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ANHUI QUANCHAI ENGINE CO., LTD

Chapter 4 Fault Diagnosis and Removal

1. Emission of white smoke

Sequen

ce No.

Position tested

Normal

Abnormal

Fuel injector

The fuel injector pressure is 23

MPa.

There is too low injection pressure,

poor atomization and oil leakage,

which affect fuel compression

combustion. Please replace the fuel

injector in time.

Water

temperature

The temperature of the cooling

water is not too low.

The temperature of the cooling water is

too low, wasting heat energy and

affecting combustion. Please start small

circulation to raise water temperature.

Cylinder

The cylinder meets the design

requirements.

There is water seeping into the

cylinder, and water vapor emitting,

which leads to inadequate combustion.

Please check the cause and remove the

fault in time.

Содержание N485D

Страница 1: ...ANHUI QUANCHAI ENGINE CO LTD 1 139 Engine Maintenance Manual Quanchai N485D and N490D Diesel Engine for generator ANHUI QUANCHAI ENGINE CO LTD Jul 2019...

Страница 2: ...ne and correctly judge maintain its faults this manual is prepared with pictures and words for the user to know the diesel engine well which is an important guarantee for better performance good relia...

Страница 3: ...Train 23 1 Maintenance equipment and tools 23 2 Torque requirements and dimensional data 23 3 Disassembly of valve train 26 4 Assembly of valve train 31 Chapter 2 Disassembly and Assembly of Crank Lin...

Страница 4: ...Crank linkage mechanism 94 3 Cooling system 97 4 Lubrication system 99 5 Electrical system 100 6 Fuel system 105 Chapter 3 Inspection and Adjustment 106 2 Cylinder pressure 108 3 Timing detection of...

Страница 5: ...ilure of engine to be started 132 21 Failure of starter to work 133 22 Idling starter and failure of engine to work 134 23 Under power starter 134 24 Screams emitted during after start or hard to disc...

Страница 6: ...onal injury The operation procedures and safety precautions must be followed 1 Scald proof sign After the engine is started personnel shall be kept away from the engine by 50 cm 2 Anti touch sign It i...

Страница 7: ...y when lifting the engine vertically adopt the lifting equipment shown in the figure directly connect it to the engine lifting ring In addition do not lift the engine when only single lifting ring is...

Страница 8: ...0 Mean piston speed m s 4 75 5 70 5 0 6 Mean effective pressure of piston kPa 630 618 723 708 Total displacement L 2 156 2 545 Compression ratio 18 1 18 1 Declared power kW 17 20 23 27 Declared speed...

Страница 9: ...ANHUI QUANCHAI ENGINE CO LTD 9 139 N485D power curve N490D power curve...

Страница 10: ...ANHUI QUANCHAI ENGINE CO LTD 10 139 2 Filling capacity Item Unit FOTON N485D N490D Water volume in diesel engine body L 4 1 Capacity of engine oil pan 6 5...

Страница 11: ...nimum 100 kpa Cooling System Cooling method Water cooling Pump flow 80 L min 3000 rpm with 5 m of pump head Water capacity of engine 4 1 L Maximum water temperature 95 Open full open temperature of th...

Страница 12: ...to the cylinder head and the body 25 7 Assembly of the engine oil pump to the body 25 8 Connecting of the starting motor to the flywheel housing 80 9 Connecting of the fuel injection pump to the gear...

Страница 13: ...ANHUI QUANCHAI ENGINE CO LTD 13 139 Left view...

Страница 14: ...ANHUI QUANCHAI ENGINE CO LTD 14 139 Front view...

Страница 15: ...ANHUI QUANCHAI ENGINE CO LTD 15 139 Right view...

Страница 16: ...ANHUI QUANCHAI ENGINE CO LTD 16 139 Rear view...

Страница 17: ...ilter 6 Fuel injector 7 Fuel return pipe of fuel injector 8 Cylinder head cover 9 Lifting lug 10 Flywheel housing 11 Fan 12 Fan pad 13 Advancer cover 14 Gear cover 15 Gear chamber 16 Front bracket 17...

Страница 18: ...gine 25 Fuel filler cap 26 Lifting lug 27 Crankshaft pulley 28 V belt for vehicle 29 Generator 30 Generator bracket 31 Front bracket 32 Cylinder head part 33 Respirator outlet pipe 34 Respirator part...

Страница 19: ...ery important to store the fuel properly Store the fuel in clear tank and warehouse and regularly drain water and sediment from the bottom of tank It is avoided to store the fuel for a long time If th...

Страница 20: ...le temperature 4 5 14 29 44 The user can select the light diesel oil according to local ambient temperature In most areas of China 0 light diesel may be used in summer while 10 light diesel may be in...

Страница 21: ...al and physical reactions which will make the oil deteriorate 3 Engine coolant The cooling water shall be clean soft water such as river water rain water snow water and tap water As soft water contain...

Страница 22: ...85D N490D diesel engine Four cylinders In line and water cooling Accessories include the followings Starting motor Generator Intake pipe Exhaust pipe Flywheel Flywheel housing Fan 2 Optional accessori...

Страница 23: ...1 Disassembly and Assembly of Valve Train 1 Maintenance equipment and tools Note Special tools Cylinder head bolt 14 M12 16 mm digital torque wrench 2 Torque requirements and dimensional data 2 1 Tor...

Страница 24: ...ve guide 0 082 mm Diameter of valve head 41 mm Angle of valve cone 120 Full length 117 5 mm Sealing mode Oil seal Exhaust valve Diameter of valve stem 8 mm Clearance of valve guide 0 025 mm Maximum cl...

Страница 25: ...g 22 mm Outside diameter of bushing 22 mm Interference fit of bushing on rocker arm H7 s7 Outside diameter of bushing after being reamed with hole 18F7 Clearance of rocker arm s bushing with shaft 0 0...

Страница 26: ...cylinder head cover and the Cylinder Head Cover C A Cylinder head nut B Bonded sealing washer C Cylinder head cover 3 2 Disassembly of valve rocker arm assembly Remove the Through Bolt C of rocker arm...

Страница 27: ...the Exhaust Manifold Gasket B Then disassemble the intake manifold bolts and the intake manifold A Exhaust manifold B Exhaust manifold gasket C Lifting lug D Intake manifold E Intake connecting manifo...

Страница 28: ...e Bolt B of fuel injector A Joint of high pressure fuel pipe B Fuel injector bolt Disassembly of fuel injector A Fuel injector ANHUI QUANCHAI ENGINE CO LTD 3 5 Disassembly of fuel injector assembly Re...

Страница 29: ...pring D Inner valve spring E Valve oil seal seat F Valve guide G Intake valve seat H Intake valve S Exhaust valve seat T Exhaust valve ANHUI QUANCHAI ENGINE CO LTD 3 6 Disassembly of cylinder head Rem...

Страница 30: ...Camshaft timing gear B Bolt Note Use the special tool of puller Remove the Camshaft A from the side of the body and disassemble the front middle and rear bushings of the camshaft by a special tool A...

Страница 31: ...rts Replace the valve collet with a new one if necessary ANHUI QUANCHAI ENGINE CO LTD Clean the cylinder head carefully before assembly Replace the fittings before the bowl type plug is and exhaust va...

Страница 32: ...all the valve spring compression tool and corresponding joints 5 Compress the valve spring accurately positively and remove the locking plate to avoid damaging the valve stem Note Do not rotate the cr...

Страница 33: ...ad gasket Install two Cylinder Head Locating Sleeve B and then the Cylinder Head Gasket A A Cylinder head gasket B Locating sleeve Note Before installing the new cylinder head gasket check whether it...

Страница 34: ...chips in the cylinder Tighten the cylinder head bolt 14 digital torque wrench 16mm sleeve A Push rod Place the push rod into the tappet seat properly Tightening torque ANHUI QUANCHAI ENGINE CO LTD Th...

Страница 35: ...valve seat to be reamed install the reamer on the guide rod and the handle Do not leave the reamer under the valve seat otherwise the reamer edge will be damaged 4 Carefully rotate the reamer clockwi...

Страница 36: ...and the cylinder fuel passage hole shall coincide and the camshaft bushing shall be flush with the front end surface of the cylinder block If the camshaft bushing is higher than the front end surface...

Страница 37: ...e Oil Seal Assembly E Inner Valve Spring D Outer Valve Spring C Upper Seat A of valve spring and Valve Collet B on the intake valve in sequence The assembly of the exhaust valve is the same as that of...

Страница 38: ...r head and adjust the dial gauge to zero 4 Carefully place the valve depth gauge on each valve head and record the measurement results 5 If the valve depth exceeds the limit check the depth at the sam...

Страница 39: ...nt rocker arm bracket B Set screw and nut of rocker arm shaft C Set screw of rocker arm shaft D Valve rocker arm E Valve adjuster F Set nut G Sleeve H Valve rocker arm spring E Rocker arm bracket ANHU...

Страница 40: ...olt 10 M8 of rocker arm bracket with 13mm socket wrench or ring spanner A Through bolt of rocker arm shaft Tightening torque 21 25 N m ANHUI QUANCHAI ENGINE CO LTD Install the rocker arm shaft assembl...

Страница 41: ...the rocker arm bushing or rocker arm shaft Note 1 When replacing the rocker arm bushing take the old bushing out with a suitable push rod 2 Align the lubrication holes of new bushing and the rocker a...

Страница 42: ...the magnetic base on the surface of the cylinder head 3 Lift the valve for 15 mm make the gauge contact the edge of the valve head and put the valve radially away from the gauge When the valve is held...

Страница 43: ...ANHUI QUANCHAI ENGINE CO LTD 4 11 Adjustment of valve clearance Special tools Feeler gauge A Feeler gauge A...

Страница 44: ...t is the top dead center of the exhaust valve if the two valves do not move it is the compression top dead center At this point adjust the valve Adjust them in the order of 1 3 4 2 and double exhaust...

Страница 45: ...he Bolt B with the socket wrench install the high pressure fuel pipe and tighten the Joint A of high pressure fuel pipe A Joint of high pressure fuel pipe B Hold down bolt of fuel injector Note Check...

Страница 46: ...e fuel return pipe to the fuel injector and fasten it with a spring clamp A Fuel return pipe B Spring clamp ANHUI QUANCHAI ENGINE CO LTD cylinder head cover Install the cylinder head cover gasket and...

Страница 47: ...ce equipment and tools Special tools 16 19 open end wrench 13 mm socket wrench 18 mm socket wrench digital torque wrench and adjustable torque wrench 2 Torque requirements and dimensional data 2 1 Tor...

Страница 48: ...the first ring 0 3 0 5 mm Closed clearance of the second ring 0 25 0 45 mm Closed clearance of the third ring 0 25 0 4 mm Connecting rod naturally aspirated engine Type H section Positioning of bearin...

Страница 49: ...eter of crank pin 54 mm Width of crank pin 34 mm Diameter of flange 84 mm Axial clearance of crankshaft 0 085 0 275 mm Maximum allowable axial clearance 0 4 mm Fillet radius of journal and crank pin R...

Страница 50: ...the piston connecting rod assembly from the cylinder A Connecting rod bolt B Connecting rod cap C Connecting rod bearing shell D Connecting rod body Note After disassembly place them neatly in order I...

Страница 51: ...emove the Connecting Rod Bushing E A Piston ring assembly B Retaining ring for hole C Piston D Connecting rod body E Connecting rod bushing F Piston pin When removing the piston pin push the piston pi...

Страница 52: ...damaged and replace it if necessary If there is a small scratch on the lip replace it Remove the crankshaft pulley and crankshaft gear before disassembling the crankshaft Disassembly of main bearing...

Страница 53: ...Cylinder Liner E to ensure that the tool base does not press against the top of the adjacent cylinder liner flange 6 Place the Bearing C in the groove at the top of the tool and make the plane of the...

Страница 54: ...d Bushing B to the small end of the connecting rod A Connecting rod body B Connecting rod bushing The installation process of Connecting Rod Bushing B is shown below Replace the connecting rod bushing...

Страница 55: ...C through the Piston A and the Small End B of the connecting rod body then lock its two ends by the Retaining Ring D After assembly the piston can swing flexibly without jamming A Piston B Connecting...

Страница 56: ...Piston A A Piston B Piston ring Installation order Oil ring the second air ring the first air ring In order to avoid leakage of combustible mixture from the opening gap of the piston ring the opening...

Страница 57: ...lder on the flange of the cylinder liner place the Bearing C in the groove on the top of the joint and turn the plane of bearing toward the bottom of the groove 4 Put the Screw A through the bearing j...

Страница 58: ...engine parts crankshaft and flywheel to the pallet turn the joint surface of oil pan up and turn the front surface forward Assembly of main bearing shell Install the upper and lower bearings of the ma...

Страница 59: ...piston rings for 120 put the Piston Connecting Rod Assembly B in the Special Tool C then push it from the cylinder head surface of the engine to the cylinder liners of Cylinder 2 and 3 by the stick an...

Страница 60: ...he same side with that on the connecting rod install the fasteners and turn the plane of bolt head toward the connecting rod When being used as the fastener adopt a new nut and gradually evenly tighte...

Страница 61: ...e bolts turn the crankshaft to check the flexibility of the rotation Torque of connecting rod bolt ANHUI QUANCHAI ENGINE CO LTD 4 8 Fastening of connecting rod bolt Turn the body for 90 and turn the b...

Страница 62: ...block turn the dial gauge to zero rotate the crankshaft until the piston is close to the top dead center carefully put the tool on the top of the piston put the probe in touch with the piston on the...

Страница 63: ...m Unit Parameter Note Connection of the pump to the cylinder head and the body N m 25 2 2 Dimensional data Water pump Type Centrifugal belt drive Diameter of impeller bore 15 mm Outside diameter of im...

Страница 64: ...gasket K Bolt N Bolt O Water pump flange pad P ANHUI QUANCHAI ENGINE CO LTD 3 Disassembly assembly and adjustment of cooling parts 3 1 Composition of cooling parts Cooling fan D fan pad E Water pump...

Страница 65: ...he water pump firstly drain the water from the radiator completely then remove the Fan generator Belt A and Crankshaft fan Belt B A Fan generator belt B Crankshaft fan belt Remove the Bolt B Fan A Fan...

Страница 66: ...e impeller Disassemble the water seal carefully to avoid damage It is prohibited to assemble the water pump bearing with non professional tool A Water pump housing B Bolt C Washer D Water pump bearing...

Страница 67: ...lerance is 0 010 to 0 030 mm The fitting clearance between the water pump bearing and the bearing hole is generally 0 02 to 0 02 mm and the overhaul tolerance is 0 02 to 0 044 mm After the pump impell...

Страница 68: ...on steps of the pump assembly thermostat and fan etc are in reverse order with disassembly steps Belt tension 98N ANHUI QUANCHAI ENGINE CO LTD parts of the pump The installation steps of the pump asse...

Страница 69: ...p to the body N m 25 2 2 Dimensional data This data is given to the personnel for engine overhaul and the dimensions shown are primarily for the factory Lubricating System Engine oil pump Differential...

Страница 70: ...sembly A Bolt B Washer C Washer D Oil pump assembly E Oil pump gasket F Bolt 3 2 Installation of oil pump assembly Install the oil pump assembly and oil pump gasket into the mounting holes of the engi...

Страница 71: ...ump nut Assemble the suction strainer at the bottom of the body properly Tighten the fixing bolts for suction strainer A Oil suction strainer ANHUI QUANCHAI ENGINE CO LTD Assemble the fixing bolts to...

Страница 72: ...t A Oil suction strainer B Oil suction strainer gasket Chapter 5 Starting System 1 Maintenance equipment and tools Introduction of special tools 18 mm socket wrench 2 Torque requirements Item Unit Par...

Страница 73: ...CO LTD 3 Disassembly assembly and adjustment of starting parts 3 1 Starting motor A Starting motor B Nut C Washer D Double end stud 3 2 Disassembly of starting motor Remove the Bolt A and Starting Mo...

Страница 74: ...2 Torque requirements and dimensional data 2 1 Torque requirements Item Unit Parameter Note Connecting of the fuel injection pump to the gear chamber N m 70 2 2 Dimensional data This data is given to...

Страница 75: ...Install the lower end of the high pressure fuel pipe on the fuel injection pump 3 2 Installation of fuel injector assembly A Hexagon head bolt B Spring washer C Plain washer D Fuel injector Connect it...

Страница 76: ...Assembly of diesel filter Installation of diesel filter assembly A Hexagon head bolt B Spring washer C Plain washer D Diesel filter assembly Connect it to the inlet pipe of diesel filter Connect it to...

Страница 77: ...Assembly of fuel injection pump 3 4 1 Assembly of parts of fuel injection pump A Hexagon head bolt B Spring washer C Fuel injection pump gasket D Tie plate of fuel injection pump timing gear E Fuel i...

Страница 78: ...ion pump assembly A Fuel injection pump B Spring washer C Plain washer D Hexagon head bolt Inlet pipe of diesel filter High pressure fuel pipe assembly Outlet pipe of diesel filter Fuel return pipe of...

Страница 79: ...Disassembly Assembly and Adjustment of Accessories 1 Data and dimensions This data is given to the personnel for engine overhaul and the dimensions shown are primarily for the factory Idler and hub Nu...

Страница 80: ...are assembly marks on the gears Only the gear chamber is assembled according to the marks can the engine be started normally ANHUI QUANCHAI ENGINE CO LTD Disassembly and assembly of gear chamber Open...

Страница 81: ...1 Maintenance equipment and tools Note Introduction of special tools Vise Manual test stand Ring spanner Torque wrench ANHUI QUANCHAI ENGINE CO LTD 3 1 Maintenance equipment and tools Introduction of...

Страница 82: ...ith your fingers 2 Tilt the nozzle fitting by 45 degrees and extract 1 3 of the needle valve cylinder working surface from the needle valve body 3 When the needle valve is released it shall be able to...

Страница 83: ...form of mist The spray shall be free of clearly visible deflection and splashing particles continuous oil column and easily distinguishable uneven concentration ANHUI QUANCHAI ENGINE CO LTD pressure v...

Страница 84: ...emoval Chapter 1 Dynamic Checks 1 Overview According to the working time and condition of the engine regularly or irregularly observe the oil consumption and timely add oil to prevent the engine from...

Страница 85: ...4 of the distance away from the upper scale line The oil filler is on the cylinder head cover After the oil is added up start the diesel engine then switch off the engine after it runs for 3 minutes a...

Страница 86: ...oling Note To avoid scalding it is not allowed to open the water storage tank cover and radiator cover when the diesel engine is hot The normal coolant level shall be between the Full and Low scale li...

Страница 87: ...elt is pressed down with a force of about 98 N the new water pump belt will sink by about 7 mm to 9 mm while the old water pump belt will sink by about 11 mm to 13 mm Otherwise adjustments shall be ma...

Страница 88: ...sure of 21 23 MPa for compression combustion Excess fuel flows back into the fuel tank through the fuel return pipe of the fuel injector As the fuel pump the high pressure fuel pipe and the fuel injec...

Страница 89: ...he cylinder head and then is pressed into the cylinder for compression combustion after being sucked into the intake valve 2 The burnt waste gas enters the exhaust passage of the cylinder head through...

Страница 90: ...ether the storage battery connectors are connected as required and whether all necessary lead wires and components are strictly matched Then determine whether there is any problem in the electrical sy...

Страница 91: ...g allows final adjustments to engine performance The engine dynamometer or the chassis dynamometer may be used for engine test In case that dynamometer is not available the engine test must be conduct...

Страница 92: ...rt of the cam on the camshaft pushes the rocker arm to swing through the tappet the push rod and the adjusting screw and then the other end of the rocker arm downward pushes the valve open and further...

Страница 93: ...hen the crank throw is at top dead center and off when the crank throw turns to bottom dead center The exhaust valve is on when the crank throw is at tom dead center and off when the crank throw turns...

Страница 94: ...linkage mechanism is the mechanism by which the engine generates and transmits power and through which the heat energy emitted by the combustion of fuel is converted into mechanical energy Working con...

Страница 95: ...very hot The piston slides along the cylinder wall surface at high speed under lateral pressure Functions of piston ring The main function of the gas ring is to seal and transfer heat The main functio...

Страница 96: ...thrust bearing Ensure that the crankshaft linkage mechanism can normally work when the crankshaft is under axial force Functions of flywheel Store part of the function input to the crankshaft in the...

Страница 97: ...pump radiato thermostat supplementary bucket engine body cylinder liner cylinder head and other accessories ANHUI QUANCHAI ENGINE CO LTD The function of the cooling system is to keep the engine withi...

Страница 98: ...ter leakage and the bearing makes abnormal noise during operation consideration shall be given to replacing the bearing No 4 calcium soap grease also called butter like grease shall be filled into the...

Страница 99: ...the engine more reliable and durable Lubrication methods Force feed and splash lubrication Composition of lubrication system Oil pump Engine oil filter Oil pan Suction strainer Lubricating oil circuit...

Страница 100: ...ear ANHUI QUANCHAI ENGINE CO LTD 5 1 1 Structural principle of starter Shifting fork Clamp ring Gasket Waterproof rubber sleeve Rubber gasket Electromagnetic switch Armature assembly Stator assembly C...

Страница 101: ...t and oil stains outside the starter to keep it clean Preheat the starter with the preheater for 30 50 s before starting it in cold days The starter can only work for a short time and the starting tim...

Страница 102: ...he electrical equipment on the vehicle with the direct current output after diode rectification and then charging the storage battery Structure diagram of generator Structure diagram of brushless gene...

Страница 103: ...D and the motor B end must be connected with a charging indicator light 2 W The neutral point output marked with N can be connected with relay switch charging indicator light etc The phase output mar...

Страница 104: ...g leg If the generator interferes with other parts on the vehicle it may become short circuit and the electrical parts inside it may hence burn up or otherwise damage due to long term impact 4 The gen...

Страница 105: ...the pressure exceeds the pre tightening force of the high pressure spring the needle valve is lifted and the high pressure diesel in the annular oil chamber of the needle valve body is sprayed at a hi...

Страница 106: ...e off at the the piston of this cylinder is at 3 Loosen the lock nut turn the adjusting screw with a screw driver while inserting the feeler gauge between the inlet and exhaust valve ends of the first...

Страница 107: ...search for other reasons 1 The piston ring is filled with carbon deposit jammed or worn 2 The cylinder head gasket leaks air ANHUI QUANCHAI ENGINE CO LTD Intake valve clearance cold 0 30 mm Exhaust va...

Страница 108: ...cted to the pressure Test gauge Test steps Connect to the first cylinder first then connect cylinders 2 3 and 4 in turn and observe changes in the pressure gauge Specification Pressure value 2 400 kPa...

Страница 109: ...fluctuates 2 Check whether the scale on the line of the flywheel which is aligned with the marked scale line on the flywheel casing is meets the optimal value specified above 3 If the advance angle o...

Страница 110: ...fers considerably rotate the plunger ring to adjust the fuel capacity Turning the plunger ring clockwise can reduce the fuel capacity and turning the plunger ring anticlockwise can increase the fuel c...

Страница 111: ...zle fitting for cleaning inspection and grinding and then conduct tests again 2 Adjust the injection pressure remove the fuel injector to adjust nuts loosen or tighten the pressure adjusting screw to...

Страница 112: ...ith pressure range of 0 700 kPa 0 6 9 bar 0 100 psi 2 Install JT05487 XXX testing tool 3 Connect JT05577 pressure gauge assembly and JT03017 hose assembly Important note If the pressure reading is les...

Страница 113: ...20F Minimum engine oil pressure engine rotating speed of 825 rpm 100 kPa 1 bar 15 psi Maximum oil pressure engine rotating speed of 2 500 rpm 277 483 kPa 2 77 4 83 bar 40 70 psi Test results 1 If the...

Страница 114: ...3 mm between the end face of the pinion and the retaining ring If not adjustment shall be made Gaskets can be placed at the bottom of the starter s electromagnetic switch to ensure good pinion engage...

Страница 115: ...on combustion Please replace the fuel injector in time 2 Water temperature The temperature of the cooling water is not too low The temperature of the cooling water is too low wasting heat energy and a...

Страница 116: ...deposit the engine oil gets into the combustor causing blue smoke during combustion Please replace the piston ring in time 2 Engine oil The engine oil surface is between the upper and lower scale line...

Страница 117: ...pump is insufficient The above two cases uneven combustion working Please re calibrate or replace the pump 3 Valve The intake valve clearance is 0 3 mm and the exhaust valve clearance is 0 35 mm Ther...

Страница 118: ...en Move the piston to top dead center and replace the valve spring 3 Valve clearance The intake valve clearance is 0 3 mm and the exhaust valve clearance is 0 35 mm Adjust the valve clearance 4 Piston...

Страница 119: ...ston and cylinder liner show no sign of wear There is no carbon deposit on the piston ring The engine oil does not get into the combustor Check clean or replace worn parts 2 Engine oil level The engin...

Страница 120: ...n the reasonable wear out error range The valve spring is broken the valve push rod is bent and the valve tappet is worn making the valve mechanism emit slight beats 7 Piston and cylinder liner The pi...

Страница 121: ...clean and in good condition The filter element is dirty or blocked 4 Fuel filter The fuel filter is unblocked The filter is blocked 5 Sediment cup The settling cup switch is on The settling cup switc...

Страница 122: ...are normal There is air entering the fuel system affecting the fuel supply of the fuel system Please remove the air inside the system 5 Advance angle of fuel supply The advance angle of fuel supply is...

Страница 123: ...r head bolts affect compression combustion working Please check the cylinder head bolts and re tighten them to the specified torque range 12 Piston ring The piston ring wears down within a reasonable...

Страница 124: ...water sealing ring The cylinder liner and the water sealing ring are damaged and hence water seeps to engine oil 2 Cylinder head gasket The cylinder head gasket is qualified The cylinder head gasket...

Страница 125: ...the pull rod jams in position indicating large fuel capacity resulting in speed surging 2 Speed governor sliding disk shaft sleeve The sliding disk shaft sleeve slides normally The sliding disk shaft...

Страница 126: ...ing spring of the fuel pump or the fuel injection pump 13 Engine overheat Seque nce No Position tested Normal Abnormal 1 Water volume There is insufficient water or air barrier in the water pipe Top u...

Страница 127: ...mally and the pulley is properly tightened The water pump fails to work normally affecting the coolant s capacity for heat dissipation 6 Thermostat The temperature is 76 when the thermostat is switche...

Страница 128: ...ally Repair or replace the rotors by a professional maintenance factory 6 Main bearing shell connecting rod bearing shell and camshaft bushing The main bearing shell connecting rod bearing shell and c...

Страница 129: ...pressure is normal Refer to the above table No engine oil pressure or too low engine pressure for fault removal 3 Engine oil The engine oil is of correct grade Change the engine oil 4 All the bearing...

Страница 130: ...ton and the cylinder liner wear severely and leak engine oil increasing engine oil consumption 3 Piston ring The dimensional tolerance is within the allowable tolerance range The upper and lower parts...

Страница 131: ...lly without damage or wrong wiring Replace the ignition switch check the wiring and tighten the connector 3 Starter The starter works normally Clean the electromagnetic switch repair the contact surfa...

Страница 132: ...h pressure fuel pipe on the high pressure pump If bubbles come up it means there is air in the fuel supply system The air may be removed by tightening the joints of the oil circuit then loosening the...

Страница 133: ...arter electromagnet ic switch The horn makes normal sound while honked The starter can rotate when the two main binding posts on the electromagnetic switch are short connected with a screwdriver Repla...

Страница 134: ...Storage battery level and connecting lead The storage battery has high level and the connecting lead is fastened without looseness Check and replace the positive wire and the ground wire of the storag...

Страница 135: ...r electromagnetic switch is broken or has too small elastic force 4 The contact of the starter relay or the electromagnetic switch is fused and bonded and the starting circuit cannot be disconnected W...

Страница 136: ...but works normally when the warmed machine is started it indicates that the starter has no fault and that the storage battery power is insufficient or there is a fault elsewhere in the circuit 2 If t...

Страница 137: ...less than 75 3 The electric brush shall run smoothly in the brush carrier without clamping stagnation 4 The pressure of the electric brush spring measured by the spring scale shall meet the technical...

Страница 138: ...nlet pipe of the fuel supply pump and its filter screen 4 Fuel supply pump and fuel injection pump The fuel supply pump and the fuel injection pump work normally and the advance angle of fuel supply i...

Страница 139: ...mm Adjust the valve clearance and grind the valve 4 Tightness of valve or piston The valve does not leak air Check the valve valve spring or piston pin and eliminate air leakage 5 Advance angle of fu...

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