Maintain N485D and N490D Diesel Engines

ANHUI QUANCHAI ENGINE CO.
, LTD
Engine Maintenance Manual
(Quanchai N485D and N490D Diesel Engine for generator)
ANHUI QUANCHAI ENGINE CO., LTD
Jul 2019
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Preface
The N485D, N490D diesel engines are four-cylinder, in-line, water-cooled, four-stroke diesel
engines, which has the advantages of compact structure, beautiful appearance, easy to operate,
good rigidity, stable performance, long service life, good economical efficiency and high
serialization, etc. It is the ideal power unit for diesel generator set. However, the good
performance of product is closely associated with a good care. In order to make the user be
familiar with the structure and performance of the diesel engine, 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 reliability and long service
life of the diesel engine.
The main purpose of this manual is to give users a better understanding of the diesel engine.
Therefore, the manual consists of various assembly views, detailed descriptions of disassembly
and assembly, step-by-step instructions of judgment, maintenance and repair, though which
users can operate and maintain the diesel engine well and master the operation and maintenance
technologies as soon as possible to ensure the normal, reliable and efficient operation of diesel
engine.
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Contents
Preface ........................................................................................................................................................ 2
Part 1 Overview.................................................................................................................................................. 6
Chapter 1 Safety Precautions ..................................................................................................................... 6
1. Scald proof sign.............................................................................................................................. 6
2. Anti-touch sign ............................................................................................................................... 6
3. Engine lifting equipment ................................................................................................................ 7
Chapter 2 Technical Parameters ................................................................................................................. 8
1. Main technical parameters.............................................................................................................. 8
2. Filling capacity ............................................................................................................................. 10
3. Main structural parameters of diesel engine ................................................................................. 11
4. Torque........................................................................................................................................... 12
5. Outline dimension parameters ...................................................................................................... 12
6. Exposed parts of the engine.......................................................................................................... 17
Chapter 3 Fuel and Engine Oil ................................................................................................................. 19
1. Use of and precautions of fuel ...................................................................................................... 19
2. Engine lubricating oil ................................................................................................................... 21
3. Engine coolant .............................................................................................................................. 21
Chapter 4 Product Features and Accessories .................................................................................... 22
1. Standard accessories for the product ............................................................................................ 22
2. Optional accessories ..................................................................................................................... 22
Part 2 Disassembly, Assembly and Adjustment ............................................................................................... 23
Chapter 1 Disassembly and Assembly of Valve 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 Linkage Mechanism ..................................................... 47
3. Disassembly of crank linkage mechanism ................................................................................... 50
4. Assembly of crank linkage mechanism ........................................................................................ 54
Chapter 3 Cooling System........................................................................................................................ 63
3. Disassembly, assembly and adjustment of cooling parts .............................................................. 64
4. Assembly and adjustment of cooling parts ................................................................................... 67
Chapter 4 Lubrication System .................................................................................................................. 69
3. Disassembly of the lubrication parts ............................................................................................ 70
Chapter 5 Starting System ........................................................................................................................ 72
2. Torque requirements ..................................................................................................................... 72
3. Disassembly, assembly and adjustment of starting parts .............................................................. 73
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Chapter 6 Fuel supply system .................................................................................................................. 74

Chapter 7 Disassembly, Assembly and Adjustment of Accessories ......................................................... 79
1. Data and dimensions .................................................................................................................... 79
2. Disassembly and assembly of gear chamber ................................................................................ 80
4. Atomization of nozzle .................................................................................................................. 82
Part 3 Inspection, Adjustment, Fault Diagnosis and Removal ........................................................................ 84
Chapter 1 Dynamic Checks ...................................................................................................................... 84
1. Overview ...................................................................................................................................... 84
2. Checks on engine oil level............................................................................................................ 85
3. Checks on level and status of coolant........................................................................................... 86
4. Checks on fan and belt ................................................................................................................. 87
5. Checks on fuel system .................................................................................................................. 88
6. Checks on inlet and exhaust systems............................................................................................ 89
7. Checks on electrical system ......................................................................................................... 90
8. Idle test on engine......................................................................................................................... 91
Chapter 2 Working Mechanism ................................................................................................................ 92
1. Valve train..................................................................................................................................... 92
2. 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 fuel injection pump .................................................................................... 109
4. Calibration of fuel injection pump ............................................................................................. 110
5. Atomization of fuel injector ........................................................................................................111
6. Test on engine oil pressure ......................................................................................................... 112
7. Inspection and adjustment of starter pinion................................................................................ 114
Chapter 4 Fault Diagnosis and Removal ................................................................................................ 115
1. Emission of white smoke ........................................................................................................... 115
2. Emission of blue smoke ............................................................................................................. 116
3. Emission of black or gray smoke ............................................................................................... 117
4.Cylinder compression pressure being insufficient....................................................................... 118
5. Blocked air filter......................................................................................................................... 119
6. Emission of blue smoke ............................................................................................................. 119
7. Abnormal sound emitted by diesel engine.................................................................................. 120
8. Abnormal operation or frequent flameout .................................................................................. 121
9. Low power.................................................................................................................................. 122
10. Engine oil-water mixture .......................................................................................................... 124
11. Surging rotating speed .............................................................................................................. 125
12. Unstable rotating speed ............................................................................................................ 126
13. Engine overheat ........................................................................................................................ 126
14. Abnormal coolant temperature ................................................................................................. 127
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15. No oil pressure or too low oil pressure ..................................................................................... 128

16. Too high engine oil pressure..................................................................................................... 128
17. Overheated engine oil............................................................................................................... 129
18. High engine oil consumption ................................................................................................... 130
19. Low starting speed.................................................................................................................... 131
20. Failure 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 disconnect pinion .............................................. 135
25. Methods for distinguishing between starter failure and storage battery failure........................ 136
26. Checks on disassembled starter ................................................................................................ 137
27. Hard to get diesel engine started .............................................................................................. 138
28. Emission of black smoke .......................................................................................................... 139
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Part 1 Overview
Chapter 1 Safety Precautions
This sign is a safety sign. If the diesel engine

is made with such sign or mark, care must be
taken to ensure safety and prevent personal
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 is prohibited to touch the heating device such as the engine body when it is in operation.
The engine can only be repaired after half an hour of downtime.
See the manual for other signs.
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3. Engine lifting equipment
When lifting the engine, use the allowable

type of lifting equipment with correct lifting
capacity. Particularly, 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 connected.
Before lifting the engine, check whether the

lifting ring is damaged or tightened. The
tightening torque of positioning screw of the
engine lifting ring is 44 N·m.
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Chapter 2 Technical Parameters
1. Main technical parameters
Note: Product design and technical parameters are subject to change without notice.
Model N485D N490D

Type Four cylinders, in line, water cooling, four stroke
Type of combustion
Direct injection
chamber
Intake mode Natural aspiration
Cylinder diameter (mm) 85 90
Piston stroke (mm) 95 100
Mean piston speed (m/s) 4.75 5.70 5.0 6
Mean effective pressure of
630 618 723 708
piston (kPa)
Total displacement (L) 2.156 2.545
Compression ratio 18：1 18：1
Declared power (kW) 17 20 23 27
Declared speed (r/min) 1500 1800 1500 1800
Stable speed governing rate
≤5
(%)
Fuel consumption rate at
declared working condition ≤ 245
(g/kW·h)
Engine oil consumption rate
≤1.63
(g/ kW·h)
Crankshaft rotating direction
Counterclockwise
(facing flywheel)
Cooling method Water cooling, forced circulation
Lubrication method Force-feed and splash lubrication
Starting mode Motor start
Ignition order 1-3-4-2
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N485D power curve
N490D power curve
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2. Filling capacity
FOTON
Item Unit
N485D N490D
Water volume in diesel engine 4.1
body L
Capacity of engine oil pan 6.5
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3. Main structural parameters of diesel engine
Rotating direction (facing

CCW
flywheel)
Number of flywheel teeth 109
Specifications of flywheel housing SAE4＃
Specifications of flywheel SAE7.5″
Mode of fuel injection Direct injection
Speed governor Mechanical type
Fuel supply pump Mechanical type
Diameter of fuel injector nozzle 0.25 mm
Opening pressure of fuel injector 2±0.5 MPa
Diesel filter Single stage
Lubricating System
Grade of lubricating oil CD-40
Capacity of lubricating oil 6.5 L
Maximum allowable temperature
115℃
of engine oil
Engine oil Maximum 650 kpa
pressure: Minimum 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
70℃/82℃
thermostat
Diameter of exhaust fan (mm) φ410
Electrical system
Specifications of generator 14 V×500 W
Pressurizer Built-in pressurizer (none in partial states)
Starting motor 12 V×3 kW
Battery voltage 12 V
Battery capacity ≥ 100Ah (recommended)
Intake and exhaust flow
Intake flow (kg/h) 58
Exhaust flow (kg/h) 60.5
Speed sensor
Interface of speed sensor M18X1.5 or M16X1.5
Distance form mounting surface
34 mm
of speed sensor to top of ring gear
Valve layout
Valve type Roof mounted
Number of valves per cylinder One intake valve and one exhaust valve
Intake valve: 0.2 ~ 0.25 mm
Valve clearance
Exhaust valve: 0.25 ~ 0.3 mm
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4. Torque
Serial Torque Note

Description
No. N.m
1 Cylinder head bolt 145 ~ 155
Through bolt of rocker shaft
2 21 ~ 25
support
3 Cylinder head nut 21 ~ 25
4 Connecting rod bolt 60 ~ 70
5 Bolt of main bearing shell cap 140 ~ 160
Connection of the pump to the
6 25
cylinder head and the body
Assembly of the engine oil
7 25
pump to the body
Connecting of the starting
8 80
motor to the flywheel housing
Connecting of the fuel injection
9 70
pump to the gear chamber
10 Injection nozzle nut 40 ~ 60
5. Outline dimension parameters
Outli Length 760

ne
Width 550
dime mm
nsion Height 608
s
Width of oil pan mm 262
Height from pump to crankshaft 202
mm
center
Fan diameter mm 410
Weight kg 205 (without water tank, air filter and silencer)
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Left view:
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Front view:
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Right view:
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Rear view:
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6. Exposed parts of the engine
6.1 Left side of the engine
1 Pump parts 2 Thermostat outlet 3 Intake pipe 4 Intake heater 5 Air filter 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 Fuel
injection pump 18 High-pressure fuel pipe 19 Engine oil filter 20 Oil pan 21 Inlet and outlet
pipe of diesel filter 22 Engine body 23 Diesel filter 24 Flywheel
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6.2 Right side of the engine
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 35 Exhaust connecting pipe 36 Exhaust pipe 37 Starting motor
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Chapter 3 Fuel and Engine Oil
1. Use of and precautions of fuel
1.1 Storage of fuel
If the diesel in the fuel tank or transport tank

flows slowly, add the fuel conditioner to the
diesel to prevent the water from concentrating .
Please purchase high-quality clean fuel from a
reputable dealer.
It is very 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
the fuel is consumed slowly in the fuel tank or
storage tank, add fuel conditioner to the tank
to prevent the water from concentrating.
Keep fuel in an easily accessible place, and
stay away from buildings.
Note: In order to reduce the separation of fuel

gelling with control wax in cold weather, fuel
or bulk storage cabinets can be added.
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1.2 Precautions for use of fuel
Fuel: The fuel is the light diesel specified in

GB/T252. And the minimum applicable
temperature is shown in the following table:
Grade of light
diesel
0# -10# -20# -35# -50#

Minimum applicable
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 winter. In special cases, for instance, in
Northeast China, -35# light diesel may be used,
while in hot areas such as Guangdong, 10#
light diesel may be used.
1.3 Fuel filling
Fill the fuel according to the fuel level shown

on the dipstick of the fuel tank.
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2. Engine lubricating oil 3. Engine coolant
Lubricating oil The cooling water shall be clean soft water,

such as river water, rain water, snow water and
Oil quality level: CF level or above oil is
tap water. As soft water contains less minerals,
adopted. In addition, the viscosity level is
and has less scale after heating, it will not
selected according to the ambient temperature
block the cooling system and affect the heat
as follows. dissipation. If no soft water is available, and
the hard water is used, such as well water,
S/ Oil grade Applicable Note spring water and other hard water containing
N ambient temp.
more minerals, it shall be softened. The easiest
1 15 W/40 Above -5℃
treatment method is to boil the water, then
2 10 W/30 -5℃ ~ -20℃ remove the impurities through precipitation.
3 5 W/30 If the diesel engine is used in a cold area, the
Blow -20℃
antifreeze shall be added into the cooling
Note: water according to the ambient temperature.
The antifreeze can be a mixture of alcohol and
1. The engine oil and diesel in proper grade
glycerin or the ethylene glycol.
shall be adopted according to the ambient
temperature. And the engine oil shall be
replaced regularly according to the regulations.
2. When changing the grade, various grade of
engine oils can't be mixed to avoid adverse
chemical and physical reactions, which will
make the oil deteriorate.
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Chapter 4 Product Features and Accessories
1. Standard accessories for the product
Engine introduction:
N485D, 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 accessories
According to the needs of overall unit, the followings can be selected:
Air filter
Water tank
Silencer
Part 2 Disassembly, Assembly and Adjustment
Chapter 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 Torque requirements
Item Unit Parameter Note
Cylinder head fixing

N.m 145 ~ 155
bolt
2.2 Dimensional data
This data is given to the personnel for engine overhaul, and the dimensions shown are primarily for the
factory.
Cylinder head
Angle of valve seat
Exhaust valve ----------------------------------------------------------------------------- 120°
Intake valve ------------------------------------------------------------------------------- 120°
Diameter of original mounting hole of valve guide --------------------------------- 13 mm
Leakage inspection pressure ------------------------------------------------------------ 400 kPa
Thickness of cylinder head -------------------------------------------------------------- 85 mm
Minimum allowable thickness of cylinder head after being processed ------------ 84.9 mm
Intake valve
Diameter of valve stem ------------------------------------------------------------------ 8 mm
Clearance of valve guide ---------------------------------------------------------------- 0.025 mm
Maximum clearance of valve 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 clearance of valve guide ---------------------------------------------------- 0.078 mm
Diameter of valve head ------------------------------------------------------------------- 33.5 mm
Angle of valve cone ---------------------------------------------------------------------- 120°
Full length ---------------------------------------------------------------------------------- 117.5 mm
Sealing mode ------------------------------------------------------------------------------ Oil seal
Valve guide
Inside diameter ----------------------------------------------------------------------------- 8 mm
Outside diameter -------------------------------------------------------------------------- 13 mm
Sealing of valve guide with cylinder head --------------------------------------------- H7/u6
Protruding length of the valve spring against the bottom of the groove ----------- 39.7 mm
Double valve spring * outside

Installation length ------------------------------------------------------------------------- 38.04 mm
Load under installation length ----------------------------------------------------------- 111 N
Number of effective coil winding ------------------------------------------------------- 4.25
Number of shock-absorbing coil -------------------------------------------------------- 6.25
Turning direction of shock-absorbing coil ---------------------------------------------- Right
Valve spring
Installation length ------------------------------------------------------------------------- 38.04 mm
Load under installation length ----------------------------------------------------------- 56 N
Number of effective coil winding -------------------------------------------------------- 6.75
Number of shock-absorbing coil --------------------------------------------------------- 8.75
Turning direction of shock-absorbing coil ----------------------------------------------- Right
Tappet, valve push rod

Diameter of tappet seat --------------------------------------------------------------------- 28 mm
Diameter of valve push rod ---------------------------------------------------------------- 8 mm
Diameter of tappet hole on cylinder block -----------------------------------------------14 mm
Clearance of tappet hole on cylinder block with tappet hole ---------- (0.016 ~ 0.052) mm
Rocker arm shaft

Outside diameter --------------------------------------------------------------------------- 18 mm
Rocker arm and bushing

Diameter of original mounting hole of bushing ---------------------------------------- 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 -------------------------------- 0.016 ~ 0.052 mm
Maximum allowable clearance of rocker arm's bushing with shaft ------------------- 0.15 mm
Camshaft
Diameter of Journal 1 ---------------------------------------------------------- 46 mm
Clearance of all journals ------------------------------------------------------- 0.025 ~ 0.085 mm
Cam lift:
Intake valve ---------------------------------------------------------------------- 6.25 mm
Exhaust valve -------------------------------------------------------------------- 6.25 mm
Maximum allowable ellipticity and wear of journal ------------------------ 0.22 mm
Axial clearance:
Production limit -------------------------------------------------------------------- 0.08 ~ 0.25 mm
Maintenance limit ----------------------------------------------------------------- 0.40 mm
Camshaft gear:
Number of teeth------------------------------------------------------------------ 56
Diameter of hole ----------------------------------------------------------------- 34 mm
Outside diameter of camshaft hub -------------------------------------------- 123.19 mm
Clearance fit of the gear with the hub ----------------------------------------- H7/js7
3. Disassembly of valve train
3.1 Disassembly of cylinder head cover
Remove the Nut A and the Bonded Sealing

Washer B on the 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 shaft
support and Fixing Bolt B, and take out the
rocker arm bracket assembly.
A - Valve train assembly
B - Fixing bolt
C - Through bolt of rocker shaft support

3.3 Disassembly of valve rocker arm
Remove the Snap Ring J at both ends, the Nut F,
the Valve Adjuster E, and then disassemble the
Front Rocker Arm Bracket A, the Valve Rocker
Arm D, the Sleeve G, and the Rocker Arm Spring
from the rocker arm shaft.
A - Front 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
L - Rocker arm bracket
J - Snap ring
3.4 Disassembly of the intake and exhaust

manifolds
Remove the exhaust manifold bolts, the Exhaust
Manifold A and 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 manifold gasket
F - Intake connecting manifold
G - Intake manifold gasket
3.5 Disassembly of fuel injector assembly
Remove the Joint A of fuel injector's high-

high
pressure fuel pipe and the Bolt B of fuel injector.
A - Joint of high-pressure
pressure fuel pipe
B - Fuel injector bolt
Disassembly of fuel injector

A - Fuel injector
3.6 Disassembly of cylinder head
Remove the Cylinder Head Bolt A and the

Cylinder Head Gasket B.
A - Cylinder head bolt
B - Cylinder head gasket
Note: Loosen them gradually and diagonally.
Tightening sequence for cylinder head bolts
The purpose is to apply even stress on the

cylinder head and cylinder gasket, and put them Note: Mark on the valve head to ensure that the
properly to avoid deformation. Remove the valve can be installed on its original position
cylinder head and place it on a flat surface that
when it is used again.
will not damage the cylinder head.
3.7 Disassembly of intake and exhaust valves
Tool: valve spring compression tool

Compress the valve spring and disassemble the
locking plate by the valve spring compression
tool and corresponding joints.
Remove the Valve Collet A, Upper Seat B of
valve spring, Outer Valve Spring C, Inner Valve
Spring D, Valve Oil Seal E, Valve Guide F, Intake
Valve Seat G, Exhaust Valve Seat S, Intake Valve
H and Exhaust Valve T.
A - Valve collet
B - Upper seat of valve spring
C - Outer valve spring
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
3.8 Disassembly of camshaft
Remove the Bolt B and the Camshaft Timing
Gear A.
A - Camshaft timing gear
B - Bolt
Note: Use the special tool of puller.
B
A
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 - Camshaft
B - Rear bushing of camshaft

D
C - Middle bushing of camshaft
B
D - Front bushing of camshaft
B
4. Assembly of valve train
Note:
Clean the cylinder head carefully before assembly.
Replace the fittings before the bowl type plug is
assembled to ensure good sealing. A B
A - Cylinder head
B - Bowl type plug
4.1 Assembly of intake and exhaust valves
Assemble the Intake and Exhaust Valve Guide F

firstly, then the Intake Valve Seat G and Exhaust
Valve Seat S, and the Intake Valve H, Exhaust
Valve T, Valve Oil Seal F, Inner Valve Spring D,
Outer Valve Spring C, Upper Seat B of valve
spring, finally the Valve Collet A.
A - Valve collet
Install the four groups of intake and exhaust B - Upper seat of valve spring
valves properly according to the above
installation requirements. E - Valve oil seal seat
F - Valve guide
Note: Install the valve collet by special tools to
S - Exhaust valve seat
avoid damaging the parts. Replace the valve T - Exhaust valve
H - Intake valve
collet with a new one if necessary.
Assembly of valve spring

Replace the valve spring (with cylinder head If the rocker arm assembly has been
installed) disassembled, the top dead center of the piston
can be found as shown on the right.
Special tools:
valve spring compression tool
Stud joint
Positioning screw joint
Note: The replacement of single cylinder valve

spring is shown below.
Warn! Wear eye protection mask during
operation.
1) For details of disassembly, see Section 3 of
this chapter.
2) Rotate the crankshaft along the normal
direction of rotation until the corresponding
cylinder intake valve is opened, and the exhaust
valve is not completely closed. In this position,
the piston is very close to the top dead center.
3) For disassembly of the rocker arm assembly,
see Section 3.3 of this chapter.
4) Install 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 crankshaft when
removing the valve spring.
6) Loosen the valve spring compression tool and
remove the valve spring cap and valve spring.
7) Install new valve springs. If two springs are
installed, the closed shock absorbing coil shall
face the cylinder head.
8) Install the valve spring cap.

Note: Be sure to compress the spring accurately
and positively, otherwise the valve stem will be
damaged.
9) Install the valve spring compression tool to
compress the valve spring and install the locking
plate, then remove the valve spring compression
tool.
4.2 Assembly of intake and exhaust manifolds
Assemble the exhaust manifold gasket and

exhaust manifold, then tighten them with spring
washer and bolt.
Assemble the intake manifold gasket and intake

manifold, and fasten them with bolts, then install
the intake manifold gasket and intake connecting
manifold in sequence.
Assemble the front and rear lifting lugs, and

fasten them with bolts.
Note: Do not use adhesive when installing the

exhaust manifold.
A - Exhaust manifold
B - Exhaust manifold gasket
C - Lifting lug
D - Intake manifold
E - Intake connecting manifold gasket
F - Intake connecting manifold
G - Intake manifold gasket
4.3 Assembly of cylinder head gasket
Install two Cylinder Head Locating Sleeve B, and

then the Cylinder Head Gasket A.
A - Cylinder head gasket B - Locating sleeve
Note:
ote: Before installing the new cylinder head
gasket, check whether it is damaged or deformed.

4.4 Assembly of cylinder head
Thoroughly clean the cylinder head before

assembly, and check whether it has cracks, then
carefully inspect the valve seat and the hole of
fuel injector.
Check whether the valve seat is worn or damaged.
According to the position of locating sleeve,

install the cylinder head to the upper end of the
t
engine body, and screw the Cylinder Head Bolt A
according to the hole.
Note:
Tighten it gradually and diagonally. A
The purpose is to apply even stress on the
cylinder head and cylinder gasket, and put them
properly to avoid deformation.
A - Cylinder head bolt
Press the locating pin into the cylinder before

installing the cylinder head to prevent the
cylinder head gasket from being damaged. Do not
use adhesive when installing the cylinder head
gasket.
Before assembly, clean the bottom of the cylinder

cylinde
head and the top of the cylinder to ensure that
there are no chips in the cylinder.
Tighten the cylinder head bolt (14-M12)

(14 with
digital torque wrench (16mm sleeve).
○
A
A- Push rod
Place the push rod into the tappet seat properly.
----------145 ~ 155N.m
Tightening torque ------------------
4.5 Correction of valve seat
Special tools:
Intake valve seat reamer
Exhaust valve seat reamer
Guide rod for use with valve seat reamer
Handle kit for use with valve seat reamer
1) Install a new valve guide before any action is

taken on the valve seat.
2) Install the guide rod into the valve guide and
tighten it.
3) Select the corresponding reamer, adjust the
reamer blade to the diameter of the 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 clockwise to cut as
little as possible and ensure the good condition of
valve seat.
5) After the valve seat is reamed, remove the
reamer & guide rod, and the chips around the
valve seat and guide rod.
6) Install the valve and gently grind the valve and
valve seat.
7) Check if the valve depth is within the limit.

Note: If the valve seat is severely damaged or
worn, and is difficult to be corrected, the valve
seat insert can be installed.
4.6 Camshaft assembly
Clean the bearing holes with white silk before

D
assembly, then check the camshaft bushing hole
B
for scratches, dust or oil stains. Especially, do not
damage the inner hole of the camshaft bushing,

A
because the bushing will not be processed after
assembly. After the camshaft bushing is pressed C
in, the bushing fuel hole 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 of the cylinder
block, it shall be reworked. The mating data of
camshaft bushing hole is -0.178 mm ~ -0.102 mm.
A - Camshaft
B - Rear bushing of camshaft B

A
C - Middle bushing of camshaft
D - Front bushing of camshaft
Assemble the camshaft timing gear with other
timing gears. Note that assemble the timing gears
according to the marks.
A - Camshaft timing gear
B - Bolt
4.7 Assembly of valve spring
Compress the valve spring and disassemble the
locking plate by the valve spring compression
tool and corresponding joints.
Installed them o the original position according to
the position marked at the time of disassembly. A

B
Install the Intake Valve Seat G, Intake Valve
C
Guide F, Valve Oil Seal Assembly E, Inner Valve
Spring D, Outer Valve Spring C, Upper Seat A of

D
valve spring, and Valve Collet B on the intake
valve in sequence.
E
The assembly of the exhaust valve is the same as
that of the intake valve.

F
Pay attention to distinguish the intake valve with
exhaust valve. The big end of intake valve is
larger than that of the exhaust valve.
A - Upper seat of valve spring

B - Valve collet
E - Valve oil seal assembly
F - Intake valve guide
H - Intake valve
Inspection
Tools:
Depth gauge
Dial gauge
1) Before removing the valve spring, check the
depth of the valve under the cylinder head.
2) Clean the valve head and the bottom of the
cylinder head.
3) Place the depth gauge on the surface of
cylinder 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 same position with a new valve. If
the valve depth is over-limit again and equipped
with a valve seat insert, replace the insert.
6) When the valve seat insert is not installed,
process the bottom of the cylinder head to reduce
the valve depth, or install the insert instead.

4.8 Assembly of valve rocker arm assembly
According to the process requirements, install the

rocker arm shaft into the front rocker arm bracket
firstly, then the Valve Rocker Arm D, Valve
Rocker Arm Spring H, Valve Rocker Arm D,
Rocker Arm Bracket E and Sleeve G in order.
Finally, locate them with the snap ring after the
four groups are respectively installed properly.
Screw the rocker arm bracket into the set screw
scre
of rocker arm shaft (double-end
end stud 5-M8)
5 and
tighten the nut (5-M5).
A - Front 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
4.9 Valve rocker arm assembly
Install the rocker arm shaft assembly to the

corresponding positions on the cylinder head, and
then fix each rocker arm bracket with Bolt A.
A - Fixing bolt of rocker arm bracket
Tighten each bolt (10-M8)

M8) of rocker arm bracket
with 13mm socket wrench or ring spanner.
A - Through bolt of rocker arm shaft support
Tightening torque ---------------- 21 ~ 25 N.m

Inspection
Clean and inspect all parts for wear or other
damage. Check the clearance of the rocker arm
on the rocker arm shaft. If the clearance is greater
than 0.13 mm, replace 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 arm, and push the bushing properly.
3) Extend the bushing on the rocker arm to keep a
clearance of 0.03/0.09 mm from the rocker arm
shaft. Thoroughly clean the bushing and check
for any chips in the fuel hole.

4.10 detection for valve guide clearance
Check whether the valve guide is worn:

The maximum clearance between the intake
valve stem and the guide hole is 0.13 mm, while
that between the exhaust valve stem and the
guide hole is 0.15 mm. If the clearance exceeds
the limit after a new valve is installed, a new D
valve guide must be installed. A
It is recommended to check the valve guide B E
clearance as follows:
1) Put a new valve into the new valve guide.
2) Place the dial gauge with the magnetic base on
the surface of the cylinder head.
C
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 at this position, zero the dial gauge.
4) Put the valve radially across the cylinder head
axis and toward the gauge. Record the gauge
reading. If the measured data is equal to or
greater than the following data, a new valve
guide must be installed.
The maximum allowable clearance is as follows
when the valve is lifted for 15 mm:
Intake valve guide: 0.24 mm
Exhaust valve guide: 0.32 mm
A - Dial gauge
B - Gauge
C - Valve head
D - Valve guide
E - Maximum clearance between the valve stem
and the guide hole
4.11 Adjustment of valve clearance
Special tools:
Feeler gauge
A - Feeler gauge
A
Adjust the valve clearance with a feeler gauge, A - Adjusting screw
open end wrench (10 mm), and slotted B - Adjusting nut
screwdriver.
The working order of the four-cylinder engine is

1-3-4-2, and the adjustment sequence is double -
exhaust - double - intake.
How to find the top dead center of Cylinder 1 is
shown below:
There is an pointer on the crankshaft pulley and
the gear chamber. Align the pointer to see if the
Cylinder 1 moves. If one valve moves slightly, it
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
- double - intake.
That is, adjust the intake and exhaust valves of
Cylinder 1.
Adjust the exhaust valve of Cylinder 3.
Adjust the intake and exhaust valves of Cylinder
4.
Adjust the intake valve of Cylinder 2.
When the adjustment is completed, rotate the

flywheel one turn, then adjust the intake valve of
Cylinder 3 and the exhaust valve of Cylinder 2.
Specifications:
Intake valve (cold): 0.30 mm
Exhaust valve (cold): 0.35 mm
4.12 Assembly of fuel injector
Tightening torque -------------- 58 ~ 71 N.m
Assemble the fuel injector
A
A - Fuel injector
Install the Hold-down Bolt B to the fuel injector,

tighten the 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 whether the fuel injector works normally
before assembly. Refer to the “Part II Fuel
Injector Atomization” for specific test standards.

4.3 Assembly of cylinder head cover
Install the cylinder head cover gasket and cylinder head cover, bonded sealing washer, and cylinder head
cover nut.
A - Cylinder head nut

B - Bonded sealing washer
Tighten the cylinder head cover nut.
Tool: 10 mm socket wrench
Tightening torque ----------- 21 ~ 25 N.m
Connect the fuel return pipe to the fuel injector, and fasten it with a spring clamp.
A - Fuel return pipe

B - Spring clamp
Chapter 2 Disassembly and Assembly of Crank Linkage Mechanism
Special tools:
16/19 open end wrench, 13 mm socket wrench, 18 mm socket wrench, digital torque wrench and adjustable
torque wrench
Connecting rod bolt N·m 60 ~ 70
Main bearing bolt N·m 140 ~ 160

factory.
Piston ring - naturally aspirated engine

The first air ring ------------- Barrel-faced ring, with chamfer at the top of the inner surface
The second air ring ------------- Cone-faced ring, with cast iron
Oil ring ------------------------------------------------ -------- YH11 chrome-copper alloy cast iron
Width of the first ring --------------------------------------------- ------ 2.5 mm
Width of the second ring --------------------------------------------- - 2.5 mm
Width of the third ring --------------------------------------------- ----- 5 mm
Clearance of the first ring in the slot -------------------------------- 0.05 ~ 0.09 mm
Clearance of the second ring in the slot --------------------------- 0.03 ~ 0.07 mm
Clearance of the third ring in the slot ------------------------------- 0.03 ~ 0.07 mm
Closed clearance of 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 bearing shell cap and connecting rod -------------------- Bolt pin
Diameter of original mounting hole of big end -------------------------- 58 mm
Diameter of original mounting hole of small end ----------------------- 32 mm
Center distance --------------------------------------------------------------- 155 mm
Connecting rod shaft shell

Naturally aspirated engine ------------------------------Steel back, aluminum/tin materials
Width of connecting rod bearing shell ------------------------------------ 26 mm
Thickness of connecting rod bearing shell ------------------------------- 2 mm
Piston pin - naturally aspirated engine

Type ------------------------------------------------- ------------------------- Full float
Outside diameter------------------------------------------------------------- 28 mm
Clearance fit in the piston sleeve ----------------------------------------- 0 ~ 0.018 mm
Small end bushing - naturally aspirated engine

Type ------------------------------------------------- ------------------------- Full float
Outside diameter----------------------------------------------------------- 32 mm
Inside diameter--------------------------------------------------------------- 28 mm
Clearance between the small end bushing and the piston pin --------- 0.02 ~ 0.042 mm
Crankshaft
Diameter of main journal ---------------------------------------------------￠65 mm
Maximum wear of journal and crank pin ------------------------------- 0.22 mm
Width of main journal ------------------------------- 31 mm
Diameter 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 --------------------------------------- R73 mm
Crankshaft gear
Number of teeth------------------------------------------------------------------ 28
Diameter of hole ---------------------------------------------------------------- 38 mm
Diameter of camshaft gear hub ------------------------------------------------- 63.59 mm
Transition fit of gear on the crankshaft ---------------------------------------- H7/h6
3. Disassembly of crank linkage mechanism
3.1 Disassembly of connecting rod
Remove the Connecting Rod Bolt A from the

crankshaft, the Connecting Rod Body D and
Connecting Rod Bearing Shell C, then
disassemble the piston connecting rod assembly
from the cylinder.
A - Connecting rod bolt

B - Connecting rod cap
D C
C - Connecting rod bearing shell
B A
D - Connecting rod body
Note: After disassembly, place them neatly in

order. In addition, cross assembly is strictly
prohibited when assembling the connecting rod
body and connecting rod cap. Check whether the
connecting rod bushing shell is worn and
deformed, and whether the connecting rod body
is deformed.
3.2 Disassembly of piston ring and connecting

rod
Remove the piston ring with a suitable piston ring

expander, and store the piston ring with the
corresponding piston.
Disassemble the Piston Ring Assembly A,

Retaining Ring B for hole, Piston Pin F, and
Connecting Rod Body D from the Piston C, then
remove the Connecting Rod Bushing E.
F
A - Piston ring assembly
B- Retaining ring for hole E
C- Piston
E - Connecting rod bushing A
F - Piston pin
B C
D
When removing the piston pin, push the piston
pin by hand. If the piston pin is too tight, heat the
piston to 40/50 ℃ (100/120℉) for removing the
piston pin.
Put the old connecting rod bushing with a

suitable joint.
Note: Check the piston ring for wear during

disassembly, and replace it if necessary.
Remove the connecting rod bushing with special

tools to avoid damage.
3.3 Disassembly of crankshaft
Lift the engine parts, crankshaft and flywheel to

the pallet, turn the joint surface of oil pan up,
and turn the front surface forward.
1) Disassemble the rear transmission parts of the
engine;
2) Disassemble the flywheel and the flywheel
housing;
3) Remove the set screw and cap screw on the
housing, the housing and seal assembly. A B C D E F G
4) Check whether the main seal lip is worn or

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 cap: Loosen the
main bearing cap bolt to make it separate from
the threaded hole of the engine, hit the two sides
of the bearing cap with a hammer, remove all the
main bearing caps, and put the main bearing caps,
bolts, upper and lower main bearing shells and
thrust bearings together on the workbench.
A - Body
B - Thrust bearing
C - Upper bearing shell
D - Crankshaft
E - Lower bearing shell
F - Bearing cap
G - Main bearing bolt
3.4 Disassembly of cylinder liner A - Handle

B - Screw
Special tools: C - Bearing
Disassembly/replacement tool for cylinder liner D - Special tools
E - Cylinder liner
F - Joint
When many cylinder liners are disassembled, or
when the cylinder liner is installed tightly, the
press machine shall be used. When only a single
cylinder liner is removed, or when the crankshaft
is held in the installation position, manual tools
can be used.
1) Discharge the lubricating oil, and remove the B

lubricating oil pan.
2) Remove the cylinder head assembly.
A
3) Disassemble the piston and connecting rod
assembly. C
4) Rotate the crankshaft to reach the cylinder
liner and protect the crank pin.
5) Place the Tool D on the top surface of the D
cylinder, and put it in the center of the Cylinder
Liner E to ensure that the tool base does not press
against the top of the adjacent cylinder liner E
flange.
6) Place the Bearing C in the groove at the top of
the tool, and make the plane of the bearing face
the bottom of the groove.
7) Install the Screw B through the top of the
bearing and the tool, put the Handle A in the
groove on the top of the bearing, adjust the screw F
at this position to let its end lower than the
bottom of the cylinder liner, install the Joint F on
the screw, put it against the bottom of the
cylinder liner, block the two lugs on the top of the
joint on the screw plane, install the washers and
nuts and fasten the nut to the joint.
8) Lubricate the handle ratchet and screw with

lubricating oil or equivalent, operate the handle,
and pull the cylinder liner from the top of the
cylinder block.
The connecting rod bushing shall be assembled

4. Assembly of crank linkage mechanism
by professional and technical personnel other
than other personnel in secret.
4.1 Assembly of connecting rod bushing
Inspection:
◆ Check whether the connecting rod is deformed.

Note: The big and small end bearing holes of the
connecting rod must be straight and parallel. The
hole shall not exceed the limit of +/- 0.25 mm
after checking on both sides of the connecting rod
axis. After installing the small end bushing, the
limit is +/-0.06 mm.
◆ Check whether the small end bushing is worn
or damaged, and replace it with new one if
necessary.
◆ Clean the connecting rod holes and clear all
sharp edges.
Install the Connecting Rod Bushing B to the B
small end of the connecting rod.
A - Connecting rod body

B - Connecting rod bushing
A
The installation process of Connecting Rod

Bushing B is shown below:
Replace the connecting rod bushing --- squeeze
the bushing hole ---- bore the bushing hole ------
grind the bushing hole. It is important to ensure
that the center distance from the small end
bushing hole and the big end base hole of the
connecting rod meet the requirements, and realize
the positioning boring of the bushing hole.
Press in the new connecting rod bushing, and

ensure that the lubrication holes in the bushing
are aligned with and on the same side with the
lubrication holes on the top of the connecting rod.
4.2 Assembly of piston pin temperature.
Inspection:
◆ Check the fit of the piston pin to the small end
If using the original piston, install it on the
bushing and the wear of the piston pin.
correct connecting rod and on its original cylinder.
Clean the piston pin and the small end of the
connecting rod before assembly, and lubricate
them with clean lubricating oil.
Preparation before assembly

◆ Remove all carbon deposits from the top of
the piston.
◆ Lubricate the piston pin bushing with clean
lubricating oil and push the piston pin into the
piston. If the piston pin is tightly installed, heat
the piston to 40/50 ℃ (100/120 ℉ ) before
installing the piston pin.
Put the Piston Pin 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
C
without jamming.
A - Piston
B - Connecting rod body
D A
C- Piston pin
B
D - Retaining ring
Install the new snap ring in the groove of the

other piston pin bushing properly and correctly.
Note:
When the piston and the connecting rod are
assembled, the direction cannot be reversed, and
the marks on them shall be noticed.
The fitting clearance between the small end
bushing of connecting rod and the piston pin is
0.0075 ~ 0.0125 mm.
The fitting clearance between the piston seat hole
and the piston pin is -0.0025 mm at normal
4.3 Assembly of piston ring assembly
Check the accuracy of the piston and related

components of piston ring before assembly.
Apply a proper amount of lubricating oil to the
piston and ring groove.
Install the piston ring with a suitable piston ring

expander.
Install the Piston Ring B onto the Piston A.
A - Piston
B - Piston ring
B
Installation order:
Oil ring - the second air ring - the first air ring A
In order to avoid leakage of combustible mixture

from the opening gap of the piston ring, the
opening directions of all air rings shall be
staggered by 90 to 120° during assembly, and the
position of the piston pin hole shall be avoided.
When installing the piston ring, its marked side

must face the top of the piston.
Note: The opening of the piston ring shall not

exceed 8 times the radial thickness during
installation.
4.4 Assembly of cylinder liner
Note: Do not hit the cylinder liner with a hammer.

A
B
C
D
E
1) Thoroughly clean the mounting hole of the
cylinder liner.
2) Thoroughly clean the outer surface of the
cylinder liner with a safe solvent.
3) Insert the Cylinder Liner E into the original
mounting hole vertically, install the Joint D to the
top of the cylinder liner, put the joint shoulder 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, joint and
F
cylinder liner until the handle touches the bearing
groove. In this position, adjust the screw to make
its end lower than the bottom of the cylinder
block.
5) Install the Joint F onto the screw, put the joint
plane against the bottom surface of the cylinder
block, install the washer and nut, place the screw
in the center of the cylinder liner, and fasten the
nut to the joint.
4.5 Assembly of crankshaft rotation.

Detection of axial
xial clearance: Mount the magnetic
Overview stand on the front surface of the engine, put the
The crankshaft is made of ductile iron. The dial gauge head in touch with the front surface of
crankshaft of the 4-cylinder
cylinder engine has five main the crankshaft, zero the dial gauge, push the
journals, that is, five pairs of main bearing shells. crankshaft parts back and forth by hand, and
check the rotation range of tthe dial gauge pointer,
The axial clearance is controlled by two semi- semi that is the axial clearance. The axial clearance of
thrust bearings on both sides of the main bearing. the crankshaft is 0.085 to 0.275 mm.
Lift the engine parts, crankshaft and flywheel to A - Main bearing cap B - Main bearing cap bolt
the pallet, turn the joint surface of oil pan up, and Torque of main bearing shell cap bolt ------- 140
turn the front surface forward. Assembly of main ~ 160 N·m
bearing shell: Install the upper and lower
bearings of the main bearing shell into the main
bearing hole and main bearing cap with white
nylon gloves, and align the locating lip with the A B C D E F G
locating groove.
Assembly
sembly of valve tappet: Install the tappet to the
corresponding position of the engine. Assembly
of crankshaft parts: Lift the crankshaft to the
bearing housing of the engine, and lubricate the
journals of the crankshaft with clean engine oil.
Assembly of thrust bearing: Install the upper
thrust bearing to the main bearing housing bore at
the rear of the crankshaft, and the lower thrust
bearing to the fifth gear, then assemble the
crankshaft gear and the crankshaft pulley.
A - Engine B - Thrust bearing

C - Upper bearing shell D - Crankshaft
E - lower bearing shell F - Bearing cap G - Main
bearing bolt
Main bearing cap: Apply a proper amount of
clean engine oil to the thread section and the
hexagon head bearing surface of the main bearing
cap bolt, install the main bearing cap and main
bearing cap bolt on the main bearing housing
according to the sequence number, and hit each
main bearing cap to the main bearing housing by
the hammer, and screw the main bearing cap bolt
for 2-3 threads by hand.
Tighten the main bearing cap bolt with digital
socket wrench.
After aligning the bolts, fasten all the main
bearing cap bolts.
After the crankshaft is assembled, turn the
crankshaft by hand to detect the flexibility of
4.6 Assembly of piston connecting rod

assembly to cylinder liner
Special tools:
Piston replacement tool
Apply a proper amount of cleaning oil around the

cylinder bore before assembly.
Place the piston replacement tool on top of the

corresponding cylinder. The tapered bore on the
tool is used to compress the piston ring when the
piston and connecting rod assembly are installed.
Turn the small end of the tapered bore toward the
surface of the cylinder block. B
A
C
Hold the piston connecting rod assembly by hand,

turn it toward the top of the piston, stagger the
openings of all 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, and lock the big
end bore of the connecting rod body on the
crankshaft connecting rod journal. Rotate the
crankshaft, and install the piston connecting rod
assembly into the cylinder liners of Cylinder 1
and 4.
Connecting rod cap: Apply a proper amount of

clean engine oil to the thread section and
supporting surface of the connecting rod bolt;
install the connecting rod cap according to the
matching mark; screw in the connecting rod bolt
for 2 ~ 3 threads by hand; and then pre-tighten it
with a digital socket wrench.
A - Cylinder liner
B - Piston connecting rod assembly
C - Special piston assembly tool
4.7 Assembly of connecting rod bearing shell

and connecting rod cap
Clean the connecting rod bearing shell and

connecting rod cap before installation, install the
bearing shell on the bearing cap, put the locating
lug into the groove properly and correctly,
lubricate the bearing shell with clean lubricating
oil, install the bearing shell cap, ensure the
assembly number on the bearing shell cap is
identical with and on the 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 tighten it to the
recommended torque.
Locating by the locating lip of the Connecting

Rod Bearing Shell C: Install the Connecting Rod
Bearing Shell C on the Connecting Rod Body D
and Connecting Rod Cap B, mount the
Connecting Rod Body D and the Connecting Rod
Cap B on the crankshaft journal, and fix the
Connecting Rod Cap B with the connecting rod
bolt.
A - Connecting rod bolt

B - Connecting rod cap
C - Connecting rod bearing shell
D C
B A
4.8 Fastening of connecting rod bolt
Turn the body for 90°, and turn the bottom of the
engine up.
Rotate the crankshaft to make the pistons of the
Cylinder 2 and 3 at the top dead center, align the
connecting rod bolts of the Cylinder 1 and 4 by
the digital socket wrench, tighten the two bolts on
the same connecting rod cap synchronously; turn
the crankshaft
kshaft to make the pistons of the Cylinder
1 and 4 at the top dead center, fasten the
connecting rod bolts of the Cylinder 2 and 3.
When the tightening machine fails, tighten the
bolt by a manually operated adjustable torque
wrench. The tightening sequence is as shown.
After tightening the bolts, turn the crankshaft to
check the flexibility of the rotation.
Torque of connecting rod bolt ---- 60 ~ 70 N.m

4.9 Inspection of the height of the piston at the

cylinder
Special tools:
Piston height tool

Dial gauge
Place the piston height tool on the top surface of

the cylinder 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 piston pin axis, turn the crankshaft
to make the piston at the highest point, and record
the reading on the dial gauge as this moment.
Height of the piston on the top surface of the

cylinder -------------- 0.35 mm
Chapter 3 Cooling System
Note:
Special tools:
16/19 open end wrench
8 mm socket wrench
13 mm socket wrench
Digital torque wrench
Connection of the pump to

the cylinder head and the N·m 25
body
Water pump
Type ------------------------------------------------- ------------------------- Centrifugal, belt drive
Diameter of impeller bore ------------------------------------------------ 15 mm
Outside diameter of impeller shaft -------------------------------------- 15 mm
Interference fit of impeller on the crankshaft ------------------------- U7/h6
Clearance between the impeller and the pump ----------------------- 0.4 ~ 0.6 mm
Diameter of bearing ---------------------------------------------------------- 30 mm
Diameter of bearing hole ---------------------------------------------------- 15 mm
Interference fit of bearing on the pump ---------------------------------- U7/h6
Thermostat type -------------------------------------------------------------- Wax thermostat

3. Disassembly, assembly and adjustment of cooling parts
3.1 Composition of cooling parts
A - Bolt B - Washer C - Cooling fan D - fan pad E - Water pump pulley F - Bolt G - Water pump H -
Bolt I - Thermometer cover J - Thermostifier cover gasket K - Thermometer L - Water pump gasket M -
Bolt N - Bolt O - Water pump flange pad P - Water pump flange gasket
3.2 Disassembly of fan and pulley
Note:
When disassembling the 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
B
Remove the Bolt B, Fan A, Fan Pad C and Pulley

D.
D
C
A - Fan
B - Bolt
C - Fan pad
D - Pulley B
E - Water pump assembly

E
A
3.3 Removal of pump assembly
Remove the Bolt A and Thermostat D.

Remove the Bolt F, water pump assembly, Water
Pump Gasket E, Water Pump Flange Pad G, and
Water Pump Flange Gasket H.
A - Bolt
B - Thermometer cover C - Thermostat cover
gasket D - Thermometer E - Water Pump
Gasket F - Bolt G - Water pump flange pad H -
Water pump flange gasket
Note: It is prohibited for non-professionals

professionals to
assemble the water pump assembly.
Remove the nut, and take out the water pump

bearing and water seal.
Remove the pump impeller with a puller
carefully to prevent damage to the impeller.
Disassemble the water seal carefully to avoid
damage.
A
B F
It is prohibited to assemble the water pump C D
A E
bearing with non-professional
professional tool.
A - Water pump housing

B - Bolt
C - Washer
D - Water pump bearing
E- Water seal
F - Pump blade
4. Assembly and adjustment of cooling parts ◆ The drain hole under the pump shall be
unobstructed.
4.1 Installation of pump assembly
◆ When installing, pay special attention to the

Clean the surface of the cylinder head and the
axial clearance and radial sealing clearance
coolant and lubricating oil channels, and clean
the water jacket with a special solvent according between the pump impeller and the pump
to the manufacturer's instructions. housing, and the lubrication conditions of the
bearing.
The installation sequence of the water pump

assembly is in the reverse order of its
disassembly sequence. However, in addition to
replacement of the gasket and sealing ring,
inspect and measure the cleaned parts, and
replace the old part with a new one if its wear is
out of tolerance, and carry out the assembly after
all parts pass the inspection.
◆ The fitting clearance between the pump shaft A

and the bearing is 0.010 to 0.012 mm. The B F
C D E
overhaul tolerance 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 impeller is assembled, it shall

be higher than the pump shaft by 0.1 to 0.5 mm. A - Water pump housing
B - Bolt
◆ After the pump is assembled, the clearance C - Washer
between the outer edge of the impeller and the D - Water pump bearing
inner cavity of the pump housing is generally 1 E- Water seal
mm; and the clearance between the impeller and F - Pump blade
the pump cover is 0.075 to 1.00 mm.
◆ The bolts and nuts of each part shall be

tightened according to the specified torque, and
locked reliably.
4.2 Assembly of other parts of the pump
The installation steps of the pump assembly,

thermostat and fan, etc. are in reverse order with
disassembly steps.
Belt tension--------------------98N
Chapter 4 Lubrication System
Note:
Introduction of special tools

13 mm open end wrench or ring spanner
Assembly of the engine oil

N.m 25
pump to the body
factory.
Lubricating System
Engine oil pump ------------------------------------------------------------- Differential rotor type
Type ------------------------------------------------------------- 1 outer & inner rotors respectively
Clearance between outer rotor and housing --------------------------- 0 ~ 0.047 mm
Clearance between outer & inner rotors ------------------------------- 0.07 ~ 0.18 mm
Axial clearance of rotor assembly ----------------------------------------- 0.06 ~ 0.12 mm
Engine oil filter

Type ------------------------------------------------- ------------------------- Spin-on
Opening pressure of the filter bypass valve ----------------------------- 149 ~ 196 kPa
3. Disassembly of the lubrication parts
3.1 Composition of oil pump assembly
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 engine
properly and correctly.
A - Mounting holes of oil pump B

B - Oil pump
C - Oil pump gasket
D - Bolt
D
C
Assemble the fixing bolts to tighten the oil pump.
A
A - Oil pump
B - Assembly of oil pump gear
Assemble the oil pump gear.
④ Tighten the oil pump nut.
⑤ Assemble the suction strainer at the bottom of the body properly.

⑥ Tighten the fixing bolts for suction strainer.
A - Oil suction strainer

Assemble the oil suction strainer and its gasket
A - Oil suction strainer

B - Oil suction strainer gasket
Chapter 5 Starting System
Introduction of special tools

18 mm socket wrench
2. Torque requirements
Connecting of the starting

motor to the flywheel N.m 80
housing
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 Motor B.
Starting Motor
Chapter 6 Fuel supply system
Note:
Introduction of special tools: 13-16 wrench and 18-21 wrench
Connecting of the fuel

injection pump to the gear N.m 70
chamber
factory.
Fuel injection pump gear

Number of teeth--------------------------------------------------------------- 56
Diameter of hole ------------------------------------------------------------- 50 mm
3. Disassembly and assembly of fuel supply system
3.1 Assembly of high-pressure fuel pipe
Connected with the fuel injector

Install the upper end of the high-pressure fuel
pipe on the fuel injector;
Install the lower end of the high-pressure fuel
pipe on the fuel injection pump.
Connected with the fuel injection pump
3.2 Installation of fuel injector assembly
Connect it to the
fuel return pipe of
the fuel injector.
Tighten it to the
cylinder head.
Connect it to the
high-pressure fuel
pipe
A - Hexagon head bolt

B - Spring washer
C - Plain washer
D - Fuel injector
3.3 Assembly of diesel filter
Installation of diesel filter assembly
Connect it to the outlet

Connect it to the inlet pipe of diesel filter.
pipe of diesel filter.

B - Spring washer
C - Plain washer
D - Diesel filter assembly
3.4 Assembly of fuel injection pump
3.4.1 Assembly of parts of fuel injection pump

B - Spring washer
C - Fuel injection pump gasket
D Tie-plate of fuel injection pump timing gear
E - Fuel injection pump
E - Fuel inlet joint
3.4.2 Installation of fuel injection pump assembly
Inlet pipe of diesel filter High-pressure fuel pipe assembly
Outlet pipe of diesel filter
Fuel return pipe of the

fuel injector
Lubricating oil pipe of fuel injection

pump
A - Fuel injection pump

B - Spring washer
C - Plain washer
D - Hexagon head bolt
Chapter 7 Disassembly, Assembly and Adjustment of Accessories
1. Data and dimensions
factory.
Idler and hub

Number of teeth--------------------------------------------------------------- 53
Diameter of hole ------------------------------------------------------------- 50 mm
2. Disassembly and assembly of gear chamber
Open the gear chamber cover and disassemble

gears A, B, C, D and E in sequence
C
A - Idler
B - Oil pump E
C - Injection pump timing gear D
D - Crankshaft gear
E - Camshaft timing gear B
Note: There are assembly marks on the gears.

Only the gear chamber is assembled according to
the marks can the engine be started normally.
3. Fuel injector
3.1 Maintenance equipment and tools
Note:
Introduction of special tools: Vise
Manual test stand
Ring spanner
Torque wrench
Item Unit Parameter Remark
Fuel injector bolt N.m 40 ~ 60
3.3 Disassembly and assembly of fuel injector
1) During disassembly, use a wrench to loosen the fuel injector's bolts, remove the high-pressure fuel pipe
and the fuel injector return pipe, and take out the fuel injector.
2) Cleaning of nozzle
(1) Clean up nozzle fitting with clean diesel.
Note: Do not touch the mating surface of the nozzle with your fingers.
(2) Check whether the nozzle seat is burnt or corroded. If there is any problem, replace the nozzle assembly.
3) Sliding test
(1) Clean up the nozzle with clean diesel.
Note: Do not touch the mating surface of the nozzle with 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 sink to its original position by its own weight.
(4) Repeat the test, gently rotating the needle valve each time.
If the needle valve cannot slide down smoothly, replace the nozzle fitting.
4. Atomization of nozzle
Poor atomization causes high fuel consumption hole. The test steps and results are described
rate, poor dynamic performance and emission of below.
black smoke. 1) Pump oil several times first and quickly flush
Test conditions: manual fuel injector calibrator, the fuel injector.
external high-pressure fuel pipe, 0# light diesel 2) Slowly press down the oil pumping handle and
Warning: do not place your finger at the injection observe the pressure gauge pointer. The highest
pressure value indicated before the pointer

suddenly drops is the opening pressure of the
injector's needle valve.
If the opening pressure (of the fuel injector) does
not conform to regulations, remove the injector
and replace
ce the gasket at the top of the pressure
spring.
3) Slowly and steadily press down the oil
pumping handle to make the fuel injector inject at
30-40
40 times/min. At this time, the injection shall
be obvious and accompanied by the noise
characterizing the structure
ucture of the nozzle or the
flutter noise of the needle valve.
4) After oil injection starts and ends, there shall
be no accumulated oil on the head of the needle
valve body.
Within 4 seconds when the pump oil pressure is 1
MPa lower than the actual opening pressure, the
pressure drop shall not be greater than 25% of the
actual opening pressure, and at the same time
there shall be no oil leakage at each sealed part.
Press the handle evenly to make the fuel injector
inject 60-80
80 times per minute; the injection shall
be in the form of mist. The spray shall be free of
clearly visible deflection and splashing particles,
continuous oil column and easily distinguishable
uneven concentration.
Part 3 Inspection, Adjustment, Fault Diagnosis and Removal
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 running short of oil or with
excessive oil, which may bring risks to the engine.
2. Checks on engine oil level
Check conditions:
1) Tighten the parking brake
2) PTO neutral position
3) The ignition lock is off
Check steps:
Park the vehicle in a horizontal position and measure the oil level after the vehicle has been off for 5 minutes.
Check the oil level in the oil pan with an oil level gauge. The oil level shall be between the upper and lower
scale lines of the oil level gauge (see Figure 6-2).
If the oil level is lower than the lower scale line, check whether the engine leaks oil, and add oil to the engine
until the oil level gets between the upper and lower scale lines and 1/4 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, and
check the oil level 5 minutes later.
Normal state:
The oil level is between the upper and lower scale lines of the oil gauge,
and slightly lower than the upper scale line of the oil level.
Abnormal state:
1) The oil level is higher than the upper scale line. In this case, the oil level may contact with the crank,
causing oil to flow into the combustor; at such time, blue smoke may come out.
2) The oil level is lower than the lower scale line. In this case, the engine is prone to insufficient oil
circulation, which would result in insufficient lubrication and oil cooling.
Position of upper scale line

Position of lower scale line
3. Checks on level and status of coolant
Glycol antifreeze or soft water, rather than hard water such as river water and well water, shall be used as
diesel engine coolant. When the temperature is lower than -16 ℃ in winter, liquid mixed with 50%
antifreeze/preservative shall be used; otherwise, liquid mixed with 70% water and 30%
antifreeze/preservative shall be used. Even if the temperature is not expected to reach the freezing point,
liquid mixed with 70% water and 30% antifreeze/preservative shall be used for corrosion prevention.
Checks on the amount of coolant in water tank

Check the coolant level in the water tank when the engine is cooling. (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 lines of the water tank. If the level is lower than the
"Low" scale line, open the water storage tank and add an appropriate amount of coolant to raise to the "Full"
scale line. Then close the cover and align the mark on the cover with that on the water tank.
Checks on quality of coolant

① Check whether the coolant is clean. If it is too dirty, replace it with clean coolant.
② Check whether there is rust around the radiator cover and the radiator core.
③ Check the coolant for oil stains.
Checks on the following parts of the cooling system

① Check the cooling system for leaks.
② Check whether the radiator and the hose are damaged or deformed.
③ Check whether the hose clamp is loose.
4. Checks on fan and belt
1) Checks on water pump belt

Check the water pump belt for cracks, cuts, deformation and abrasion. If necessary, check the belt tension.
When the middle part of the belt 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 made.
Belt tension--------98N
2) Checks on fan
① During assembly of the fan, make sure that its
marked side faces outward.
② Check visually whether the fan blades are
damaged.
③ Check whether the fixing bolts of the fan are
tightened.
5. Checks on fuel system
In the fuel system, the fuel flows through from the fuel tank to the diesel filter and the pipeline, then is sent to
the high-pressure fuel pump by the fuel supply pump, and is pumped out by the high-pressure pump; and then
it runs through the high-pressure fuel pipe and is injected into the cylinder by the fuel injector (with pressure
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 injector are under very
high fuel pressure, do not loosen any pipe joint when the engine is running; otherwise, personal injury and
property damage may occur. The pipe joint of the high-pressure fuel system shall only be loosened until the
engine is shut down for at least 10 min and the fuel pressure decreases as a result. Connect the pressure gauge
to measure and check the fuel pressure.
6. Checks on inlet and exhaust systems
1) Air enters the intake manifold through the

air filter and the heater, then enters the air
passage of the 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 the
exhaust valve and is discharged by the
silencer through the exhaust pipe.
Check the intake and exhaust systems for
leaks and ensure that all hose clamps are
tightened.
7. Checks on electrical system
Explosive gas may escape from the storage

battery. To avoid serious personal injury, the
engine compartment must be well ventilated
before operation. Make sure that during each
operation, first disconnect the negative-electrode
(-) storage battery cable, and after everything is
done, connect it. Basic electrical systems of
storage battery, starting motor, generator and key
switch: Check whether 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 system
based on the running condition of the engine. If
any, the system shall be maintained according to Electric system diagram
1. Generator 2. Oil pressure sensor 3. Water temperature sensor 4. Oil pressure
the fault maintenance method of the electrical gauge 5. Water temperature gauge 6. Ammeter 7. Voltage regulator 8. Fuse box
9. Starter relay 10. Starting motor 11. Accumulator motor 12. Circuit key switch
system. 13. Glow plug or air inlet heater
8. Idle test on engine
Engine test is a process in which engine running-

in and performance are tested in an all-round
manner. The running-in process of the engine
allows all parts of the engine to reach final
precision and coordinate with each other.
Performance testing 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 conducted by simulating
dynamometer test.
The dynamometer shall be checked first before
testing. The dynamometer must be able to test the
engine performance when the engine is running
at maximum rotating speed and full power.
Minimum idle speed of engine----------800 r/min

Maximum idle speed of engine -------2,650 r/min
Chapter 2 Working Mechanism
1. Valve train
1.1 Functions of valve train
The cylinder head is used to close the top surface A - Valve rocker arm
of the cylinder to form a combustor and a B - Valve
working chamber together with the cylinder and C - Tappet
the piston. The cylinder head is in direct contact D - Pusher
with hot gas and under bolt pre-tightening force, E - Camshaft
gas pressure and alternating stress. Thus, it shall
be of certain strength and rigidity, cooled
properly, and have flat joint surface to ensure
reliable sealing.
Functions:
When the working cycle of the cylinder requires
the valve to be switched on for air exchange, the
crankshaft will drive the camshaft to rotate
through the transmission mechanism, so that the
convex part of the cam on the camshaft pushes
A
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 compresses the spring. B
When the convex part’s apex of the cam rotates
A
C
away from the tappet, the pushing force on the
tappet is gradually reduced, and the opening
degree of the valve is gradually reduced under the
spring tension until the valve is finally switched E
off. During the compression and power stroke,

D
the valve is tightly switched off under spring
tension.
According to the requirements of the working

cycle and firing order in each cylinder of the
engine, the intake and exhaust valves shall be
switched on and off regularly, so that the fresh air
enters the cylinder in time and the exhaust gas
discharges from the cylinder in time.
1.2 Valve timing
The valve timing, as the actual switched-on

switched on and off time of the intake and exhaust valves, is usually
represented by an annular chart of the crankshaft angle relative to the crank throw positions of the top and
bottom dead centers. Such chart is called valve timing chart.
Switched-on
on intake valve before top dead center 12±3°
Switched-off
off intake valve after bottom dead center 38±3°
Switched-on
on exhaust valve before bottom dead center 50±3°
Switched-off exhaust valvee after top dead center 14±3°
Theoretically, the intake valve of a four-stroke

four stroke engine is on when 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
bottom
tom dead center, and off when the crank throw turns to top dead center. Both intake time and exhaust time
account for 180° crankshaft
rankshaft corner. However, the actual rotating speed of the crankshaft is very high, and
each stroke of the piston is very short. Such short-term
short term intake or exhaust process often leads to insufficient air
inflation or incomplete exhaust, thus reducing the engine
engine power. Therefore, modern engines all adopt the
method of prolonging intake and exhaust time. That means that the switched-on
switched on and off time of the valve is
not exactly the time when the crank throw is at the top and bottom dead centers; instead, a cert
certain crankshaft
angle is advanced and delayed respectively to improve the intake and exhaust conditions, thus improving the
engine power.
For different types of engines, the valve timing also varies due to their different structures and rotating speed.
Reasonable valve timing shall be determined through repeated tests according to the performance
requirements of the engine.
2. Crank linkage mechanism
2.1 Working mechanism
Functions:
Crank linkage mechanism is a transmission mechanism for internal combustion engine to realize working
cycle and complete energy conversion. It is used to transmit power and change motion mode. During
operation, the crank linkage mechanism converts the reciprocating motion of the piston into the rotational
motion of the crankshaft in the power stroke, and outputs power to the outside, while converting the
rotational motion of the crankshaft into the reciprocating linear motion of the piston in the other three strokes,
namely, the intake, compression and exhaust stroke. Generally speaking, the crank 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 conditions:
When the engine works, the crank linkage mechanism directly contacts with hot and high-pressure gas; the
rotating speed of the crankshaft as well as the reciprocating motion speed of the piston are quite high;
meanwhile, the crank linkage mechanism is subjected to chemical corrosion as it contacts with combustible
mixed gas and combustion waste gas, and is hard to be lubricated. Therefore, the crank linkage mechanism
faces rather harsh working conditions, including high temperature, high pressure, high speed and chemical
corrosion.
Working mechanism:
A mechanical device that converts linear motion into rotational motion.
A - Piston
B - Connecting rod A
C - Crankshaft
D - Flywheel D
B
C
2.2 Introduction to components
Composition:
Engine body components: Cylinder block, cylinder liner, cylinder head, cylinder head gasket, oil pan, etc.
Piston connecting rod group:

Piston, piston ring, piston pin, connecting rod, etc.
Crankshaft flywheel group:

Crankshaft, flywheel, etc.
Functions of piston:
Bear the pressure of gas, and drive the crankshaft to rotate through the piston pin and the connecting rod.
Working environment: The piston is under gas pressure and reciprocating inertial force. The piston top is in
direct contact with hot gas and gets 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 function of the oil ring is to scrap off the excess engine oil splashing onto the cylinder wall and coat
an even oil film on the cylinder wall.
Functions of piston pin:

Connect the piston with the connecting rod and transmit the force borne by the piston to the connecting rod,
or vice versa.
Functions of connecting rod:

Transmit the force of the piston to the crankshaft, and convert the reciprocating motion of the piston to the
rotational motion of the crankshaft.
Functions of connecting rod bearing shell:

Protect the connecting rod journal and the connecting rod’s big end hole.
Functions of crankshaft:
Convert the gas pressure from the piston connecting rod group into torque for external output, as well as
drive the valve train of the engine and other auxiliary devices.
Working conditions: Bear gas pressure, inertial force and inertial torque, as well the impact of variable loads.
Functions of 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 power stroke to overcome the resistance in other
strokes, drive the crankshaft linkage mechanism to cross the top and bottom dead centers, ensure the rotation
speed and output torque of the crankshaft to be as even as possible, enable the engine to overcome short-term
overload, and transmit the power of the engine to the clutch at the same time.
3. Cooling system
The function of the cooling system is to keep the

engine within an appropriate temperature range
under all operating conditions.
The cooling system of the diesel engine is a

forced circulation water cooling system, in which
the water pump is used to increase the pressure of
the coolant and force the coolant to circulate in
the engine.
Composition: Water pump, radiator,

radiato cooling fan,
thermostat, supplementary bucket, engine body,
cylinder liner, cylinder head and other accessories.
The cooling system consists of heat radiating water tank, water pump fan assembly, thermostat components
and connecting rubber pipe. The whole cooling system is a forced circulation closed water-cooled system.
1) Cooling water route: When the diesel engine works, the crankshaft pulley drives the water pump to work
through the belt, presses the cooling water into the water cavity of the engine body to cool the cylinder liner,
the engine body and the cylinder head, and then enters the thermostat. When the outlet water temperature is
lower than 70 ℃ , the thermostat is off; then cooling water flows back to the inlet chamber through
corresponding small water pores at the bottom of the cylinder head and the upper plane of the engine body,
and then enters the water pump again to realize small circulation in the engine body. When the outlet water
temperature is higher than 70℃ to 80℃, the thermostat is fully on. At this time, the cooling water flows into
the upper water chamber of the water tank through the thermostat and flows down the radiating pipe to the
lower water chamber. In this process, the cooling water is cooled by the air sucked or discharged by the fan to
realize major circulation.
2) Water pump
Centrifugal water pump is used in this diesel engine.
During use, when the water seal is worn out and the outlet entrance under the water pump body leaks
seriously, the water seal shall be replaced. The outlet entrance is not allowed to be blocked; otherwise water
will enter the bearing, causing the bearing to wear out quickly. If there is too much water 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 water pump oil filler regularly,
usually once after the diesel engine has been running for about 200 hours. The grease filled shall be no more
than 1/3-1/2 of the bearing cavity. Excessive grease will cause the bearing overheat.
3) The thermostat is of corrugated-pipe single-valve type and is installed in the thermostat shell at the water
outlet at the front end of the cylinder head. It contains liquid sensitive to temperature and automatically
switches on/off the valve. The thermostat is 155B type.
When the initial water temperature in the diesel engine does not reach 70℃, the thermostat valve remains off,
and the cooling water begins small circulation in the engine body. When the diesel engine heats up and the
water temperature exceeds 70℃, the thermostat valve is on, and the cooling water begins major circulation.
If there is water flowing out of the water outlet pipe when the water temperature does not reach 70℃ after the
cold-machine diesel engine starts, or if there is no water flowing out of the water outlet pipe when the water
temperature exceeds 70℃, it indicates that the thermostat breaks down and shall be disassembled for
inspection. The thermostat can be inspected by means of heating slowly in water. When the water temperature
reaches 70℃, the thermostat valve is supposed to start to open, and when the water temperature reaches 85℃,
it shall fully open. If the inspection results do not conform to the regulations, the thermostat shall be replaced.
Refrain from removing the thermostat. Too cold cooling water is harmful to the normal operation of the
diesel engine.
4. Lubrication system
The function of the lubrication system is to

continuously input a sufficient amount of
clean lubricating oil to the friction surfaces
of all transmission parts when the engine is
working, and form an oil film between the
friction surfaces to realize liquid friction.
That helps reduce friction resistance, power
consumption as well as wear and tear
suffered by components, making the engine
more reliable and durable.
Lubrication methods:
Force-feed and splash lubrication Schematic diagram of lubrication system
1. Oil filter 2. Oil pump 3. Oil pan 4. Oil filter 5. Idler gear 6. Gear train
Composition of lubrication system:

Oil pump
Engine oil filter
Oil pan
Suction strainer
Lubricating oil circuit
Functions of lubricating oil:

Lubrication - Reducing wear of parts with oil film
Sealing - Preventing gas leakage with oil film
Cooling - Lubricating oil can absorb heat
Cleaning and rust prevention - Taking away metal scraps, impurities and acid contents
Vibration damping and buffering - Buffering vibration with oil film
5. Electrical system
5.1 Introduction to starter
5.1.1 Structural principle of starter
Fork shaft Shifting fork Clamp ring

Fork seat Gasket
Waterproof rubber sleeve Electromagnetic switch
One-way clutch
Rubber gasket
Armature assembly
Stator assembly Carbon brush carrier assembly
Rear cover
Planetary gear
Ball Planetary gear ring
Front end cover
Rubber pad
Planetary shaft collar
Waterproof rubber Waterproof

External friction plate gasket rubber gasket
Shock absorber Bearin Planetary axis Planetary gear ring cover plate
Internal friction plate Bump-type rubber pad

5.1.2 Use and maintenance of starter
1) Precautions for daily use of starter

◆ Check frequently the connection of parts and the tightness of lead wires.
◆ Remove oxides of lead wires and binding posts, and dust 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 time shall not exceed 5 s at a time. Restart the
starter after 2-3 min in case of failure to start it at one time.
◆ After the engine starts, immediately release the start switch to avoid unnecessary idling and reduce wear
of the isolator.
5.2 Structure principle of generator
Brief introduction to AC generator

The principle of the generator, which is a three-phase AC generator, is converting mechanical energy into
electrical energy with rotational magnetic field, then powering the 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 generator
Rectifier diode
Rear bearing Pump seat

Rear end cover
Inner stator coil

Rotor assembly
Regulator
Bearing press plate
Front end cover
Fan impeller
Inner stator core

Framework oil seal
Outer stator assembly Rear end cover

Front bearing Claw pole
Pulley Shaft sleeve
Precautions for use of generator
1. Precautions for electrical wiring

When the motor is in use, it must be connected in parallel with the storage battery, and all lead wires must be
connected firmly and reliably, without looseness or improper connection. The same lead wire cannot be used
for both the vehicle air conditioner and other electrical appliances. The diameter of the lead wire for other
electrical appliances must meet the following requirements: Ф ≥ 6 mm2 when current is 35 A; Ф ≥ 13 mm2
when current is 70 A; Ф ≥ 20 mm2 when current is 100 A; the diameter (Ф) of excitation and signal lead wire
is 0.75-1.5 mm2. The connection point of the output lead of the generator to the storage battery and vehicle-
mounted electrical appliances shall be close to the generator to the greatest extent, which can reduce the
voltage drop. The output end of the motor indicator light, marked with 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, marked with W, can be connected with
rotating-speed signal sensor, relay switch, charging indicator light, etc., with output current of 50 0mA at
maximum. When the tachometer is connected to the speed sensor, the number of claw pairs (6 or 8 pairs) of
the motor rotor must be found out.
2. Precautions for mechanical assembly
• Adjust the adjusting arm appropriately to ensure proper belt tension, and tighten all the fastening
nuts of the motor to the specified torque;
• Ensure that the mounting frame of the motor can meet the requirements for strength and rigidity;
• For motors with a pump, ensure that the air pipe and fuel pipe connected to the vacuum pump are
unblocked.
3. Assembly and drive system
Check whether the fastening bolts of the generator are loose and whether the adjusting sleeve and support
sleeve are complete. Check whether the drive belt reaches the specified tension (20-30 kg). If the drive belt is
too loose and the load of the generator running at high speed is large, the drive belt may slip (with a smell of
burning rubber) and lead to decreased power generation of the generator, and the overheated motor will harm
the service life of the bearing. Excessively tightened drive belt may bring damage to the generator bearing,
cause the rotating rotor core to touch the stator core, or break the hitching 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 generator emits abnormal sound
• The running generator emits abnormal sound: Reason - Internal circulation sound emitting after the
bearing is damaged, the rotating rotor core touches the stator core and the rectifier tube is punctured.
Check whether the drive belt is too tight, whether the generator adjusting sleeve has fitting allowance
and is firmly attached to the generator mounting frame, and whether the generator vibrates normally.
6. Fuel system
6.1. Fuel injector
Working mechanism:
The high-pressure fuel pump sends high-pressure

diesel to the lower end of the needle valve body
through the oil inlet joint and the fuel passage
and acts on the pressure-bearing conical surface
of the needle valve. When 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 high speed in
the form of mist along the gap formed by the
needle valve and the needle valve body. When the
fuel injection pump stops feeding fuel, the
pressure in the annular fuel chamber is reduced,
the high-pressure spring makes the needle valve
fall into the valve body, then the fuel injection
stops.
180°) and check and adjust the valve clearance of

the third
ird cylinder in the same way as above. Then
Chapter 3 Inspection and turn the crankshaft by half a turn (180°) to adjust
Adjustment the valve clearance of the second cylinder. (pay
attention that adjustment through reverse rotation
1. Valve clearance (mm) is not allowed). An alternative method: When the
Reason: first cylinder
der is at the top compression dead
center, eight valves shall be arranged in positive
Insufficient compressing force of cylinder, and sequence (from the first cylinder to the fourth
cylinder). The odd number denotes exhaust valve
black smoke and abnormal noise emitting during
and the double number denotes intake valve.
exhausting.
Adjust the clearance of the 1s
1st exhaust valve, 2nd
intake valve, 4th intake valve and 5th exhaust
Equipment: valve first, then rotate the crankshaft for a turn
Open spanner, slotted screwdriver and feeler (i.e. 360°), and then adjust the clearance of the
gauge. 3rd exhaust valve, 6th intake valve, 7th exhaust
valve and 8th intake valve.
Test steps and adjustments:

1) Remove the cylinder head cover, check and
tighten the rocker arm support and press out nuts.
2) Turn the crankshaft to the position where the
pistons of the first cylinder and the fourth Clearance of intake (exhaust) valve
cylinderr are at the top compression dead center

(at this time, the "0" scale line on the crankshaft
pulley is exactly aligned with the pointer on the
timing gear chamber cover, where the inlet and
exhaust valves of one cylinder must be off at the
same time, then the piston of this cylinder is at
the top compression dead center.)
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 cylinder and the rocker arm head
respectively, check and adjust the clearance, and
keep the cold clearance at 0.30-0.35
0.35 mm.
4) Adjust the tightness of the valve push rod until
it can be rotated evenly with fingers. After correct
adjustment is made, fasten the nut to prevent it
from loosening during operation.
5) Pull out the feeler gauge and re-check
re whether
the clearance is correct.
6) The working sequence of the four cylinders is

1-3-4-2.
2. Turn the crankshaft for half a turn (i.e.
Specifications:
Intake valve clearance (cold): 0.30 mm
Exhaust valve clearance (cold): 0.35 mm
Test results:
If the problem is still unresolved after adjustment
has been made as required, search for other
reasons.
1) The piston ring is filled with carbon deposit,
jammed or worn.
2) The cylinder head gasket leaks air.
2. Cylinder pressure
Reason:
The compression force of the cylinder is
insufficient, and the cylinder emits white smoke
during exhausting.
Equipment:
Pressure test gauge and open end wrench
Connection:
The sensor is connected to the preheating plug

hole and then connected 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 ± 175 kPa
Test results:
The following factors shall be taken into account
if the requirements are not met:
1) The valve leaks air.
2) The valve spring is broken.
3) The valve clearance is incorrect.
4) The piston ring is filled with carbon deposit,
jammed or worn.
5) The cylinder head gasket leaks air.
3. Timing detection of fuel injection pump

Reason: Specifications:
The advance angle of fuel supply is 16°±1°.
High fuel consumption rate, poor power
performance and emission of black smoke. Test results:
If there is no problem with fuel injector timing,
Equipment: other factors may need to be considered.
JDG465 Special sleeve or open end wrench
Connection:
Test steps:
1) Remove air from the fuel system, repeatedly
run the crankshaft to fill the fuel injection pump
with diesel, remove the high-pressure fuel pipe of
the first cylinder, blow off the remaining fuel in
the joint hole of the tight seat of the outlet valve,
slowly rotate the crankshaft in the forward
direction while closely observing the fuel level in
the joint hole; immediately stop rotating the
crankshaft when the fuel level 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 of fuel supply is too large
or too small, loosen the three nuts on the
triangular flange plate of the fuel injection pump.
Turning the fuel injection pump outward (in the
same direction as which the crankshaft rotates in)
can reduce the advance angle of fuel supply,
while turning inward (in the opposite direction to
which the crankshaft rotates in) can increase the
advance angle. Tighten the three nuts on the
flange plate and check the advance angle of fuel
supply until the requirements are met.
4. Calibration of fuel injection

pump
Reason:
Fuel supply for each cylinder is uneven.
Equipment:
Fuel pump test bench
Connection:
Test steps:
1) Install the fuel pump on the fuel pump test
bench, connect the standard fuel injector, and
turn the fuel pump to pump oil.
2) If the fuel supply for the cylinders differs
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
capacity. Turn the plunger ring until the fuel
supply unevenness for each cylinder meets the
requirements.
Specifications:
Fuel supply unevenness of each cylinder:
standard: 10%, calibrated: 10%, and under idle
speed: 30%.
Test results:
If there is no problem with fuel supply
unevenness for each cylinder, other factors may
need to be considered.
5. Atomization of fuel injector Test results:

If the injection pressure cannot be reached, the
Reason: nozzle fitting shall be cleaned, ground or replaced
Faults of diesel engine such as black smoke, with new qualified fuel injectors.
insufficient power, and rising fuel consumption.
Equipment:
Pressure test gauge and open end wrench
Connection:
The pressure test gauge is connected to the pump

connector.
Test steps and adjustments:

1) Pump fuel by hand until the gauge pressure is
10.78 Mpa, continue to slowly press the hand
pump, raise the gauge pressure to the calibrated
pressure and inject oil. Observe that whether
there is oil drip or leakage at the nozzle orifice. If
there is still oil drip after many tests, remove the
nozzle 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 make the injection
pressure conform to the calibrated value, then
tighten the pressure regulating nut and conduct
retest.
3) Observe the spray quality and conduct
atomization test at a speed of about once per
second. The fuel mist shall be even and free of
visible splashing oil foam, uneven concentration
and single-side injection. There shall be clear and
crisp sound when the fuel is cut off.
Specification
Opening pressure value of fuel injector: 24-25
MPa
6. Test on engine oil pressure

Reason:
It is for determining whether the bearing or
lubrication system components are worn.
Equipment:
JDG465 Special sleeve
JT05577 Pressure gauge assembly
JT03017 Hose assembly
JT05487 (XXX Test kit)
JDG282 Thermometer
Connection:
1. Remove the engine oil pressure sensor
Note: The thread is 1/8 of that of the conical pipe,
and special joint JT05487 and hose shall be used
for connection with 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 less
than 72 kPa (0.72 bar) (10.5 psi), the engine
will shut down.
4. Install the JDG282 thermometer at the engine

oil filter element.
Note: When the engine and oil pressure gauge
work under extreme conditions, the reading of the
oil pressure gauge will reach 582 kPa (5.82 bar)
(85 psi). That will not cause damage to the engine.
5. Run the engine for about 5 min, and check the
engine oil pressure after the temperature of the
engine oil reaches specified value.
Specification
Temperature of engine oil (engine rotating speed
of 825 rpm): 93℃ (200F)
Temperature of engine oil (engine rotating speed
of 2,500 rpm): 105℃ (220F)
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 oil pressure value is not within the
technical parameters, check the oil-pressure
regulating valve for damage, the spring for
breakage or the valve for jams.
A-JDG282 Thermometer
7. Inspection and adjustment of starter pinion
1) Inspection and adjustment of the clearance between pinion and retaining ring
Turn on the electromagnetic switch circuit to make the iron core be sucked fully. At this time when the starter
pinion moves to the farthest position, check that whether there is a clearance of 0.5-3 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 engagement.
2) Inspection and adjustment of pinion’s installation position
During installation of the starter, clearance of 3-5 mm shall be kept between the pinion end face and the
flywheel gear ring end face. Otherwise, add or remove gaskets between the stop plane of the starter and the
flywheel housing of the engine to ensure reliable meshing of the pinion.

Chapter 4 Fault Diagnosis and Removal

1. Emission of white smoke
Sequen
Position tested Normal Abnormal
ce No.
There is too low injection pressure,
poor atomization and oil leakage,
The fuel injector pressure is 23
1 Fuel injector which affect fuel compression
MPa.
combustion. Please replace the fuel
injector in time.
The temperature of the cooling water is
Water The temperature of the cooling too low, wasting heat energy and
2
temperature water is not too low. affecting combustion. Please start small
circulation to raise water temperature.
There is water seeping into the
cylinder, and water vapor emitting,
The cylinder meets the design
3 Cylinder which leads to inadequate combustion.
requirements.
Please check the cause and remove the
fault in time.
2. Emission of blue smoke
Seque
Position
nce Normal Abnormal
tested
No.
The piston ring severely wears
out, or because it has insufficient
The piston ring wears down within a elasticity due to carbon deposit,
1 Piston ring reasonable range and there is no carbon the engine oil gets into the
deposit on it. combustor, causing blue smoke
during combustion. Please replace
the piston ring in time.
The engine oil level is too high,
The engine oil surface is between the causing oil leakage. Please
2 Engine oil upper and lower scale lines of the discharge some engine oil, until its
vernier. level gets up to the specified
range.
The gas ring is installed upside
3 Gas ring The gas ring is assembled as required. down, causing engine oil leakage.
Please reassemble the gas ring.
3. Emission of black or gray smoke
Seque
Position
nce Normal Abnormal
tested
No.
The fuel injector or nozzle fitting
damages or blocks, and there is
1 Fuel injector The fuel injector pressure is 23 MPa. poor atomization and insufficient
combustion. Please replace the
fuel injector.
1. The fuel injection starts
abnormally late and some of the
fuel combust during exhausting.
2. The fuel supply for all cylinders
Fuel injection The fuel injection pump works
2 of the fuel injection pump is
pump smoothly.
insufficient.
The above two cases uneven
combustion working. Please re-
calibrate or replace the pump.
There is incorrect valve clearance,
The intake valve clearance is 0.3 mm, poor valve sealing and insufficient
3 Valve and the exhaust valve clearance is 0.35 fuel compression combustion.
mm. Please readjust the valve clearance
to the specified value.
The air filter is blocked, slowing
down air inflow, and the
The filter element is kept clean, with
4 Air filter insufficient air inflow affects
low air resistance and smooth air inflow.
combustion. Replace air filter
element.
The load is too heavy, causing
5 Load The load is within a reasonable range. insufficient torque for combustion
working. Please reduce the load.
4.Cylinder compression pressure being insufficient
Seque
Position
nce Normal Abnormal
tested
No.
Intake and Check whether the valve is sealed
The clearance of intake and exhaust
1 exhaust
valves is adjusted correctly. properly; grind the valve.
valves
The valve spring is normal and Move the piston to top dead center
2 Valve spring
unbroken. and replace the valve spring.
The intake valve clearance is 0.3 mm,
Valve
3 and the exhaust valve clearance is 0.35 Adjust the valve clearance.
clearance
mm.
There is no carbon deposit on the piston
Clean up carbon deposit or replace
4 Piston ring ring, and the piston ring works normally
the piston ring.
without jams or wear.
Tighten the cylinder head bolt.
Cylinder head The cylinder head gasket is in good
5 Replace the cylinder head gasket
gasket condition without air leakage.
if it is damaged.
5. Blocked air filter

Seque
Position
nce Normal Abnormal
tested
No.
The air filter is not blocked and the
1 Air filter Clean or replace the filter element.
filter element is not damaged.
6. Emission of blue smoke
Seque
Position
nce Normal Abnormal
tested
No.
The piston ring, piston and cylinder
liner show no sign of wear. There is no
Piston Check, clean or replace worn
1 carbon deposit on the piston ring. The
components parts.
engine oil does not get into the
combustor.
The engine oil level of the oil pan is
Engine oil Check the engine oil level and
2 within the specified range of the engine
level drain off excess engine oil.
oil gauge.
The piston ring is assembled correctly Reassemble the incorrectly
3 Piston ring with the marked side facing the top of assembled piston ring, or replace it
the piston. with a new one.
7. Abnormal sound emitted by diesel engine
Seque
Position
nce Normal Abnormal
tested
No.
The advance angle of fuel supply
Advance
The advance angle of fuel supply is is too large, and there is rhythmic
1 angle of fuel
16°±1°. metal clicking sound in the
supply
cylinder.
The oil-dripping nozzle entangles
2 Nozzle The nozzle pressure is 23 MPa. with the needle valve, emitting
suddenly clicking sound.
The intake valve clearance is 0.3 mm, The valve clearance is too large
3 Valve and the exhaust valve clearance is 0.35 and there are clear rhythmic
mm. knocks.
There are heavy and powerful
The clearance of the valve and the
4 Piston knocks when the piston hits the
connecting rod bearing is normal.
valve.
The thickness of the cylinder head
The thickness of the cylinder head gasket is not enough; there are
Cylinder head
5 gasket is within the allowable tolerance heavy and powerful knocks when
gasket
range. the piston hits the bottom of
cylinder head.
The valve spring is broken, the
Valve spring,
The valve spring, valve push rod and valve push rod is bent, and the
valve push
6 valve tappet are within the reasonable valve tappet is worn, making the
rod and valve
wear-out error range. valve mechanism emit slight
tappet
beats.
With large clearance between the
The piston and the cylinder liner are piston and the cylinder liner, the
Piston and
7 within the reasonable wear-out error piston emits excessive noise,
cylinder liner
range. which will be lowered as the
diesel engine heats up.
While the clearance of the
Connecting The clearance of the connecting rod connecting rod bearing shell is too
8 rod bearing bearing shell is within the range of 0.05- large, a heavy and powerful
shell 0.108 mm. impact sound can be heard as the
rotating speed suddenly decreases.
The clearance between the
Connecting The clearance between the connecting connecting rod bushing and the
9 rod bushing rod bushing and the piston pin is within piston pin is too large, and there is
and piston pin the range of 0.025-0.09 mm. slightly sharp sound, which is
especially clear at idle speed.
When the axial clearance of the
The axial clearance of crankshaft thrust worn crankshaft thrust bearing is
Crankshaft
10 journal is within the range of 0.085- too large, the impact sound of the
thrust bearing
0.275 mm. crankshaft moving back and forth
can be heard at idle speed.
8. Abnormal operation or frequent flameout
Check conditions:
1) Tighten the parking brake
2) PTO neutral position
3) The ignition lock is off
Seque
Position
nce Normal Abnormal
tested
No.
The air pipe of the oil tank cap is
The air pipe of the fuel tank cap is
1 Fuel tank cap unblocked and there is negative
unblocked.
pressure in the oil tank.
The fuel tank is refueled according to The diesel is not of the correct
2 Fuel tank
the requirements for diesel usage. grade or is insufficient.
Air filter The filter element in the air filter is The filter element is dirty or
3
element clean and in good condition. 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 switch is off.
There is nothing wrong with the
6 Thermometer The thermometer is damaged.
thermometer.
The intake valve clearance and the
Intake and The intake valve clearance and the
exhaust valve clearance are within
7 exhaust exhaust valve clearance exceed
tolerance range (0.30 mm and 0.35mm
valves tolerance.
respectively).
8 Fuel injector The nozzle has good atomization effect. The nozzle is faulty.
Check the piston ring, cylinder
Piston Piston components wear out severely.
9 liner, intake and exhaust valves,
components (The cylinder pressure is 2,400 kPa.)
and cylinder head gasket.
9. Low power
Seque
Position
nce Normal Abnormal
tested
No.
The filter screen of the inlet and
outlet fuel pipe joint is blocked,
Diesel filter or
which affects the fuel capacity and
1 fuel supply The oil circuit is unblocked.
injection pressure of the fuel
pump
system. Check and replace the
filter element.
The fuel injector or nozzle fitting is
damaged or blocked; the fuel
2 Fuel injector The fuel injector pressure is 23 MPa. injector pressure is incorrect or its
atomization effect is poor. Replace
the fuel injector.
1. The plunger fitting of the fuel
injection pump wears out severely.
2. The speed governor spring
deforms, and get loose, failing to
reach the rated rotating speed.
Fuel injection 3. The speed governor spring
3 The fuel injection pump works smoothly.
pump deforms, and get loose, failing to
reach the rated rotating speed.
Refer to Chapter X for solutions
for abnormal operation of the fuel
injection pump, or replace the fuel
injection pump.
There is air entering the fuel
There is no air in the fuel system, and the
system, affecting the fuel supply of
4 Fuel system fuel capacity and pressure there are
the fuel system. Please remove the
normal.
air inside the system.
The incorrect advance angle of fuel
supply and insufficient fuel
Advance angle The advance angle of fuel supply is combustion affect compression
5
of fuel supply 16°±1°. working. Please readjust the
advance angle of fuel supply to the
specified value.
The uneven fuel supply of the
Fuel supply Each cylinder is fed with stable fuel cylinders affects compression
6
quantity supply. working. Please re-calibrate the
pump or replace it with a new one.
The unblocked air filter and low air
The filter element is clean with low air intake affect compression
7 Air filter
resistance. combustion working. Please clean
the filter element or replace it.
The intake valve clearance is 0.3 mm, The valve leaks air, causing
and the exhaust valve clearance is 0.35 insufficient mixed combustion of
8 Valve
mm. oil and gas, and affecting working.
Please readjust the valve clearance.
Switched-on intake valve before top
The incorrect valve timing, due to
dead center 12±3°
excessive cam wear, affects
9 Valve timing Switched-off intake valve after bottom
compression combustion working.
dead center 38±3°
Please replace the camshaft.
Switched-on exhaust valve before
bottom dead center 50±3°

Switched-off exhaust valve after top
dead center 14±3°
There is no air leakage on the contact The fuel injector seat leaks air,
Fuel injector
10 surface between the fuel injector and the affecting combustion. Please
seat
cylinder cover. replace the fuel injector seat.
The loose cylinder head bolts
affect compression combustion
The torque of the cylinder head bolt is
11 Cylinder head working. Please check the cylinder
145-155 N.m.
head bolts and re-tighten them to
the specified torque range.
The piston ring is filled with
The piston ring wears down within a
carbon deposit, jammed or worn.
12 Piston ring reasonable range and there is no carbon
All these cases affect power.
deposit on it.
Replace the piston ring.
The air leakage of the cylinder
The cylinder head gasket has a
Cylinder head head gasket affect compression
13 compaction thickness of 1.2±0.08 mm
gasket combustion working. Please
(with tightening torque of 150 N•m).
replace the cylinder head gasket.
10. Engine oil-water mixture

Check conditions:
1) Engine flameout
Seque
nce Position tested Normal Abnormal
No.
Cylinder liner The cylinder liner and the water sealing
There is no fault in the cylinder
1 and water ring are damaged, and hence water
liner and the water sealing ring.
sealing ring seeps to engine oil.
Cylinder head The cylinder head gasket is The cylinder head gasket is damaged,
2
gasket qualified. leaking water.
The cylinder head is damaged, leaking
3 Cylinder head The cylinder head does not leak.
water.
The engine body is in good The engine body is damaged, leaking
4 Engine body
condition without leakage. water.
11. Surging rotating speed

Check conditions:
1) Engine flameout
Seque
Position
nce Normal Abnormal
tested
No.
The speed governor goes wrong, and the pull rod
Speed The speed governor
1 jams in position indicating large fuel capacity,
governor works normally.
resulting in speed surging.
Speed
governor The sliding disk shaft The sliding disk shaft sleeve of the speed
2
sliding disk sleeve slides normally. governor jams.
shaft sleeve
The adjusting arm is in
3 Adjusting arm The adjusting arm gets out of the shifting fork.
normal position.
There is no engine oil
4 Engine oil There is excessive engine oil leakage.
leakage.
12. Unstable rotating speed
Sequ
ence Position tested Normal Abnormal
No.
1 The blocked diesel filter slows down
Quality of The diesel engine is clean, the flow of fuel supply. Replace the
engine oil free of impurities. engine oil with a new type and diesel
filter assembly.
Check its atomization
2 Fuel injector Replace the fuel injector.
effect as stated above
Each cylinder of the fuel Replace the speed-regulating
Fuel injection
3 injection pump pumps fuel stabilizing spring of the fuel pump or
pump
evenly. the fuel injection pump.
13. Engine overheat
Seque
Position
nce Normal Abnormal
tested
No.
Top up the water tank and raise
There is insufficient water or air barrier the water level until the cooling
1 Water volume
in the water pipe. water level is higher than the
water outlet of the water pump.
There is too much water scale in the
Radiator and
2 Clean water scale.
water pipe water tank and pipe.
Water pump The water pump works normally and Check the water pump clearance
3 assembly or and belt tightness, and make
the tightness of the fan belt is normal.
fan belt adjustment to stop water leakage.
Check or replace the pressure
4 Thermostat The thermostat works normally.
gauge.
14. Abnormal coolant temperature
Check conditions:
1) Engine flameout
Seque
Position
nce Normal Abnormal
tested
No.
The engine works under normal load The engine will overheat after
1 Load
range. working too long under overload.
The fuel injection is in good
condition, the advance angle of the
The poor combustion affects coolant
2 Fuel system fuel injection is within required
temperature.
range, and the gas valve phase is
correct.
There is insufficient water or air
The cooling water level is higher than
3 Cooling water barrier in the water pipe, resulting in
the water outlet of the water pump.
cooling water at high temperature.
The excessive water scale in the water
4 Water tank The water tank is kept clean.
tank and pipe affects heat dissipation.
The water pump fails to work
The water pump works normally and
5 Water pump normally, affecting the coolant’s
the pulley is properly tightened.
capacity for heat dissipation.
The temperature is 76° when the
The thermostat goes wrong, affecting
thermostat is switched on fist, and
6 Thermostat coolant flow and temperature
temperature is 86° when the
regulation.
thermostat is fully switched on.
Insufficient or excessive engine oil,
low engine oil pressure, insufficient
Engine oil in CD grade or above is
7 Engine oil flow rate, spoiled engine oil due to
filled in as required.
mixture or wrong grade affects the
heat load of the engine.
The excessively small bearing
Bearing There maintains reasonable bearing
8 clearance increases the friction
clearance clearance.
temperature.
The piston ring leaks air, and the
Piston ring piston and the cylinder liner worn out
The piston ring and the cylinder liner
9 and cylinder severely. The gas gets into the
wear down within a reasonable range.
liner crankcase, deteriorating the engine oil
and affecting heat dissipation.
15. No oil pressure or too low oil pressure

Seque
nce Position tested Normal Abnormal
No.
The engine oil level in the engine Fill engine oil until its level gets
1 Engine oil level oil casing is within the specified between the upper and lower scale
scale range. lines of the engine oil gauge.
Engine oil There is no leakage in the engine oil Check the engine oil pipeline and
2
pipeline pipeline. remove faults found.
Engine oil Clean the pipeline and filter, and
The engine oil pipeline and the oil
3 pipeline and oil replace the oil filter element if
filter are unblocked.
filter necessary.
Engine oil The engine oil pressure gauge Check or replace the pressure
4
pressure gauge works normally upon testing. gauge.
The inner and outer rotors of the oil
Repair or replace the rotors by a
5 Oil pump pump are not worn and work
professional maintenance factory.
normally.
Main bearing
The main bearing shell, connecting
shell, connecting
rod bearing shell and camshaft
6 rod bearing shell Check, adjust or replace parts.
bushing are not worn, and have
and camshaft
normal clearance.
bushing
There is no deformation or fracture
Pressure-adjusting Replace the pressure-adjusting
7 in the pressure-adjusting spring of
spring of oil pump spring of the oil pump.
the oil pump.
The oil pump gasket is not
8 Oil pump gasket Replace the gasket.
damaged.
9 Fuel passage The fuel passage is unblocked. Clear the fuel passage.
16. Too high engine oil pressure
Seque
Position
nce Normal Abnormal
tested
No.
Pressure- The pressure-limiting valve of the oil
1 limiting valve pump works normally, and the fuel Check and adjust it.
of oil pump returns smoothly.
Use engine oil of specified grade,
Viscosity of The viscosity of engine oil meets the
2 and the warmed machine will then
engine oil operating requirements.
reduce the viscosity automatically.
17. Overheated engine oil
Seque
Position
nce Normal Abnormal
tested
No.
Check whether the engine oil level
Engine oil The engine oil level is between the scale
1 is between the scale lines of the
level lines of the engine oil gauge.
engine oil gauge.
Refer to the above table "No
Engine oil
2 The engine oil pressure is normal. engine oil pressure or too low
pressure
engine pressure" for fault removal.
3 Engine oil The engine oil is of correct grade. Change the engine oil.
All the Bearing clearance is normal and does Adjust the clearance of each
4
bearing shells not decrease. bearing.
The piston ring leaks air, the piston and Check or replace the piston ring,
Piston
5 the cylinder liner worn out severely, and piston and cylinder liner to
components
the gas gets into the crankcase. eliminate air leakage.
18. High engine oil consumption

Check conditions:
1) Engine flameout
Seque
Position
nce Normal Abnormal
tested
No.
The viscosity of engine oil is too
1 Engine oil The grade of the engine oil is CD or above. low and too high, which affects
lubrication.
The dimensions of the piston and the The piston and the cylinder liner
Piston and
2 cylinder liner are within the allowable wear severely and leak engine oil,
cylinder liner
tolerance range. increasing engine oil consumption.
The upper and lower parts of the
The dimensional tolerance is within the gas ring are installed reversely,
3 Piston ring
allowable tolerance range. causing excessive wear and engine
oil leakage.
The front and rear oil seals of the
4 Oil seal The oil seal is not worn or damaged. crankshaft leak engine oil, causing
extra engine oil loss.
The junction surface of the oil pan
The oil pan gasket is in good condition
5 Oil pan gasket and other sealing positions leak
without leakage.
fuel, increasing fuel consumption.
19. Low starting speed
Seque
Position
nce Normal Abnormal
tested
No.
Storage
1 The storage battery is fully charged. Charge the storage battery.
battery
Replace the ignition switch, check
Ignition The ignition switch works normally
2 the wiring and tighten the
switch without damage or wrong wiring.
connector.
Clean the electromagnetic switch,
repair the contact surface of the
3 Starter The starter works normally. comb or carbon brush, replace the
carbon brush, and check and repair
the armature coil.
Check the installation of the
4 Starter The starter gear works normally. starter and align the axes of the
starter and the gear ring.
20. Failure of engine to be started

The prerequisite for the diesel engine to work normally is that the well atomized diesel can be injected into
the combustor accurately and timely, and that the compressed air in the combustor must reach sufficient
temperature before ignition and explosion. To meet the two conditions, there must be high enough rotating
speed and certain temperature in the cylinder when the diesel engine is started. When the diesel engine cannot
be started, the starting system and the fuel supply system shall be checked first.
Abnormal conditions for starting system:
The starting speed is low or the starting system does not work. If the ambient temperature is too low, the
diesel engine shall be preheated first, otherwise it is not easy to be started. If the starting speed is extremely
low, it is largely due to the starter is under-power. The electrical circuit shall be checked carefully to
determine whether the storage battery is fully charged, whether the lead wires are connected tightly and
whether the starter works normally (see details below).
Abnormal conditions for fuel supply system:
1) There is no fuel in the fuel tank or the fuel tank is not switched on.
2) There is excessive air or water in the fuel supply system. In such case, the starting speed is not low but the
engine fails to be started, and the exhaust pipe emits white smoke. The check method is to loosen the bleeder
screw on the diesel filter or the high-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 bleeder screw on the high-pressure pump and turning the crankshaft. Water found in diesel
can also be removed by the same method. If there is too much water in the diesel, replace the diesel.
3) The pipeline or filter is blocked. The solution is to blow through the pipeline with an air cylinder, clean the
filter, and check whether the filter screen at the fuel tank filler is in good condition.
4) The plunger of the fuel injection pump is worn. In this case, the plunger shall be replaced.
5) The outlet valve of the fuel injection pump is stuck or the outlet valve spring is broken. A feasible solution
is to remove the high-pressure fuel pipe joint, then take out and clean the outlet valve and the valve seat. The
outlet valve spring needs to be replaced when it is broken.
6) The plunger spring of the fuel injection pump is broken, resulting in no pressure on the fuel injection pump.
7) The plunger of the fuel injection pump is stuck in the plunger sleeve. In case of normal oil circuit, if the
plunger does not move when the crankshaft is shaken, it means that the plunger and plunger sleeve are stuck.
The solution is to disassemble the fuel injection pump and clean the plunger and plunger sleeve.
8) The needle valve of the fuel injector is stuck. The solution is to remove the fuel injector and take out the
needle valve of the nozzle for cleaning, or replace the needle valve fitting.
9) The injection time is incorrect. The solution is to readjust the injection time as required.
21. Failure of starter to work
Seque
Position
nce Normal Abnormal
tested
No.
Positive wire The positive wire and the ground wire Check and replace the positive
and ground of the storage battery are connected wire and the ground wire of the
1 wire of
storage normally, and the horn and the storage battery, and tighten the
battery headlamps work normally. two wires.
The storage battery works normally,
Storage Charge or replace the storage
2 which is determined by testing the horn
battery battery and tighten the two wires
and the headlamps.
The horn makes normal sound while
honked. The starter can rotate when the
main binding post and the control Check the starter relay and circuit,
3 Starter relay
binding post on the electromagnetic and replace them if necessary.
switch are short connected with a
screwdriver.
The horn makes normal sound while
Starter honked. The starter can rotate when the

Replace the electromagnetic
4 electromagnet two main binding posts on the
ic switch switch.
electromagnetic switch are short
connected with a screwdriver.
The electric brush runs smoothly in the Check the contact between the
Electric brush brush carrier without clamping electric brush and the brush
5 and brush
carrier stagnation. The horn makes normal carrier, and clean up the contact
sound while honked. surface.
Starter
armature and The starter is normal and the armature is Replace the starter rotor and
6 clearance
between shaft not out of shape. enlarge the bushing hole.
and bushing
Magnetic The magnetic field coil and rotor
Replace the starter stator or the
7 field coil and winding are not short-circuited or open-
rotor winding rotor.
circuited.
Distance Under normal circumstances, the Adjust the distance to the
between standard distance between the starting specified value.
8 starting pinion pinion and the flywheel gear ring is 3-5
and flywheel mm.
gear ring
22. Idling starter and failure of engine to work
Seque
Position
nce Normal Abnormal
tested
No.
When the starter circuit is powered on,
Check the locking torque of the
1 Isolator the starter runs at a high rotating speed
isolator.
with hum.
The pinion can normally mesh with the Replace the buffer spring or the
Buffer spring
2 flywheel gear ring and the elastic force isolator.
of isolator
of the buffer spring is normal.
Distance Under normal circumstances, the Adjust the distance to the
between standard distance between the starting specified value.
3 starting pinion pinion and the flywheel gear ring is 3-5
and flywheel mm.
gear ring
23. Under-power starter
Seque
Position
nce Normal Abnormal
tested
No.
Storage Check and replace the positive
battery level The storage battery has high level, and wire and the ground wire of the
1 and the connecting lead is fastened without storage battery, and fasten the two
connecting looseness. wires to charge or replace the
lead storage battery.
The armature shaft is not bent, the rotor Replace the starter and install it
Armature does not rub the magnetic poles, and the correctly.
2
shaft fitting clearance of the bushing meets
the requirements.
Excitation The excitation winding and the armature Disassemble and check the
3 winding and are not short-circuited excitation winding and the
armature armature
Commutator Turn on the headlights, start the engine, Clean oil stains between the
and electric and then observe changes in the commutator and the electric brush,
4 brush headlamps. If there are little changes, or replace the brush spring.
the electric brush may have poor contact
with the commutator.
24. Screams emitted during/after start or hard to disconnect pinion
Serial
Reason Fault Measure
No.
Screams are
emitted
immediately after
The starter armature shaft is
the engine is Repair or replace the armature and the
1 bent, and the isolator and
started, and the isolator.
the front cover are jammed.
starter is reversely
rotated at high
speed.
Dirt on the starter shaft and

the spline jams the starter
isolator, making it fail to
2 return its original position Clean dirt on the starter shaft and the
and thus fail to disconnect spline; check whether the isolator is
the pinion and the gear flexible and whether the return spring
ring. of the starter electromagnetic switch
is broken or has too small elastic
force.
The return spring of the
armature in the starter
3 electromagnetic switch is The starter is
broken or has too small reversely rotated at
elastic force. high speed.
When the ignition switch is returned
to the normal working mode, if the
starter is still running, the engine shall
be shut down immediately. If the
The contact of the starter
starter is still running at high speed
relay or the electromagnetic
after flameout, the power supply shall
4 switch is fused and bonded,
be cut off immediately; otherwise the
and the starting circuit
starter will be damaged. This fault is
cannot be disconnected.
generally caused by fused contact of
the relay or the electromagnetic
switch. Remove the fault before
reuse.
The improperly installed
starter inclines, resulting in
too short center distance
After the engine is
and too small meshing-
started, there is Re-install the starter and adjust the
teeth side clearance. (Or the
5 meshing sound and center distance to ensure a more
center distance is designed
screams for a long suitable side clearance.
incorrectly, or the number
time.
of teeth of the starter pinion
and the flywheel gear ring
is incorrect).
25. Methods for distinguishing between starter failure and storage

battery failure
1) If the starter is under-power when the cold machine is started, 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 the starter fails to work or to run smoothly, or to drive the crankshaft to work after the cold or warmed
machine is powered on, it indicates that there is a fault in the starter.

26. Checks on disassembled starter
Serial Component Check content Check requirements

No. checked
1 Stator Checks on short circuit Check with a multimeter.
Checks on open circuit
Checks on grounding
2 Armature 1. Checks on short circuit 1. Check with a multimeter.
2. Checks on open circuit 2. When the run-out tolerance of the armature shaft
3. Checks on grounding exceeds 0.05 mm, make adjustment or replace the
4. Checks on curvature of armature shaft.
armature shaft 3. Clean up the surface of the commutator, and conduct
5. Checks on commutator turning in case of bulging mica or scratched surface.
4. Round the commutator on the lathe if its roundness
error exceeds 0.05 mm. The thickness of copper sheet
after rounding shall be over 4 mm, otherwise it shall be
replaced.
3 Electric 1. Checks on height of 1. The electric brush is generally 14 mm high; its limit
brush and electric brush height is 8 mm.
brush carrier 2. Checks on insulativity 2. The contact area between the electric brush and the
of brush carrier commutator shall not be 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
requirements.
5. The grounding brush carrier shall be grounded
reliably without looseness.
4 Transmission 1. Checks on shifting fork 1. The shifting fork shall be not deformed, fractured
mechanism 2. Checks on buffer and loosened.
spring 2. The buffer spring shall be free of rust with normal
3. Pinion gear elasticity.
4. Checks on isolator 3. The pinion gears shall not have broken teeth or worn
tooth heads.
4. The pinion shall rotate smoothly when turned
clockwise, and be locked when turned
counterclockwise.
5 Electromagn 1. Checks on contact 1. The resistance value between the two binding posts
etic switch resistance between tactile of the switch checked with a multimeter shall be 0; if
disc and contact not, the contact shall be repaired.
2. Checks on sucking coil 2. The resistance value of the holding coil is 1 ohm. If
and holding coil for open the resistance is ∞, it indicates that the holding coil is
circuit open circuit. The resistance value of the sucking coil is
about 0.5 ohm; if the resistance value is ∞, it indicates
that the sucking coil is open circuit.
27. Hard to get diesel engine started
Seque
Position
nce Normal Abnormal
tested
No.
There is sufficient fuel in the fuel tank Fill in diesel and turn on the
1 Fuel tank
and the sediment cup is opened. switch.
There is no air in the fuel system, no
Discharge air, replace diesel, and
2 Fuel system water in the fuel, and no oil leakage at
tighten the joint.
the joint.
Clean the pipeline, clean or
replace the diesel filter element,
Oil circuit or
3 The oil circuit and filter are unblocked. and clean the fuel inlet pipe of the
filter
fuel supply pump and its filter
screen.
Check whether the fuel supply
Fuel supply The fuel supply pump and the fuel
pump and fuel pump and the fuel injection pump
4 injection pump work normally, and the
injection work normally, and adjust the
pump advance angle of fuel supply is correct.
advance angle of fuel supply.
Disassemble and repair the fuel
injector, adjust the injection
The fuel injector works normally while pressure on the fuel injector test
5 Fuel injector
injecting fuel. bench, and clean, repair or replace
the fuel injector fitting. Replace
the spring.
The fuel outlet valve and plunger fitting
Fuel injection
6 of the fuel injection pump work Grind, repair or replace parts.
pump
normally without wear and tear.
28. Emission of black smoke

Seque
Position
nce Normal Abnormal
tested
No.
The traction load is normal and not
1 Load Reduce the load.
overloaded.
Adjust the fuel supply capacity of
Fuel injection The fuel injection pump works normally
2 each cylinder to lower the fuel
pump during fuel supply.
supply unevenness.
The intake valve clearance is 0.3 mm,
Valve Adjust the valve clearance and
3 and the exhaust valve clearance is 0.35
clearance grind the valve.
mm.
Tightness of Check the valve, valve spring or
4 valve or The valve does not leak air. piston pin and eliminate air
piston
leakage.
Advance The advance angle of fuel supply is Adjust the advance angle of the
5 angle of fuel
supply normal. fuel injection pump.
The air inlet pipe and the air filter are Remove dust on the filter element
6 Intake pipe
not blocked. or replace it.
The nozzle has normal atomization Clean, repair, adjust or replace the
7 Fuel injector
effect. fitting.
Fuel injection The plunger spring of the fuel injection
8 Replace the plunger spring.
pump pump is not broken.

Maintain N485D and N490D Diesel Engines

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ANHUI QUANCHAI ENGINE CO.

Engine Maintenance Manual

(Quanchai N485D and N490D Diesel Engine for generator)

ANHUI QUANCHAI ENGINE CO., LTD

Chapter 6 Fuel supply system .................................................................................................................. 74

15. No oil pressure or too low oil pressure ..................................................................................... 128

Chapter 1 Safety Precautions

This sign is a safety sign. If the diesel engine

The operation procedures and safety

1. Scald proof sign

After the engine is started, personnel shall be

See the manual for other signs.

3. Engine lifting equipment

When lifting the engine, use the allowable

Before lifting the engine, check whether the

Chapter 2 Technical Parameters

1. Main technical parameters

Model N485D N490D

N485D power curve

N490D power curve

3. Main structural parameters of diesel engine

Rotating direction (facing

Serial Torque Note

5. Outline dimension parameters

Outli Length 760

6. Exposed parts of the engine

6.1 Left side of the engine

6.2 Right side of the engine

Chapter 3 Fuel and Engine Oil

1. Use of and precautions of fuel

1.1 Storage of fuel

If the diesel in the fuel tank or transport tank

It is very important to store the fuel properly.

Store the fuel in clear tank and warehouse, and

regularly drain water and sediment from the

It is avoided to store the fuel for a long time. If

the fuel is consumed slowly in the fuel tank or

storage tank, add fuel conditioner to the tank

to prevent the water from concentrating.

Keep fuel in an easily accessible place, and

stay away from buildings.

Note: In order to reduce the separation of fuel

1.2 Precautions for use of fuel

Fuel: The fuel is the light diesel specified in

0# -10# -20# -35# -50#

4℃ -5℃ -14℃ -29℃ -44℃

The user can select the light diesel oil

1.3 Fuel filling

Fill the fuel according to the fuel level shown

2. Engine lubricating oil 3. Engine coolant

Lubricating oil The cooling water shall be clean soft water,

1. Standard accessories for the product

N485D, N490D diesel engine:

In line and water cooling

Accessories include the followings:

According to the needs of overall unit, the followings can be selected:

Part 2 Disassembly, Assembly and Adjustment

Chapter 1 Disassembly and Assembly of Valve Train

1. Maintenance equipment and tools

Cylinder head bolt 14-M12

2 Torque requirements and dimensional data

2.1 Torque requirements