~®

SERIES Y90 DIESEL ENGINE

OPERATION & MAINTENANCE MANUAL

VANGOONG

co.,

LTO.

THE PEOPLE'S REPUBLIC OF CHINA

FOREWORD

Series Y90 multi-cvlinder ditsel eneines are ideal power units for lieht vehicle, aeromotor.small tractor,air conditioner in bus,eenerator set and en2ineerine machinery.

The normal and reliable operation and lone service life of the eneine depend n'ot only on the manufacturine quality,but also on the reasonable operation and correct maintenance.

In order to provide the detailed description and instruction of this eneine for operators to manipulate it correctly in short time,we offer this manual which briefly describes the performance of series Y90 diesel eneines to operators

19 maintenance workers and relevant maneers.

Since the construction of this eneine is sub.iect to frequent improvement and development durin! production and practice

19 it is possible tllat the eneine supplied is somewhere not exactly the same as one described herein.Please pay attention to that when readine the manual.

Warning Notice

1.It is strictly forbidden to use inferior and dirty diesel fuel or lube oil. Please choose to use fuel and lube oil with stipulated number accordioe to the instruction.

2.It is strictly forbidden to leak out from an intake system(air filters.pipelines and connectin2 components).

3.It is strictly forbidden to have hard water(well water or soprine water)as cooline water,If necessary to apply the hard(water),soften it first.

4.lt is strictly forbidden to start under the circumstances of lack of lube oil or water.

5.It is strictly forbidden to operate at overload or under other conditions aeaiost the rules.

6.lt is strictly forbidden to reaulate the fuel in.iection pump at will.

7.It is strictly forbidden to chao2e the diameter of the pulley.

S.To control the startine time(less than 15 seconds) and the startine interval (more than 2 minutes) strictly_

9. It's a must tomaintai. the diesel en2ine techanically in the allotted time.

to.Unskilled workers are not allowed to dismantle and assemble the en2ine and its spare parts.

CONTENTS

I .

Configuration and Installation Dimensions of Model YSD490Q Diesel Engine I

II .Performance Curves of Model YSD490Q Diesel Engine ..........•..................• II

SECTION 1. DIESEL ENGINE SPECIFICATIONS AND

TECHNICAL DATA

I .

Specifications of diesel engines .............................••.. ... .•. ••• •.• •..

II .

Specifications of the main accessories···

III .

Main technical data of diesel engines

IV .

Fit clearance and wear limit of main parts ..

I-I

.........•.•.....•... 1-2

.........•.....•..... 1-3

•.•...•..•.•...

1- 4

SECTION 2. OPERATION

I .

Fuel oil,lube oil and cooling water ......................••.........•...••......... 2-1

II .

Preparation before starting

III .

Starting

IV .

Operating

V .

Stopping

... .•• ... ... ... •.• .•. ••. .••...... 2-2

.•........•......•.............•.. 2-2

.........•.•.•.•........••..•. 2-3

. .•.....................••.... 2-3

SECTION 3. MAINTENANCE

1 . Routine maintenance .

3-1

II .

Maintenance after every 100 accumulated operating hours 3J

III .

Maintenance after every 500 accum~lated operating hours··· ..• •.. •.• 3-2

IV .

Preservation and storage of engine ............•...•.................

u • • • • • • • • • • • • • • •

3-3

SECTION 4. ENGINE ADJUSTMENT

I .

Adj ustment of valve lash

II .

Adjustlnent of injection timing

III .Adjustment of injector

IV .Adjustment of lube oil pressure

V .

Adjustlnent of injection pump

VI .

Adjustlnent of decompression ann lash :

.

.

.

.

~ 4-1

···4-1

4-2

···4-4

4-4

·4-4

SECTION 5. CONSTRUCTION OF DIESEL ENGINE

I .

Cylinder head

II .

Cylinder block

III .

Piston and connecting rod

1\1 .

Crankshaft and flywheel .

5-1

5-2

5-3

5-5

v .

Camshaft

VI .

Gear transmission system

\'lI .

Fuel and governing system

VIU • [..

ubricating system

IX .

Cooling system

X .

Electric system

" 5-5

5-6

" 5-7

5-8

······5-10

5-11

SECTION 6. FAULTS AND REMEDIES FOR DIESEL ENGINE'

I ..

Hard or refuse to start .........•..

6-1

II ..

Power j nsufficiency ......................•••.•

III .

Stnoking exhaust

.

6-1

6 2

IV .

Knocking noise in engine

V .

Lube oil insufficiency or no pressure···

VI .

Overheatin~ of engine

VII .

Engine running-a\vay

•.....

.•.

•...........

6-2

6-2

6-3

6-3

lxhdUSf viJaet Ceftl~me j)4.5

'-OIIJ'"\

('-.J

~ f"t"I'---

-0.

~

I

Connecting dimp!1sions of flywhe~l and its hDirdng

~-J.Jf

~b

215,',

135

~116H1r:'O~l

Vie", B

=~----,fl4

I

134

17Y - - - - r - n 9

214.7

i 201

530

View~

Exhaust outlet centerline

1:2 ~60 ~46

I.

Configuration and Installation Dimensions of Model YSD490Q(YS490) Diesel Engine

..............- -.........- - - . - -............... Me

(N·m)

160

ISO ge

(glkw·h)

230

250 1

1600' 180Q.

2000 2200 2400 2600 2800 3000 3200

35

25 n.

Performance Curves· of Model YSD490Q Diesel Engine n

SECTION 1. DIESEL ENGINE SPECTFICATIONS AND

TECIINICAL DATA

I .Specifications of Diesel Engines (see Table 1)

Table t

Model YSD490Q

Number of c;"finder 4

- - - -

.Bore(mm)

90

Stroke(.mm)

I

100

CompreSSion tatio

_._----------_

....

--_._-------------_

..

I

!

18

__

._--------~--.------'\_..

-------_

..

_--_

........

_------

.....

_----_._

...

_--------.

__

._--------_._-----_

..

_

..

_ . _ - - .....

-

Total displacement(L)

...

_~-~-_ ..

__

..

_-------~-~-------------~-~-----~

Fuing order

2.54

1-3-4-2

~-----_-

Rated

PO\\ er(kW)

----------_-_--_-_-·----_--_---ti----.---

37.0·~45.6

~ ~

Rated speed(r/min) I 2600--3200

- -- ._--_.._-_._..... _-------_._----_._-_..

~_._---------_ .._.-...!-. -------- ._-- -_._----...._--- --- .__._------_.._---- ---._--_...__._------_._._--._.._.- _ ...._._.

----_

...

Max Torque(N m) ~ 149.3

_--_

..

_-------------------_.-._-_._-_

..

_----_.-_.

__ .-_._._--~_

...

_--------_.

__ ..

- - - - - , - - - - - _ ....

_._---,---_._._--

Min Specific fuel consumption at full load

_

(glkW.h)

--.---------..- --.----.....-.------------------.---+-..

---~------

.. ----------....------------....----.-.---.--.----.---.-----....--..-.----..

- - - - 1

Oil- fuel consumption ratioC~) ~O.8

Advance I t~ection Angle/Speed

(Before TOC) (OC)(rpm)

15± 1/2800

With Advance Device

I

!

i

18± 1/2600

Specific lube oil ccnsumption(g/kw.h) 2.72

Direction of crankshaft rotation

(facing to flywheel)

Countercloc·kwise

Cooling Inethod

OveraU dimensions

(LX WX H)(mm)

Forced water cooling

Lll bricating method Pressure and splash lubrication

Startting method Electric

.---------- - - - - - - - - - . - . - - - . - - - - - - - - - . ---·----·----------1-·-----.....--·-----------·-------- ..-------------------------·--------------..

---------------1

Net lnass(kg) 230

716X530X670

1-1

n

.S~·ification of Main Accessories(see Table 2)

Table 2

Nil

~+

I

Designation

- - - - - - - - ,

l--

Type .. .

r==

~ovemor

_

F

Specification

YSD490Q

Series I or BQ pump

Fuel injection pump

.

I Plunger diameter(mm)

--i_--~el d~~ pu~

=t all-speed, mechanical centrifugal ------

8

Single-acti;:-:----is--to-n----type----------

2

I

I

I Fl" t

~ ue InJec or i •

~~~!e

set

I

~.E~~t:~~!~~eh~le(~Ei)

_

ZCK154-S427?r

CN-DLL~~~~~~~

4

holes,

<IlO.27

I i !

Injection pressure(Mpa) 19.6+

0

1

--------1--------------------,----- ----------------------------------------------------

~.-.----.-------!~~-------I--------------Rotor

type .

.

_

3

I

I

Lube pump

1-----c:=~~1a~L)----1--------·----·-·-- ~~~: .--~--------------

!--------- ---------.- .---.-.----------- - - - i - - - - - - - - · - - - - - - - · - - - - - - - - - - · - - - - - - - · - - - - - - - - - - - - - - - i .

i Pressure(kpa)!

400

-.----.--t---.--------.---.-----:---.-----------------------·--------------r-----------------------------·--------------. --.. ----

_

4

I i

1.....-._-- .

.

Type

.

!..

Speed(r/min) i

Water pump

~-~-~~~-~~:~i~~~2

...

.. - _ _ .

.-+ i

I

--4----- -

..

4000

..

..__

=~-)~~---=~===~==-~=

-- .-t-.-.- --- ...-.-.-.---

-j--. -.-. ---- .-...-

5 i

I

;

I .

Startmg motor

'l

-·-·-·······-------t-.----- --.. -----.-- .-------------.-----------

I T y p e !

Series DC motor

1- -- ------- - - - ------ - - - - - - - , - - - - - - - - - - - - - - - . - - - - - - - - - - - - - - - - - - - - - - - - - - -

Model i

1~-·----Vol~ge(V)------I~----

.

QD1315A,D138Y

12 .

I r - - - - - - - - - - - - - - - - - - - - - - - - - - - I - - - - - - - · - · - - - - · - - - - - - - - - - - · - . - - - - - - - -

~ Power(kw)

I

2.5

I

-------t---------·- --_.--_.-,

6 f-·..-..-----------·-·-------- ..·--·--..

------·---~-------··------------------..-----------------------.-----------------

Dymamo i Model r----------------------------------

I

JFIIA

--.---.----t------------------------_..---- -------.--.--...-------------.-------------- .. --

!

Power(W) i

350 f----- - ...----- --.--_.. -----. ---

- - . - . - - - - - j - - . - - - - - - - -..- - - - - - - - -......- .... - - - - - - - - - - . - - - - - - - - . - - - - - - - - - - - - - - - - - - . - - . - .--

-------1--· ... -

I Voltage(V)

1

14

-.-------------f--..----------.-------...

----------------.---r---------.--------.-------------.-------------------

7!

Fuel filter

I-.------J~:I.-.--------f-~-.---------~!~gle sta~~:~~eleme~------_--

. - - - , - - - - - - - , - - - - - - - - - - - - - - - - - - - - - - - 1 - - - - - - - - - - - - - - · - - - - · - - - - - - - - - - - - - - - - - - - - - - - - . - . -..---

8

I

I

Lube

.

011 filter

I

Type f------------------------------...-----..

!

Single stage,paper element

------------r--·---·----.---.-------.-----------.. ---------.. -------------.---- ...- - - . - - -

I

------1"- - .. ---------.---...--.--..

i Model

I

J0801H

+-------------.--------.--------..----..

---------------·1--··---·--------..- - - - - - - - - - - - - - - · - - - - - - - - - -

9 \ Air titer

! .

T y p e !

--------j

Oil-immersed

------------ .. -..-.--..------.---..- -- -.. ---.---..---._-------.-----.---------- .----

10 : !

:

Electrothermic

!

f---

M o d e l !

Type

-.---- .. - . - - - . - -..- - --.-_.-.-----.....

t---·-----..---..--·---------------·--··--------------------------..----------.-.._---

Shrorded

!

plug

I

M o d e l !

Nil accessory

1-2

ill.Main te4:hn.ieal Data of Diesel Enline

1. Valve lash(mm)

Intake valve(cold)

Exhaust valve(cold)

0.30- 0.35

0.35- 0.40

2. sinkage ofvalve(mm) 0.7- 0.9

3.Torque

limits of main bolts and nuts(N· m)

Cylinder head bolts

Main bearing cap bolts

125145

140- 160

100-.." 120 Connecting rod bolts

Flywheel bolts 100-.... 120

4.Temperature and pressure limits

(l)Exhaust temperature(OC ) n~ 3200rpm

3200rpm>n>2600rpm n~ 2600rpm,

(2)Lube oil temperature(OC ) t~ 620 t~ 600 t~ 550

~ 100

(3)Lube oil pressure in Main Passage(Mpa)

At normal operation

.l\t luin.

Steady Speed

0.2- 0.45

?

0.05

5.Govemor Characteristics

Min. idling steady Speed

Steady regulation

~ 900rpm

5% -- 10%

]-3

IV' .• ~it Clearance and Wear {.limit of Main Parts(see Table 3)

Table 3

Designation

I

I

Assenbly limit' Wear linlit

(mm) (mm)

Connecting rod journal and connecting rod bushing 0.060-0.172

0.25

2 Piston pin and connecting rod small end bushing 0.025-0.050

0.10

3 Piston skirt and cylinder liner

..._._-_.. .•_._ ..

-_ .•--.._ .. _ '-"'-_- .. _

~

- .• _._ _ •. _-_ - - -•.... - - . __•... _ ·1

0.130-0.

195

_ . __ " ' ' ' __ ···_····__ ·•

0.40

~·.·

..

·-.·--------.---······-·I

4 Side clearance bet\veen the .~ st ring and its groove O.070-0~ 102 0.20

5 Side clearance bet~reen the 2nd ring its groove 0.050-0.082

0.15

6 Side clearance bet\veen the oil scraper r~ng and its groove 0.030-0.062

7 Gap of the 1st ring

_._.'--' -' ..- "-'--" .. _ -_

8 Gap of the 2nd ring and oii scraper ring

0.300-0.450

_ _._._- --.- ., _.. +--.- ..__.. ---.---- ---..- ..

-t -

0.300-0.450

0.15

- .-

9 Crankshaft main journal and main bearing 0.070-0.149

••. ' •• _ • • • c _ _

0.25

0.025-0. 114 0.18

..

] 1 Idle gear shaft journal ~nd bushing

....- - -_ __ """'" -- ..- "'-'-'-'-_._._

--

~.,

....__

- - - - -..-.- -_.- ..- __

0.025--0.075

-.--+-- -..- ,,--------+-.-

12 Intake valve stem and valve guide 0.025-0.077

0.18

--..- - -

'-1

0.15

0.040-0.092

0.15

13 Exhaust valve stem and valve guide

14 Rocker arm shaft and bushing 0.016-0.061

0.20

15 Axial ClearcltlCe of crankshaft

. .

-_

..

_-

..

_ -._" -_._-_ ..

_ _

..

--...•...

-

16 l\xial clearance of canlshaft

0.075-0.265

_.

__ ._

...,

_-_.

__ ._---

_

_ .;-

_

-

--""'.'--"-"-'

._

..

0.080-0.250

1-4

SECTION2. OPERATION

I .

Fuel Oil ,Lube Oil and Cooline Water

I.Fueloil

Users can select the proper ~ade of fuel oil accrdin~ to the local ambient temperature.'.Jn

the ~eneral area in China,the ~de of fuel oil is accordin~ to the standard GB252 li~ht dies~1 fuel.Use

~rade "0" light diesel fuel in summer, while in winter, use grade " - 10" light diesel fuel.Before

bein~ filled into the engine fuel tank,the diesel fuel must be settled for a long period

(normally at least 48 h).Then draw out the upper part.The fuel should be filterd by silk cloth while filling it into the engine fuel tank.It will extend service life of injectors and injection pumps by usin~ the well settle diesel fuel.

2.Lube oil

In the ~eneral area in China,users can select the proper' grade according to GB/Tl1122

Lube Oil of Diesel Engine.Use grade CD40 lube oil in summer,while in winter use grade CD30 lube oil.When

bein~ filled into the engine oil tank,the oil should be filtered by screen.

3 .Cooling water

It is recommended to use soft water such as rain water,city tap water,or clean river water for en~ine cooling. Well water or tap water f~om well water could not be used. Cooling water containing too much minerals will form water scali in an engine cooling system,affecting the engine cooling efficiency and giving rise to engine troubles.

Hard water(well or spring water,etc.) should be softened before being used.There are two softening methods;

(I )Boiling up the hard water;

(2)Adding 20g caustic soda (sodium hydroxide) to each 30L hard water to make up a solution.

When the engine operates in cold weather where the cooling water is liable to freeze,anti freezer can be added to the cooling water to prevent it from freezin~.

Glycol or alcohol aqueous solution is most ordinary.

If it is difficult to start the engine under IOYler ambient temperature, heat the water to about

80°C before filling it into the cooling system.

2-1

II .Preparation before Startine

I.Check the ti~htness and reliability of ali connectin~ parts. Check control levers (speed control lever and stoppin~ lever) to see whether they can be moved freely.

2.Rotate the crankshaft several turns"be sure that all movin~ parts move freely.

3.Check the oil level in the oil sump and injection pump to see whether it is kept within two marks on the dipsticks.Make sure that the fuel tank has sufficient fuel and that the fuel pipel~nes are unblocked.

4.0pen the fuel tank cock..Check whether there is a.ir in the fuel system. If necessary,Joosen the vent screws on the fuel filter and injection pump,operate the primin~ pump on the fuel delivery pump by hand until the fuel flows out of these screws without bubbles,and reti~hten the vent screws.After that, loosen the union nuts of injection pipes on the injectors an~ rotate the cankshaft to bleed air from in1ection pipes,then retighten the union nuts. Check all fittings of the fuel system to see whether there is any leakage at all joints.

5.Check the radiator to see whether it is filled fully with water and whether there is any leakage at all ioints.

6.Check the accessories to see whether they are firmly and reliably connected.Check the electrical system to see whether the battery is fully charged,all wirings are correct and all connections are tightened.

7.Check the clutch to see whether it has disengaged.

m.

Startin2

1.Set the speed control lever at the middle speed position.

2.Tum the ignition switch to "preheating" position to heat the electrothennic plug for 20r~.

30s.

3.Turn the ignition switch to "on" position.Press the starting button to start the engine.lf it fails to start.,release the button immediately. Wait 2minutes 3 Ininutes.. before starting the engine again.lfthe engine fails to start after 3 attetnpts.,check the cause and remedy the fault.

4.As soon as the engine has been started.xelease the press button itnmediately.Then tum the ignition switch to another position to charge the bat1ery.

At the same titne move the fuel control lever until the engine runs at idling speed.C~heck the operation condition of the engine to see whether there is any abnormal noise.EspeciaJly pay close attention to the readings of oil pressure gauge, which should be within specified pressure limits."Then \varm the engine up with engine speed gradually increasing to 1800-~-J 2000r/min

2-2.

IV .

Operatin2

1.00

not load the engine until the cooling water telnperature is over 50°C and the lube oil temperature is over 40 "C .

The engine should not be operated undrer rated operated under rated output before the outlet water temperature reaches approximately 80°C .

2.1ncrease or decrase the engine load and speed gradually and evenly.In normal case,do not load and unload the engine suddenly.

3.During operation,observe the gauges on the instrument panel frequently where the readings should be within the specified limits.Pay close attention to the exhaust gas color and the operatingnoise.lfthere is any fault..stop the engine and inspect it.

v .

Stoppine

1.Before stopping..take off the load and reduce the engine speed gradualJy.Let it run at idling speed for a fe\\' minutes.Do not stop engine until the outlet water temperature fans to below 70°C.

2.A fier stopping the engine, the ignition s\vitch should be turned to the middle position.

3.1n

winter,when ambient telnperature falls to bellow 5 °C ,after the engine stops and the cooling \vater temperature falls to below 60 "C~ .,open all drain cocks on the cylinder block and radiator to drain off all \vater remnant within the cooling systelTI.,in order to avoid dalnages 01 parts due to freezing.If anti ---.__. freezer is added to the cooling water,it is not necessary to drain off.

2-3

SECTION3. MAINTENANCE

For reliable engine operation with less wear and longer service life,all maintenance work must be carried out as follows.

I .

Routine Maintenance

I.Check the oil level in the oil SUlnp and it should be between two marks on the dipstick and near the upper one.For a new engine or the engine reused after stopping for a long period,the lube oil must be filled to the upper mark,and operate the engine at lower speed for 5 ----10min, then stop the engine and measure the lube oil level once again.

2.C:heck the cooling water level in the radiator.

3.Check the lube oil level in the governor of the injection pump,replenish the oil to the specified level if needed.

4.Eliminate oil"water and gas leakags of the engine.

5.Check tightness and correctness of all components attached to the engine.

6.Check tightness and reliability of engine foundation bolts and the conn~ction between the engine and the dirven Inachinery.

7.Keep the engine clean.Oil,water and dust gathered on the engine surface should be wiped away \vith a dry rag or cloth dipped in gasoline.Especially keep the electric equiplnent clean and dry and clean out the dust on the fins of the radiator.

S.For the new engine"after SOh t(ial running,renew the lube oil in the oil sump,fuel injection pump and governor,and tlush the oil filter elclnent,oil sump and oil strainer.

9.Promptly elinlinate the troubles and faults found.

II .Maintenance after Every 100 Accumulated Operatine Hours

Besides the ,. routine Inaintenance" \vork,and the follo\ving items:

1. Rene\v the oi I in the sump.

2.Clean the oil filter or renew the paper element if necessary.

3.(~lean th~ fuel filter or renew the paper element if necessary.(1t may as \vell be replaced after every 200 acculTIulated operating hours.)

4.Clcan

the oil filter or renew the paper eletTIent if necessary.

5.(~lean the valve necessary.

lashes.. readjust theln according to the recotTIlnended procedure if

3-1

6.Check the tension of the fan belt,and readjust it if necessary.

7.Fill the nipple of cooling water pump bearing with ZG- 4 calciumbased grease with a grease gun.

8.Clean out the dust in ,intake manifold'lclean the inside of the aircleaner,brush otT the dust gathered on the paper element surface,and clean the inside of the exhaust manifold and silencer.

9.After every 200 accumulated operating hours,check the injection pressure and spray pattern of iniection.lf necessary..dismantle the injector,clean the nozzle set,and readiust the injection pressure.

IO.Check the voltage of battery and the specific gravity of battery acid ..which should be within 1.27

r'_ 1.28(at ambient temperature of 20°C ). When it is less than 1. 14,the battery should be recharged.The level of battery acid should be I 0 .'~--, 15mm above the pole plate.lf insufficient add distilled water to the required level.

11.AII

parts dismantled for maintenance should be washed,and cleaned and correctly reasselnbled.l\fter reasselnbly.stat1

the ~nginc and check \vhether it is in proper operation,AII faults should be retnedied.

ill .Maintenance after Everv 500 Accumulated Operatine

Besides the work of Inaintenance after every 100 acculnulated operating hours..the

following items are needed:

I.Check the injection pressure and spray pattern of the injector.lf necessary.. dislnantle the injector'lclean the nozzle set and readjust the injection pressure.

2.Check fuel delivery of the injection pump,and recalibrate it on a test bench if possible.

Check the injection tilning,and readjust it if necessary_

3.(~heck the sealing of the intake and ~xhaust valvcs.lf necesary ..grind and lap the valve seats and readjust the valve lashes.

4.Check the tightness of the connecting '.>a roo.,mian bearing cap and flywheel bolts.

5.Retightcn the cvlinder head bolts and adjust the valve lashes according to directions given in section 4.

6.C:Iean or replace the paper elclnent of air cleaner.

7.('lcan the cooling ~ystem.T'he cleaning solution can be prepared hy adding 150 granls ot caustic soda(Na()H) to every litre of v~ater.Before

cleaning_drain the systelll cOlnpletely and then fi II in the saIne capacity with cleanIng solution. Let it relnain in the systenl f<lr 8 r-

-~

12h.Then start the en.glne

and run it until the tenlperature of cleaning solution reaches normal operating tClnperature.Stop the engine and drain the system itnnlediately in order 10 avoid settling of scale

\vithin the systetn.Final1y,tlush the system with clean w'ater until all seditnent is flushed out.

3-2

8.Check whether the thermostat is in good order.Examine the water dropping out from a weep hole of the water pump. It is necessary to renew the water seal,if flowing out too much of water.

9.Check the wiring contacts of the electric equipment to see whether they are connected firmly and well.Bumt marks should be removed.

1O.After every] ,000 accumulated operating hours,add the following items;

(1 )Make an overall check on all parts and components.Make necessary adjustments and repairs.

(2)Dismantle the dynamo and starting motor.Clean out the dirty grease in the bearings and refull thern with clean grease.Check the pinion of starting motor.

II.After every 1,500 accunulated operating hours,add the following items:

(t )Rernove the cylinder head,check the valve and valve seats and other parts of cylinder head asselnbly.

(2)Remove the carbon d~posits on the surfaces of cylinder head,liner, piston and piston ring, etc,and wash down them.

(3)Check and measure wear of the pistons and piston rings.

(4 )<.-:heck and rneasure wear of the cylinder liner.

(5)Check and measure \vear of the crankshaft main journals and crank pins.Clean lube oil passages of the crankshaft.

(6 )Check \vear of the Inain bearing and connecting- rod bearing shells.

(7)Clean oil passages of the cylinder block and replace lube oil.

IV .Preservation and Stora2e of En2ine

If the engine is to be put out of service for a cOlnparatively long period of time,it is necessary to preserve it according to the follo\ving procedure:

I.After the engine stops and still does not cool yetdrain out conlpletely the lube oil,cold water and fuel itnrnediately.Clean the oil sump and oil strainer.

2.Clear out the dust and oil on the engine surface. With antirust oil sinear all the unpainted exposed surfaces of engine except rubber and plastic parts.

3.Heat the filtered lube oil 10 ) 10 120 'C'; ..

until all bubbles in the surface of oil disappear.

~rhen pour the dehydrated oil Into the oil sunp until oil level reaches the upper mark.,and turn the engine,in order to nlake sure that the lube systenl is cOlnpletely tilled up with this oil.

.1-3

4.Pour some dehydrated oil into cylinder through injector assembled holes on the cylinder head,and turn the crankshaft to make sure that the piston,piston ring,cylinder liner and valve seat are alJ covered with a layer of this oil.

5.Block the outlets of intake and exhaust manifolds (silencer)with wooden plugs or wrap up properly with plastic film in order to prevent any dust from getting in.

6.The engine should be stored in a clean room with good ventilation and low humidity.,The engine should be covered.Chemicals near it are strictly prohibited.

The preservation according to the above procedure may be valid for 3 months.Over this period,repeat the procedure.

3-4

SECTION.4 ENGINE ADJUSTMENT

I ..

-\d.iustJnent of Valve I.J3sh

When the engine is maintained and repaired.,it is necessary to check and adjust the valve lashes.'fhe recommended nlethod of adjusting the valve systenl and valve lash is as follows:

1.Remove the cylinder head cover.(~heck and tighten the nuts fastening the rocker aml shaft stands.

2.Turn the crankshaft to rnake sure that the piston of 1st cylinder is at the conlpression TDC position.'The tirrling nlark on the inspection window of the fly\vheei housing exactly points to the '.

0" tnark on the tly\vhecl ritn '!or

th{~ "

011 rnark on th{~ crankshaft pulley is aligned \,,"ith the pointer on the cover ofthning gear housing.

3. slip a feeler gauge between th,-:~ rocker arnl and the tip of the intake or exhaust valve steins of the 1st cyl inder respectively to check and adjust the Fig.

t Adjustment of valve lashes valve la~;,hcs.lntake

va.ive lash and exhaust valve tash in cold l11ust be tht: value specified in section) .1l·len after turnin~~ the crankshaft by 180" to adjust the valve lash of other cylinders according to the engine firing order(! - 3- 4-2)for the four cylinder engine and' -3-2 tor three cylinder engine.

II.

Adjustment of In it~tion Tiolinf,!

1\1 obtain the tnosl econon1ical specific 111ei conSllInption and to ensure norlnal operation of th~ engineJnjection tirning should be adJusted properly.For the Model 485 die~el engincs,the ang)c at \vhich injection begins should be the value specified in section I .

'fhe adjusting inl~thod of injection timing is as l(lllo\\'s:

1. Vent the air trapped in the fuel system'land t, ~ln the crankshaf-t to f111 up the injection pUlnp \Vl!h

fuel.l)isconnect Hle injection pipe of the 1st cyiinder..turn

the crankshaft slowly in the direction of its rota[;on and at the satne tin1C ohserve the fuel level in the hele of fuel pipe union.

\Vhen this fuel level iust starts to risc'!stop

lurn the crankshaft imtnediately.

4-1

2.Check the timing mark on the inspection window of flywheel housing to see whether it aligns with the correct gradulated mark of specified advanced injection angle on the flywheel rim

(or on the crankshaft pulley).

3.ln case that they do not match \vith each other,the advanced injection angle can be adjusted by removing, off the front cover on the tinling gear housing and loosening the three screws fastening the injection plunp tilning gear support(see tig.2).lf

the injection timing is too advanced,turn the timing gear support anticlockvvise to the proper angle.Otherwise.turn the support clockwise.If adjusting range is not enough due to limitation of the three elongated holesJoosen a little the three fastening nuts on the triangular flange of the injection pump and tum the injection pump.

Facing the front end of engines,when the injection pump rotates clockwisc,the fuel injection will retard;

\\lhile the pump rotates anticlockwise.Jhc

fuel injection will advance.

4.Additionally,if the engine has injection angle advance device,the advanced injection angle can be adjusted hy loosening the three nuts on the triangular flange of injection pump and turn the injection pu,np shafLFacing the front end of engines<t

\vhen the injection pump rotates clock\vise,the fuel injection will' retard:while the pump rotates anticlockwiseJhe fuel injection will advance.After

Fig. 2 Adjustment of specinect advanced injection angle turn the injection pump once. it is lnust to tighten the three nuts and c.heck the advance injection angle again untill the advance injection angle fits the spcified value.

ill.

Ad.iustment of Iniector

Injector test and adjustment ,nust he performed on a injector tester in order to adjust iniectin~ pressure"inspect sprary pattern and relnedy faults.

Too high or too lower Injector injecting pressure,and abnormal spray on dalnaged injector parts'\vill cause engine troubles'lsuch as black smoking,power and speed dropping..increasing

exhaust temperature and diesel knocking.,etc.Generally..the "shut off" method is recommended to

4-2

check a fauly iniector,Le.loosen the nuts of iniection pipe from the injector of every cylinder successively,and observe the exhaust smoke. When the cyl1nder with the faulty inlector stops firing~black smoke wouid disappear and engine speed is not appreciably affected or not affected

. at all.It may also be checked by listening to the chattering action of the injector of every cylinder

\vith the flywheel rotating.Ifthe

d~stjnct clear sharp sound of certain cylinder could not be heard, the injector in this cylinder may be faulty.

I.Procedure of injector testing and adjustnll~nt

(1 )W ()rk the injector tester hand pump unti I the gauge pressure reaches about specified injection pressur~.

'rhen operate the hand pUlnp slo\\'ly and adjust the inlection pressure at

\Nhich injection begins.'rhe nozzle should not sho",' any si~~ns of leakage. If fuel drips around the nozzle tip after several tests.,the nozzle set must be dismantled for cleaning and ~'Tinding~"'hen test it again.

(2)Rernove the lock nut,turn the adjusting screw to get the pressure at the beginning of injection which should be specified value in section I.Then tighten the lock nut,and test it again.

(3)Work the hand pump at a rate of approxirnatetv 1 stroke per second and observe the nozzle spray 'The fuel spray shoulJ be even,and well atomized in a shape of cone.At any cross section of the conc,the atomizt:d thel should be finely and evenly distributed.Fuel droplets and irregular pattern \vhich can be seen by naked eyes should not be present in the spray_ There should be a distinct clear sharp sound at the end of iniection.Generally"ilTcgular pattern of the spray is caused by needle valve seizure~fuel drrpping is generated by danlaged conical sealing surface of needle valve and spray spIlt results frorn carbon deposits on the tip of nozzle and its heat dt~fornlation.

2.Iniector dismantlclnent and repair

(' i )Before dismantling the injector.clean off the dirt gathered on 1t ,(~lamp the nozzle body in a vice lined by copper sheets on its law \\lith the nozzle up\vard.rrurn

off the nozzle cap nut and take out the nozzle set,[)ra\v Ollt 1he needle valve from the nozzle body and soak it in c.lean

tllei oil.Then

clalnp the injector in the vice upside dow'n again.Disnlantle the adjusting nut,and adjusting scre\v,then take out the lnlcctor spring and splndle.

(2) If the nozzle set is seized or elnits fuel badlv.it

nHl,St he cleanecl.Soak the seized nozzle in fuel oil tc)r a while.and clalnp the needle valve by a p1it:~rs with cloth lined.Then rotate and draw it out slo\vly,iust to avoid scratching its su~'fac.e,Decarbonize the needle valve and nozzle body 'Nith wooden chip soaked in fllCI oi1.It is forbidden to clean them with 111 eta I chip. If the

4-3

guiding surface of the needle valve and nozzle body is not smooth enough,it may be lapped with a little bit of clean fuel oil,then clean off any metal particulates in clean fue1.While lapping of needle valve with nozzle body..never knock the needle valve against the body.

IV .

Ad.iustment of Lube Oil Pressure

See fig.3.Lossen the lock nut and turn the adjusting screw with a wrench to take the lube oil pressure within 200 .'~ 400kPa(in cold state the pressure may be higher slightly). f\fter adjustment.the pressure adjusting screw must be locked by the Jock nut.

v .

Adjustment of In.iection Pump

The injection pUlnp has tested and calibrated at the factory.If

it is necessary to readjust,the readjustment must be perf(}nned in a injection pump test bench with a standard injector and injection pipes of standard length according to the instructions in

Operation Manual of the Injection PUlnp.

VI .Adiustlnent of Decompression Arm Lash

Turn the crankshaft to make that the piston of 1st

Fig. 3 Adjustment of lube oil pressure cylinder is at the conlpression T.D.C. position.Turn the decompression arnl to decompression position.Loosen the Jock nut.Turn the adjusting screw to bring just into contact with the lock arm of intake valve (i.e.no valve lash).Screw the adjusting scre,v by 3/5--.-4/5 turns again (Inake the intake valve lifling to 0.6--O.8mm

).~rhen tighten the lock nut.After this"according to Item 3 of" f\diustlnent of Valve Lash", nlake the piston of another cylinders at the compression TDe position one by one and adjust by the same method.

4-4

SECTION 5. CONSTRUCTION OF DIESEL ENGINE

I .

Cylinder Head

When assembling,cylinder head is fixed on the cylinder block with cylinder head bolts.A

torsion spanner should be used during tightening the bolts.T'lle bolts are tightened several times in sequence shown in Fig.4 until they reach the specified torque Bmit.After dismantling and asseJnbling the cvlinder head.it is necessary to shut down the engine \vhen first wanning up period is over.

Retighten each bolt on the cylinder head according to the specified value of torque

J.hnit

and readjust the valve +-e--+ lashes.

The intake and exhaust

Fig. 4 Tightening sequence of cylinder head bolts valves arc made of different materials. Each couple of the valve and valve seat should be ground in order to prevent leakage.

It is necessary to grind \vhen gas leaks out due to burning out'lmechanical pitting and "vear appeared on the sealing face of valve and valve seat.When grinding'lapply a grinding paste(tlne valve sand)on the conic [.;ealing surface of valve.l~hen the valve and valve seat are lapped in pair unitJ a even.continuous and lustreless sealing band appears.1t is strictly forbidden that the grinding paste enters the valve guide.After lapping.,clean the valve.valve seat and valve guide carefulty.\Vearing of the valve guide may CC:l.use

the eccentric wear of valve sealing band which results in abnormal sealing.Pour

sOlne kerosene or diesel fuel into the gas passage'land observe

\vhether there is any leakage.then check the valve sealing.

l~he sealing band of valve and valve seat is normally 1.2'-,·1.6

mIn in width ..After a long period of service and regrinding many tinlcs,the V\idth of v?lve

sealing band nlay get wider..

vvhich may cause abnormal sealing.Being kept concentrica!

\\.tith

respect to the valve guide hole'!

the contact band on valve seat is to be refaced by a reanlcr.'Then gring the valve and valve seat in pair.

5-1

long

.A

fier service for a period

and

regrinding many times.

the sinkage '\NiH increase.

When it exceeds 2.0mm., replacing the valve seat should be considered.

Check the valve lashes trequently.T'hc recoITunended adjusting lnethod is shown on paragraph I of Section 4,

,Fig. 5 V'alv~ sinkage

If the lashes are too largc.,it lnay affect the correctness of valve tinting and the noise level o'f valve device dses.On the contrarY'tit rnay cause leakage or valve burnt out.

II. .

Cylinder BLock l'he cylinde,f block is lnade of cast iron and is of crankshaft centerline oft:. split face structure. f3esides the fitting hores for the hncr and the cylinder head boltholes,on the top plane of the block 'there are holes leading \vater to the cyiinder h(~ad.N0ar

the fear end of the block there' are channels delivering

!ube. oil upvvBrd to the cylinder head.

T'he "vater pump is lnounted on the upper front face of cylinder block .,and the gear system is on the lower part.'fhe tly\vhecJ housing is installed at

Fig. 6 Prot.rueliog

beig,bt of the Uner Dange plane relative to the plane of cyUnder block the rear face of the b!ock.()n the block ho1tonl~therc are a lube oil inlet,a hole tor the lube oii plnnp and tap holes l()f installing the sUlnp.There

are a side cover and a hreather on the left side of the block(facing to the front end).l'here are the lube oil filter'\fut~J filter and drain (;ock on the right side of this block 'fhe ITtain lube oil lin~ and Its branl;hes are arran~;ed in horizon,The lube oil passages deliverin~~ lube oil to the camshaft bushes are slant.

When dislnantling and repairIng

5-2

the diesel engine,flush all lube oil passages,and be sure that they are clean and unb locke~.

All passage plugs should be sealed reliably and leakproof.

The main bearings are of complete suspension- support type.Since the main bearing caps and cylinder block are matched to bore,the matching marks are both on the bolck and main bearing caps.Misplacement or inverted installation,when assembling,are prohibited.The main bearing shells are made of high- tin aluminium-base alloy. When dismantling for cleaning,be sure that the upper and lower bearing shells are in right places(the upper shell with an oil groove).The

crankshaft thrust plates are assembled on the last main bearing with an upper piece and a lower piece on each side.The thrust plates bear the axial force [roln the crankshaft.There are oil channels on its operating surface \\!hich

should be located a~ainst the thrust planes on the crank, and its back surface is smooth.Never

locate therTI in reverse.When tightening the nlain bearing biots,t\\'O bolts on the bearIng cap should be tightened several times in tl1rn.L~efore tightening the

Inain bearing cap,strike the crankshaft for\'vard and backw'ard in order to keep the upper and lo\ver thrust plates in the saIne plane.Then tighten the bolts until they reach the specified tightening torque. When cOlllpleting the c.rankshaft

assemblY,turn it at the flywheel cnd by hand to check \vhether it can be rnoved freely.

l'he Iiner is slipped into the cylinder bore vertically so that deformation of the liner Inay be avoided.rrhe liner flange plane should protrude out the top plane of cylinder block by 0.07--- 0.] 5 lTIln to keep an excellant scaling bet\vcen the cylinder liner aud cylinder head,as shown in Fig6.

III .

Piston and Connectin2-rod

'The piston and connecting- rod assembly conlprises the piston~piston rings,piston pin, retainIng f1n~:.. connecting-rod,connecting rod cap,connecting-rod bolts and connecting-rod bearing shelts and bush,etc.The lnass difference of piston and connectingrod assetllblies in the sanle engine should be vvithin 20g.

/\11 of the cOlnpression rings are made of alloy cast iron.l'he outer circle surface of the first rin,g is plated with porous chronlC in order to decrease the \\Jear between the cylinder liner and piston ring.rrhe

second ring has a conical surface.

W·hen assenlblinp,,,the surface rnarked with a sign

II

Up " should be kept against the top of piston and be careful to avoid assenlbling in reverse.

The oil-control ring is oftensionin~, ring type.'The radial force of oil ring is still kept while decreasing the elasticity due to \vear:rhus the service life of oil ring is prolonged.

5-3

Check the ring end gap before assembling the piston ring.The method measuring this gap is recommended as follows: Press down the piston ring evenly into the cylinder liner by 15--

20mm from the top surface of liner.

Measure the clearance with a feeler gauge.In

normal case,the measuring value should be O.2--0.4mm(Fig.7).In

2

3

Fig. 7 Measurement of piston riog end gap

1. Thickness feeler (gauge) 2. Piston ring 3.. Cylinder liner case the gap value is less ,enlarge it by a file.If it is excess,replace it with another one.In addition.,measurement should be Inade with a feeler(gauge)to check the side clearance between the piston ring and ring groove.The side clearance for the first ring should be O.07r~O.1

02mm and o.

05---0.082mm

for the second ring as shown in Fig8.

When disnlantling and asselnbling the piston ring,a special tool may be used.

'fhe ring end gap of piston rings should be set off with each other by 120°C to prevent being in line with the piston pin

Fig. 8 Measurement of side surface gap of piston ring seat hole.

If the piston ring is seized and could not move when checking,soak it in diesel fuel(kerosine or gasoline)for 24h or more.l'hen knock the piston ring slightly to tnake it become flexible of itselt~On getting out the piston ring,clean it in diesel fuel or carbon tetrachloride.

Check the piston to see whether there is any cracks or scars_Change the defective piston and renew its rings.

The cross section of the connecting- rod is 1- shaped,with the splitting surface of large end being perpendicular to the center line of connecting- rOd.Boring the connecting- rod hole and connecting-rod cap must be Inated.l~herefore when assembling,pay close attention to the mating

5-4

marks on both the connecting- rod and connecting- rod cap in order to avoid making mistakes.

The connecting- rod bearing shell is made of steel with high tin aluminium alloy.When the clearance between the connecting- rod bushes and crankshaft journal exceeds the specified value after wearing or severe stripping and burning occur on their surfaces,they must be renewed in pair.

During engine overhaul or renewing the connecting-rod,check the axis parallelism of the connecting-rod small end to the large end,which is specified to be within O.Olmm/IOOmm(both in vertical and horizontal direction).If it goes beyond the scope,alignment should be made.

Before dismantling the piston and ~onnecting-rod assembly in cylinder liner or assembling, , it is necessary to scrape and clean the carbon deposit and greasy dirt on the top part of cylinder

Iiner.Before assembling,smear some clean oil on the cylinder liner bore,external surface of piston and piston rings,connecting- rod bearing shells and crankshaft journal.Then place the piston guide sleeve in the cylinder liner.Jlt the piston and connecting-rod a~selnbly into the cylinder liner carefully,and tighten in tum the connecting-rod bolts according to the specified tightening torque limit in several separate times.After finishing the assembly,turn the crankshaft, be sure that it rotates smoothly.

IV • Crankshaft and Flywheel

The crankshaft timing gear and pulley are fitted on the front output end of crankshaft.

Positioned by the locating pin,the flywheel is fitted on the rear end flange of the crankshaft \vith six bolts tightened according to the specified torque value.A bearing E60203,\vhich supports the transmission shaft of gear box,is fitted on the flange center at the rear end of the cranks haft. An angular calibrating line is marked on the crankshaft pulley and a pointer"which is fitted on the cover of the timing gear housing,indicates the reading of advanced injection angle.

A flywheel gear ring is bound on the outside diameter of flywheel in shrinking fit.A

calibrating line.,\vhich provides observation for advanced injection angle,is marked on the flywheel.

v.

Camshaft

'fhere is a gear driving the lube oil pump in the front of the last set of cams(facing to the front end). When the camshaft revolves,the earn on the shaft drives the tappets,push rods,valve rocker arms and valves,which respectively control the intake and exhaust valves for each cylinder.

5-5

There is a thrust flange at the front end of camshaft,and a thrust plate of camshaft is located at the front end to control the camshaft axial moving. The lube oil is delivered to the camshaft bushings separately through the main oil line.Before assembling the front bushing of camshaft, check whether the oil holes on the bushing and oil passage in the cylinder block cOlnmunicate with each other. As the camshaft gear is engaged with the driven gear oiNhe oil pump,therefore, before dismantling the camshaft,it is necessary to disassemble the lube oil pump,then draw the camshaft out from the front end.

The axis of the tappet deviates from the center line of canl width .During operating,the tappet rotates so as to provide an even wearing on the bottom surface and the cylindrical surface of tappet.

VI .

Gear Transmission System l'he gear transmission system consists of the crankshaft timing gear..

tilning idler'lCanlshaft timing gear,injection pump timing gear and hydraulic pUlnp gear.

Except the hydraulic pump gear,all the titning ~"ears are all Inarked with timing signs which,

'Nhen assembling,should align \vtih each other at the nleshing position (the single tooth marked with a sign is inlaid bet\veen the t\VQ adjacent Jnarked teeth)in order to ensure the tnOVenlent relationship of

a.

11 nloving parts,as shown in Fig.9.

Fig. 9 Timing gear meshing signs

5-6

Special tools are necessary for dismantling or assembling the crankshaft timing gear.The

camshaft timing gear can be got out by two bolts M8 on the gear spoke which are turned staggeringly and evenly.The timing idler is located on the cylinder block by slide fit.The

injection pump timing gear is assembled on the timing gear seat which is fixed on the camshaft of the injection pump.Whenever three bolts setting the injection pump gear are loosened,the injection pump gear can be drawn out.The injection pump gear is pushed out when the three bolts M8 X 35 are staggeringly tigbtened on the gear seat.

.

The fuel and governing system is the main operating section of the diesel engine . It is composed of the fuel delivery pump, (uel filter, injection pump, governor, fuel injection and fuel return pipes, etc.as

shown in Fig.IO.

'The fuel is pumped by the fuel delivery pump from the fuel tank into the injection pump through the fuel filter.

rrhe diesel fuel

IS

2

1_~_--3

4

5 delivered through the inlection pipe under high ~ pressure produced in the pUlnp, and is then atonlized by the injector before burning in the

COll1bustion chanlber.

rrhe fuel delivery

Fig.l0

Fuel and governing system

1. Fuel return pipe 2. Fuel injection pipe 3. Injector

4. Injection pump S. Fuel filter 6. Governor 7. Fuel delivery pump ptunp is a single-acting piston type pump located on the outside of the injection pump. The eccentric cam,which is set on the camshaft of injection pump,dnves the fuel delivery pump"

\vhich finally presses the fuel into the fuel cavity in the injection punlp.

5-7

The injection pump has been calibrated by the manufacturer.Be sure not to dismantle it at will. When the dismantlement,repairment and adjustment are required,it is forbidden to interchange the pluger sets and discharging valve sets,and be sure to keep clean when assembling.

The all speed mechanical- centrifugal governor is applied. The governing handle can be operated to control the speed of diesel engine.When the governing handle is turned in the direction of tightening the governing spring,the fuel supply would increase and the engine speed

\\-'ould be up consequently. When this fuel supply would decrease and the relevant engine speed would go down.Do not move either the high speed or the idling speed set screws or screw the maximal fuel supply set screw on the governor at will during operating.

On the governor housing,a stop handle is mounted which,if necessary,can be operated to stop the engine at emergency.

'rhe needle valve and its body are a precise set lapped in couple ..therefore.,close attention IS paid to that,when dismantling and assembling them.Be sure not to interchange them and to keep them clean.

VID.Lubricatine System

The lubricating system is composed of the strainer,lube oil pump,oil filter and pipelines,as shown in Fig. II .

rrhe engine adopts pressure" and splash lubrication.The pressure lubrication is applied to the

I1lain bearing..connecting-rod bearing,camshaft bushing.The cylinder sleeve,piston,piston pin, connecting- rod bushing.,cam and its tappet,as well as valve and its guide are lubricated by splashed oil spray.l'he bearings for the water pump shaft are lubicated regularly by adding lubricating grease.

The lube oil is sucked up to the lube oil pump from the oil sump through the strainer and the oil inlet pipe,and pumped into main oil line through the oil filter.One path of the lube oil lubricates the nlain bearing and the connecting-rod bearing through the oil hole on the crankshaft: other path of the oil lubricates the camshaft bushing,and also ~he oil is supplied intermittently to the rocker arm shaft bushing throrgh the eccentric oil channel in the rear journal of the camshaft; and the third path of the oil is ted to the timing idler bearing.~rhe lube oil pUlnp is of slantingly mounted type.A single ~tage paper cartridge oil pUlnp is used.The filter element can be replaced regularly.ln case of blocking up during xoperation,the oil flows into the main oil line by opening

5-8

the safety valve while the oil filter loses the function of filtration,so it is necessary for the cartridge to be cleaned or replaced regularly according to the maintenance.

___.........

r~........--- 10

11

14

,

4

Fig. 11 Lubricating system

1. Oil sump 2. Strainer 3. Lube oil pump 4. Piston and connecting rod assembly and cylinder liner S. Lube oil rllter 6. Gear train 7.

on pressure gauge 8. Rocker arm 9. Valve push rod, valve tappet and block hole for tappet 10. Rocker arm shaft 11. Valve and valve guide 12. Camshaft and bushing 13. Oil lines in the block

14. Crankshaft and bearing

5-9

IX .

Coolin! System

'The cooling system is a forced circular water cooled type,as shown in Fig.

12.~rhe system consists of a radiator,water pump,cooling fan ,thermostat and

-1

2 diversion hood, etc.

The cooling water,pumped from the radiator into the cylinder block water gallery ,flows tangentially and round to

3

4

5 the cylinder liner,then up to the cylinder head. The hot \vater fronl the front end of cylinder head flows back into the radiator through the thermostat and outlet water pipe.When

the temperature of cooling

F'ig.12 Cooling system

1.

Radiator 2. Thermostat 3. Cooling fan

4. Water pump S.lnlet water pump

\-vater is below 70C~ ,the thermostat closes,and the cooling water will be short-cut for circulation froln the branch water pipe on the front end of the cylinder head to the water purnp inlet pipe and the water pump;when the temperature of the cooling water is above 70 ,-.....- 80°C "the thermostat opens,and the cooling water flows into the upper part of the radiator through the thermostat and flows downward the thermostat and flo\vs downward along the flat- tube into thelo\ver part of the radiator,during \\lhich the cooling \vater is cooled by the fan and cOJTIpletes the regular circulation.

'fhe cooling fan can be of either suction or blast type according to its application.

rrhe centrifugal water punlp is driven by the fan belt on the crankshaft pulley.ln case of severe water dropping out fronl the \vcep hole at the lo\ver part (rf the pump housing due to the damage of \vater seal during operation.,it IS necessary to replace the V\/ater seal hut blockitlg the

\veep hole at the time of leakage IS not perrrlitted,or the \Valer \\;ill enter into the bearings"vvhich causes their quick "vearJ~eplacell1ent

ITIUst be considered \vhile

abnornlal

noise

occurs during

operation.

rhe grease nipple of \Valer pUJnp rnllst be filJed regularly with ZG~ 4 caJcilun based grease \vhich alnounts to about L'2,,·-.; 1/3 of the capacity of bearing cavity acc,ording to the rnaintenance.'The bearing l\'ill be overheated with excessive grease. The single valve type therrnoslat \vith corrugated pjPt~ is 1i lied with temperaturcsensitive fluid \vhich can automatically control the valve openin,g and closing.

The tan belt Inllst be checked and adjusted regularly f<1r its tension according to the proedures for the lnaintenance.'The slack is 10 r '

20 !nni

\vhen pressing the belt bet\veen the ian and the dynamo pul!eys.

5-10

x .

Electric System l~he electric system is composed of the battery,starting motor,dynatno,electrothennal plug'!

starting button and instrulnents,ctc...as sho\vn in Fig.13.

The parallel excited silicon rectifying dynarno model JFl] comprises the three ._phase

8 9

Fig. 13Eleetric system

1. Battery 2. Starting motor 3. Wire 4. Glow plug 5. Preheating and starting switch 6. Galvanometer 7. Ignition switch 8. Regulator 9.

Dynamo alternator and silicon diode rectifier.Be

caref\Ji that the arrnature ITlust be negitive pole grounded..

or the dynamo \vil) be damaged.

Refer to operation and Jnaintenance rnanual for .IF series silicon rectifying dynamo for the operation and tnaintenancc of the dynanlo.

After turning on the starting switch,the flywheel gear rin~ is engaged \vith the nlotor pinion by the solcnoid'lnleanwhile the fly\\rheel is driven by closing the current circuit of starting motor.

As soon as the en~~ine is started..thc starting s\vitch

111lJst be turned off inllnediately 'fhen the core along with the pinion returns to the original place under the actuation of spring. The continuous \\forking tl1ne for the startIng motor should not exceed : 5 seconds,"fhe intl~rval between t\\'o starting operations is 2 r · ,

3 tninutes.1t

is necessary to check and elilninate the faults in case of starting failure for three atternpts. l'he elcctrif\'ing tilne of the glo\v plug cae-h time during operation is not permitted to be over 30 seconds.

5-11

SECTION 6. FAULTS AND REMEDIES FOR DIESEL ENGINE

I .Hard or refuse to Start (see Table 4)

Table 4

Causes

1.Fuel filters and fuel pipelines bolcked.

2.Air trapped in fuel system.

3.Advanced fuel injection angle incorrect.

4.Fuel spray abnormal.

5.-Conlpression preessure low.

6.Valve lash incorrect

7.Battery charge insuffcient.

8.Wire connections loosened.

9.Ambient temperature too low, and oil too viscous

Remedies

J.Clean.

2.Exhaust air and tighten all fuel pipdline connector.

3.Readjust it according to specifications.

4.Readjust fuel injection pressure according to specifications and clean or replace injector needle valve sets.

5.Cheak or replace piston rings,and cylinder liners.

Grind valves.Cylnder head nuts should be tightened in case of leakage on cylinder head gaskets.

6.Adjust it according to specifications and align gear marks.

7.Charge it.

8.Check and tighten wire connections.

Clean up contact points.

9.i

1 reheat cooling water and lube oil.

II .Power Insufficient(see Table 5)

Table 5

Causes

1.Compression pressure inside cylinddcrs too low.

2.Advanced fuel injection angle incorrect.

3. Valve lash incorrect.

4.Fucl supply for each cylinder unbalanced.

5.Ari

filter clo¥ed.

6.Fuel injection pumps. fuel i'1iector sets \vorn ofl or fuel injection pressure incorrect.

7.Rotation speed incorrect.

Remedies

I.Refer to iteln 5 in paragarph I and replace components exceeding \vear limit.

2.Adjust it according to specifications.

3 .A~just it according to specifications.

4.Adjust fuel injection pumps to proper supply.

5.Clean.

6.Replace thenl \vith new sets~ adjust tilel injection pressure and check fuel spray.

7.Adjust it \vith speed governing handle in order to reach specified speed.

6-1

III.Smokinl! Exhaust (see Table 6)

Table 6

Causes

1.Engines overloaded.

2.Fuel injectors not well atomized

3.Fuel unqualified

4.('ombustion incolnplete

IV.Knockin2 Noise in Eneinc (see Table 7)

Table 7

Remedies

I.Reduce the load properly and in case of unsuited matching. aqjustlnent should be lnade.

2.Check the injection pressure and fuel spray. Replace then in case of damage.

3.Use qualified fuel.

4.Mainly caused by unqualified fuel injectors.. incorrect advanced fuel injection angle,leakage at cylinder head gaskets and lo\\' compression pressure.Remdy

in accordance with specific problems.

Causes

1 .Advanced fuel injection angle incorrect.

2.Air trapped in fuel systems.

3.Fuel supply for each cylinder unbalanced.

4.Fuelunqualified.

5.Wear of certain components exceeds limits

Remedies

I.Readjust it according to specification.

2.Exhaust air.

3.Readjust fuel supply.

4.lJse qualified supply.

5.Replace theln.

V

.Lube Oil Insufficient or No Pressure (see Table 8)

Table 8

Causes

1.0illevel in oil sumps too low.

2.Serious leakage from oil pipelines.

3.0il

strainers,oil filters and pipelines clogged.

4.0il gauges damaged or gauge lines clogged.

5.0il too thin.

6.f)il pump gears seriously worn off ,with excessive clearance.

7.Pressure relief valves of oil filter cease to function.

8.Main bearings, connecting-rod bearings and camshaft bushings seriously worn off \\;ith excessive clearance.

Renedies

I.Add oil up to nlark line on dip sticks.

2.Eliminate leakage.

3.Clean and replace elenlents if ner'essary.

4.Check and replace elenlents if necessary

5.lJse qualified oil.

6.Adjust the clearance or replace them.

7.Check and repair or readjust theIne

8.Check and repair or replace theln.

6-2

VI.Overheatin2

of En2ine (see Table 9)

Table 9

Causes

I.Temperature of cooling water too high;

(1 )Insufficient cooling water or vapor lock in water pipes.

(2)Bad working state of water pumps.

Remedies

(1 )Fill the rank to make cooling water level higher rhan the center line of water pump.

(2)Check water pump clearance and tightness of belts. Eliminate leakage.

(3)Remove it.

(3)Water scale in cooling systems too thick.

2.0il temperature too high:

(1 )Insufficient or excessive oil.

(2)Oil pressure too low with insufficient flow.

3.Engines overloaded

(1 )Cheak whether the oil level is between the dip stick scale lines.

(2)Refer to paragraph V.

3.Relieve load.

Vll.En2ine Runnio2-awav (see Table 10)

Table 10

Causes

I.Malfunction of governors.

. 2.Control rod fuel injection pump gets stuck.

3.hljection pump delicery too much.

4.Excessive oil burnt.

Remedies

] .Stop engines imnlediateJy, check and repair.

2.Stop engines immediately, check and repair.

3.Stop the engine and readjust injection pump delivery.

4.Stop engines ilntnediately,check and repair.

6-3

MANUFACTURING LICENSE: XK06 -205 -00141

PRODUCT STANDARD: 0/321284 JCA06 -2002

LICENSE APPROVAL DATE: JULY 2,2003