Xinchai 490B Series Manual Download

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CONTENTS

The overall dimensions of 490B series diesel engines and the mountings

Chapter 1 General description of the diesel engine

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Chapter 2 Operation of the diesel engine

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Chapter 3 Technical maintenance of the diesel engine

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Chapter 4 Adjustment of the diesel engine

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Chapter 5 Sketch maps for five main systems of the diesel engine

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Chapter 6 Engine trouble shooting

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Appendix 1 Special Parts List

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Appendix 2 Specifications of main Auxiliaries

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Appendix 3 Outsourcing spare parts list

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Summary of Contents for 490B Series

Page 1: ...ean or replace the cartridge of fuel filter timely and check for its soundness Check clean and replace the cartridge of air filter and the inlet connecting pipe Make sure all are well air tight Don t...

Page 2: ...n meet the state requirements for emission and noise with good cold starting ability and low fuel consumption 490B series engines can be widely used for 2 3 ton fork lift construction machineries trac...

Page 3: ...it may be harmful to human Note Means it may be harmful to engine Remark Means it is important but not harmful Fuel Engine preheating Coolant temperature Oil pressure Lubricating parts Necessary check...

Page 4: ...f the diesel engine 15 Chapter 3 Technical maintenance of the diesel engine 20 Chapter 4 Adjustment of the diesel engine 24 Chapter 5 Sketch maps for five main systems of the diesel engine 30 Chapter...

Page 5: ...escription of Diesel Engine 1 1 Engine Model Types and Serial Numbers 2 1 2 Engine Performance Curves 2 1 3 Engine Technical Performance Data 5 1 4 Main Characteristic Data 7 1 5 Overall Dimensions of...

Page 6: ...fore asking for maintenance or parts service please look up the relative information indicated in the nameplate The Position of Serial Number of the Block The stamped serial number is under the left s...

Page 7: ...490BPG 490BT A490BPG C490BPG 3...

Page 8: ...C490BT C490BG 4...

Page 9: ...00 1700 1900 Maximum mean effective pressure k Pa 756 4 732 2 659 6 738 3 738 3 Min fuel consumption at full load g kW h 238 238 230 230 228 Oil consumption g kW h 1 63 1 63 1 63 1 63 1 2 Min steady i...

Page 10: ...um mean effective pressure k Pa 667 8 738 3 738 3 661 4 666 9 Min fuel consumption at full load g kW h 238 230 228 238 228 Oil consumption g kW h 1 63 1 63 1 2 1 63 1 2 Min steady idle speed r min 750...

Page 11: ...e angle 10 12 CA C490BPG C490BT C490BG 21 1 CA 490BT 490BD B490BT 17 1 CA 490B 490BPG 490BT A490BPG B490BPG 3 Temperature and pressure requirements 1 Exhaust temperature 550 C 490B 620 C 2 Oil tempera...

Page 12: ...1 5 Overall Dimensions of Diesel Engine 490B Front view with fan Intake side view Rear view Exhaust side view 8...

Page 13: ...490BPG Front view with fan Intake side view Exhaust side view Rear view with clutch 9...

Page 14: ...490BT Single Pump Intake side view Front view with fan Exhaust side view Rear view with clutch 10...

Page 15: ...490BT Double Pump Front view with fan Intake side view Rear view with clutch Exhaust side view 11...

Page 16: ...C490BPG 12...

Page 17: ...C490BT 13...

Page 18: ...C490BG 14...

Page 19: ...1 Preparation for the First Operation of the Diesel Engine 16 2 2 Starting of the Diesel Engine 17 2 3 Operation of the Diesel Engine 17 2 4 Shutting Down of the Diesel Engine 18 2 5 Attentions for E...

Page 20: ...engine the diesel fuel should be keep still for more than 72 hours to clear out the water and impurities 3 Fill coolant Open the cap and the drain cock Fill the coolant to the mark of filler Close th...

Page 21: ...he start button to start the engine If it fails to start the button should be released and restart it after waiting for two or three minutes If the engine still fails to start after three consecutive...

Page 22: ...and damaging the engine if anti freezing fluid has been added it will not be necessary to do so 2 5 Precaution during Engine Operation 1 Operation and maintenance of the engine should be done accordin...

Page 23: ...l to cooling effect and may damage the engine It may need to add antifreeze into the cooling system to prevent water freezing in cold winter The most common antifreeze is glycol water solution or alco...

Page 24: ...Chapter 3 Technical Maintenance of the Diesel Engine 3 1 Maintenance Tools 21 3 2 Maintenance Periods 21 3 3 Technical Maintenance in winter 23 3 4 Storage for the Engine 23 20...

Page 25: ...12500km 4 Grade 3 maintenance After 1000 hours or 50000km Interval Maintenance Items Daily Maintenance 1 Check the oil sump air filter and the oil level in the injection pump If the oil level rises fi...

Page 26: ...compressed air to blow out the deposited dust in the generator Check all the parts and deal with the troubles on the abnormal parts 7 Adjust the valve clearance and check the valve spring 8 Check the...

Page 27: ...the Engine 1 If the engine will not be used for a long time the oil cooling water and fuel should be drained out while the engine is still warm and clean the oil sump and screen filter 2 Do relevant t...

Page 28: ...djustment of Starting Motor 26 4 5 Adjustment of Generator 26 4 6 Expelling Air from Fuel System 26 4 7 Maintenance of Air Filter 26 4 8 Draining Out Coolant 27 4 9 Renewing Spin on Fuel Filter 27 4 1...

Page 29: ...f 29 49N at the middle part of the belt a depressed distance not exceeding 10 15mm is recommended Too tight belt will lead to excessive wear of bearings in generator fan and water pump Too loose belt...

Page 30: ...Generator 1 Don t disconnect the wire from its terminal when the engine is running 1 Not be confused with the polarities 2 Use compressed air to clean out dust from inside the generator after long ti...

Page 31: ...the filter cover Be sure to keep the inside of filter clean 5 Smear the sealing of the new fuel filter with a little clean fuel Tightly fix the new filter on to the filter cover 6 Expel the air in the...

Page 32: ...he other cylinders valve clearances Adjustment done as follows Take off the cylinder head cover Shut down the engine and wait for 30 minutes before adjusting valve clearances Oil temperature should be...

Page 33: ...stand The purpose is to adjust the injector pressure and watch the atomization quality and deal with the troubles The steps for the adjustment of injector 1 Push the handle of the hand pump to raise t...

Page 34: ...Chapter 5 Sketch Maps for Five Main Systems of the Diesel Engine 5 1 Fuel System 31 5 2 Lubricating System 31 5 3 Cooling System 32 5 4 Gear train System 32 5 5 Electrical System 34 30...

Page 35: ...d Bearings 5 Oil Filter 6 Gear Train 7 Oil Pressure Gauge 8 Valve Rocker Arms 9 Push Rods and Tappets 10 Valve Rocker Arm Shaft 11 Valves 12 Camshaft 13 Oil Galleries 14 Crankshaft Fuel tank Low Press...

Page 36: ...ystem 5 4 Gear Train System 490B Radiator Water passage Water pump Outside of the cylinder head Cylinder head Front of the cylinder head Thermostat 1 Crankshaft timing gear 2 Injection pump timing gea...

Page 37: ...ming idle gear 3 Injection pump timing gear 4 Crankshaft timing gear 5 Bridge gear 6 Hydraulic pump gear 1 Hydraulic pump gear 2 Camshaft timing gear 3 Timing idle gear 4 Injection pump timing gear 5...

Page 38: ...Injection pump timing gear 5 Rear hydraulic pump gear 6 Crankshaft timing gear 490BT B490BT C490BT Double Pump 5 5 Electric System 1 Battery 2 Starting Moor 3 Wire 4 Preheating Plugs 5 Starting and P...

Page 39: ...haust Smoke 38 6 4 Blue Exhaust Smoke 39 6 5 High White Exhaust Smoke 39 6 6 Insufficient Power 40 6 7 Abnormal Noise 42 6 8 Severe Vibration 44 6 9 Engine Over Heated 44 6 10 High Oil Consumption 45...

Page 40: ...livery pump Air trapped in fuel system Check fuelsupplypipeandrepairdelivery pump Dismantle the injector and adjust it on test stand Fault in injector Valve clearance is too small Adjust and lap the v...

Page 41: ...ulating spring Check and repair Check and adjust Fault in pressure regulating valve Oil return passage blocked Too low ambient temperature or too high oil viscosity Pre warm the engine and use specifi...

Page 42: ...ithin specified range Too late injection timing Adjust the injection timing Incorrect valve clearance or valve leak Check valve clearance valve sealing band and valve spring force and eliminate all tr...

Page 43: ...with Xinchai service station Piston ringsworn or stuck oil entering combustion chamber Clean or change piston rings Too low injection pressure poor atomization or nozzle dripping Check adjust repair o...

Page 44: ...n Adjust as specified Adjust fuel delivery quantity and repair broken parts Injection pump elements worn The distorted and loosed governor spring fails to reach the rated speed Adjust and replace the...

Page 45: ...sed cylinder head bolts Tighten with specified torque Change copper washer clean injector sleeve evenly tighten injector fixing nuts Gas leak through injector hole Contact with Xinchai service station...

Page 46: ...ightly touches screws on top of cylinder head cover a beatof piston impinging can be felt Increase valve clearance decrease connecting rod bearing clearance or change connecting rod bushing Piston and...

Page 47: ...ange crankshaft thrust bearing Sound resulting from too big clearance in crankshaft thrust bearing An impinging sound of crankshaft axially moving to and fro can be heard Contact with Xinchai service...

Page 48: ...tighten fixing bolts Incorrect mounting of engine loose mounting fixing bolts Knocking inside cylinder Check injection timing Don t take load until engine gets warmed up Contact with Xinchai service...

Page 49: ...l hole Clean or replace Check and replace related parts Oil leak through front or rear crankshaft seal oil sump seal or cylinder head rear cover gasket Stuck ring or inversely fitted compression ring...

Page 50: ...tioned above Great amount of oil enters combustion chamber Contact with Xinchai service station Governor arm gets out from the shifting yoke Seized piston or crankshaft journal Air trapped in fuel sys...

Page 51: ...ak through faulty cylinder head gasket Change cylinder head gasket block or cylinder head Check and repair Water leak through faulty cylinder block or cylinder head Seized injector Contact with Xincha...

Page 52: ...ear 490BPG 02009 1 10 Cover 490BPG 16001 1 11 Gasket 490BPG 16002 1 12 Timing gear housing 490BPG 16003 13 Gasket 490BPG 16009 1 14 End plate 490BPG 82001 1 15 Screw 490BPG 82002 1 16 Washer 490BPG 82...

Page 53: ...8 Camshaft bushing 490BT 01007 2 9 Rear camshaft bushing 490BT 01008 1 10 Water pipe 490BT 01011 1 11 Timing idle gear 490BT 02006 1 12 Timing gear for crankshaft 490BT 02007 1 13 Camshaft timing gear...

Page 54: ...2 1 31 Flywheel housing plug screw 490BT 13008 1 32 Side bracket 490BT 15001 1 pair 33 Cover 490BT 16001A 1 34 Gasket 490BT 16002 1 35 Gear housing 490BT 16003 1 36 gasket 490BT 16005 1 37 Gasket 490B...

Page 55: ...03109 6 Piston A490B 04001 7 Cylinder head cover A498B 11001 8 Rubber pad A498B 11002 9 Stud M10 50 GB T899 1988 10 Injector lead off pipe A490B 25100 11 Cylinder high pressure fuel tube A490B 23000 1...

Page 56: ...earing cover 495B 01032A 4 7 Rear main bearing cover 495B 01023A 1 8 Upper thrust bushing 495B 01026A 2 9 Lower thrust bushing 495B 01022A 2 10 Upper half main bearing 495B 01034A 5 11 Lower half main...

Page 57: ...F131A JF11A 350 14 Injector Nozzle Hole Diameter mm Opening Pressure Mpa PF68S4 0 28 20 21 Fuel filter CX7085 Water Pump Model Flow Rate L min Centrifugal 130 3000r min Oil Filter JX85100 C Special Pa...

Page 58: ...LTD 5 cylinder liner HENAN ZHONGYUAN ENGINE FITTINGS STOCS CO LTD 6 cylinder head gasket HANGZHOU CYLINDER PAD CO LTD ZIANGSHAN CYLINDER PAD CO TD 7 front and rear oil seals of crankshaft SHANGHAI SH...

Page 59: ...Memoire 55...

Page 60: ...Memoire 56...

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