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MAINTENANCE MANUAL OF ENGINE 

148 

21. The diesel engine is started difficultly

Steps 

Inspection 

position 

Fault causes 

Troubleshooting 

1 

Fuel tank 

The fuel quantity is insufficient. 

Add fuel 

2 

Sediment 

bowl 

The sediment bowl switch is off. 

Turn on the switch 

3 

Fuel system 

1. There is air or water in the fuel sys-
tem; 
2. There  is  fuel  leakage  from  the  low
pressure fuel line connection. 

1. Release  the  air  or  water,  or  re-
place the diesel. 
2. Fasten  the  connection  or  replace
it with a 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  pump  cannot  deliver  fuel  or  the 
fuel  supply  advance  angle  is  inappro-
priate. 

Overhaul  the  fuel  delivery  pump, 
fuel  injection  pump  or  adjust  the 
fuel supply advance angle. 

6 

Fuel injector 

The atomization effect obtained by the 
fuel injector is poor. 

Repair  or  replace  (Refer  to Section 
6, Chapter 3 of this Part) 

7 

Fuel injection 

pump 

The fuel delivery valve, or plunger and 
barrel  assembly  of  the  fuel  injection 
pump is worn. 

Grind or change it (Refer to Section 
5, Chapter 3 of this Part) 

Содержание KM/4L22

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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