pipe from the fuel filter to the fuel injection pump 5 Dismantle the remaining fuel...

Page 94: ...g 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 3 3 Dismantling the fuel injector assembly 1 Dismantle the...

Page 95: ...espectively to fa cilitate subsequent installation A Mark 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 ge...

Page 96: ...l 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 4 2 Installing the fu...

Page 97: ...genuine filter is very important and use of a wrong filter element will result in damage to the fuel injection pump Ingression of contaminants into the fuel system is not allowed and it is required to...

Page 98: ...camshaft hub 30 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 100 0 035 0 mm Crankshaft gear Number of teeth 25 teet...

Page 99: ...INE 93 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...

Page 100: ...L OF ENGINE 94 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...

Page 101: ...NGINE 95 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 Ex...

Page 102: ...talling 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 nu...

Page 103: ...ulley B Crankshaft pulley Attention During dismantling of the crankshaft pulley wedge a woodblock at inner side of the pul ley after loosening the fastening bolt and use a hammer to tap the woodblock...

Page 104: ...ntle 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 Dismant...

Page 105: ...ction 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 t...

Page 106: ...mp 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 in...

Page 107: ...or 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 Insta...

Page 108: ...vidu 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 cam...

Page 109: ...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...

Page 110: ...chamber cover B Timing gear chamber cover 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...

Page 111: ...s 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 bo...

Page 112: ...nkshaft A Rear end of the crankshaft 1 Install the dowel pin A and install the gasket B A Dowel pin B Flywheel cover gasket Attention During installation replace the gasket with a new one 2 Install th...

Page 113: ...Attention Prior to installation of the flywheel in spect whether the dowel pin at the end of the crankshaft is lost 4 Fasten the set bolt A for the flywheel A Bolt Attention After installation turn t...

Page 114: ...bleshooting 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 eng...

Page 115: ...er Install the oil dipstick and ensure it is installed at place Remove the oil dipstick and inspect whether the oil level meets the requirements Normal conditions The oil level is not too low The engi...

Page 116: ...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...

Page 117: ...ht 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 accord...

Page 118: ...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...

Page 119: ...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 exh...

Page 120: ...nd 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...

Page 121: ...iv 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 thus the other end of the rocker arm pushes th...

Page 122: ...ank 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 proce...

Page 123: ...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 erg...

Page 124: ...nnecting 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 lubric...

Page 125: ...ability and durability Lubrication manner Pressurization splash lubrication The lubricating system is composed of Oil pump Oil filter Oil cooler Oil sump Suction filter Lubricating oil pipeline A Gear...

Page 126: ...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 valve When the pressure exceeds the...

Page 127: ...er 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 lea...

Page 128: ...ic 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 Plane...

Page 129: ...ed 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 ca...

Page 130: ...a magnetic field When the brush transmits the direct current to two collector rings a direct current flows through the magnetic field winding and an axial magnetic flux is generated to get one claw po...

Page 131: ...lternator 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 Functio...

Page 132: ...of the stator winding the negative tube at the phase with minimum voltage breaks over at certain instant but there are two closed tubes at the same time of which one is a positive tube the other one i...

Page 133: ...he 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...

Page 134: ...cate 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 regu...

Page 135: ...lve 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 tighten...

Page 136: ...ure 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 t...

Page 137: ...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 temperat...

Page 138: ...rpm 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 parameter...

Page 139: ...mmediately 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 supp...

Page 140: ...p 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...

Page 141: ...he 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 pr...

Page 142: ...4 Fuel The fuel contains water Remove the water contained in the fuel in time or change the fuel 2 Blue smoke Steps Inspection position Fault causes Troubleshooting 1 Piston ring The piston ring is wo...

Page 143: ...t the valve clearance Refer to Section 1 Chapter 3 of this Part 4 Air filter The air filter is blocked and the air in take quantity is insufficient Clean the air filter or change the filter element 5...

Page 144: ...ylinders exceeds the specified range Replace or repair the fuel injection pump Refer to Section 5 Chapter 3 of this Part 3 Valve clear ance The valve clearance is inappropriate Adjustment Refer to Sec...

Page 145: ...lve tappet is worn resulting in a slight knocking from the valve mechanism Change the damaged part Refer to Chapter 1 Part II 7 Piston and cylinder liner The clearance between piston and cyl inder lin...

Page 146: ...aminated or blocked Clean or replace the filter element 4 Fuel filter The filter is blocked Replace 5 Sediment bowl The sediment bowl is off Turn on the sediment bowl switch 6 Intake and exhaust valve...

Page 147: ...specification Adjust the delivery unevenness of cyl inders to specified range Nominal 10 Calibrated 10 Idling 30 7 Intake pipe Air filter The air intake is not smooth Clean or replace the filter eleme...

Page 148: ...Inspection position Fault causes Troubleshooting 1 Speed regula tor The speed regulator is failed and the tie rod is stuck at the big fuel quantity posi tion resulting in galloping Repair or replace R...

Page 149: ...ding disk bushing is jammed Repair or replace Refer to Sec tion 5 Chapter 3 of this Part 13 Engine overheat Steps Inspection position Fault causes Troubleshooting 1 Cooling water The water quantity is...

Page 150: ...level is over 5mm below the sealing surface of the radiator cover or remove the air 5 Water tank The scale deposit on the water tank and water passage is too much Clean the water tank 6 Water pump The...

Page 151: ...5 Oil pump It is blocked or aged Clean or replace it Refer to Sec tion 4 Chapter 4 Part II 6 Engine oil pump safety valve Failure or damage Change the safety valve or adjust the opening pressure of th...

Page 152: ...efer to the Chapter 1 and 2 Part II 18 High engine oil consumption Steps Inspection position Fault causes Troubleshooting 1 Engine oil The engine oil grade is inappropriate Select a kind of engine oil...

Page 153: ...ficient Replace or charge 6 Fuel filter The filter is blocked Clean or replace 7 Starter The engine speed is less than 90rpm min at the instant when the engine is started Repair Section 6 Chapter 2 of...

Page 154: ...new one 4 Fuel line or filter The fuel line or filter is blocked Clean the pipeline or replace the filter element 5 Fuel delivery pump fuel injection pump The fuel delivery pump or fuel injec tion pum...

Page 155: ...O 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 i...

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