User’s Handbook

发电机组用柴油机照片
(由销售提供印刷)

The 1000 Series Engines Used For Genset

Part No. T76812896

LOVOL engines for Genset

4 and 6 cylinder diesel engines for Genset

1004G
1004TG
1006TG1A
1006TG2A
1006TAG

User’s Handbook
Contents：

General inormation……………………………………….………… 1

Engine views……………………………………………………….. 2

Instructions for operation…………………………………………… 3

Preventive maintenance………………………………………………4

Engine fluids………………………………………………………… 5

Fault diagnosis……………..…………………………………………6

Engine preservation ………………………………………………… 7

Parts and service………………………………………………………8

Engine data……………………………………………………………9

Supplement……………………………………………………………10
General inormation 1
Introduction….……………………………………………….…1.02
How to care for your engine………………….…………………1.03
Safety precautions…...……………………….……………….…1.04
Engine identification………………………………………….…1.05
Lifting equipment of engine………………….………….………1.06

1.01
1.02
1.03
1.04
1.05
1.06
Engine views 2
Introduction ….……………………………………………….……….……2.02

Location of engine parts…….………………………………….……….……. 2.03

2.01
2.02
2.03
Operation instruction 3
How to start the enginer………………………………………….……….……3.02

How to stop the enginer………………………………………….……….……3.02

Adjustment of engine speed range ……………………………….……….…….3.05

Running-in.….……………………………………………….……….……..3.05

Altitude .….……………………………………………….……….……..3.05

3.01
3.02
3.03
 3.04

3.05
Preventive maintenance 4
Preventive maintenance period…………………………………….……….……4.02

Schedule …………………………………………………….……….…… 4.03

How to drain the cooling system ………………………………….……….…….4.04

How to check the drive belt …………………………………….……….…….. 4.05

How to clean the gauze strainer of the fuel lift pump………………….……….……..4.06

Fuel pre-filter ………………………………………………….……….……4.07

How to renew the element of the fuel filter ………………………….……….……. 4.10

Atomiser fault ………………………………………………….……….……4.11

How to renew an atomiser ……………………………………….……….……4.11

How to eliminate air from the fuel sysytem ……………………….……….………. 4.12

How to renew the lubricating oil…………………………………….……….……4.16

How to renew the canister of lubricating oil filter……………………….……….……4.17

How to clean the closed breather system ……………………………….……….…4.18

Air cleaner .….……………………………………………….……….……4.19
How to check the value tip clearances ………………………………….……….… 4.20

4.01
4.02
4.03
4.04
4.05
4.06
4.07
4.08
4.09
4.10
4.11
4.12
4.13
4.14
Eliminate Air from the fuel system fitted with in-line PB type of fuel
injection pump.
If air enters the fuel system, it must be eliminated before the engine can be started.
Air can enter the system if

The fuel tank is drained during normal operation.

The low- pressure pipe broken are disconnected.

A part of low-pressure fuel system leaks during engine operation.

In order to eliminate air from the system, proceed as follows:

Caution: The engine cabinet muse not be contaminated by the
fuel. An oil pan should be put at bottom of the engine and the
waste fuel should be disposed of in accordance with the local
stipulations.
1. Loosen the vent plug on the top of fuel filter (A1) by turning it two or three turns, operate the
filling pump on the fuel lift pump (B) until the fuel without air is spurted from air-vent hole.
Tightening the plug.
2. Loosen the connecting screw (B1)on the housing at driving side. Operate the filling pump on the
fuel lift pump until the fuel without air is spurted from joint loosened. Tightening the connecting
screws on the housing.
3. Loosen connecting nut (C1)on fuel starting aid if the pipe connected to the fuel starting aid has
been drained away until the fuel without air is spurted from joint loosened. Tightening the
connecting screws on the fuel starting aid. Put a wrench on the plane(C2) of fuel starting aid to
prevent the connecting nut as loosening or tightening from moving.
4. Ensure that the stop controller is at the ‘running’ position, and speed controller is at ‘maximum
speed’ position. Operate the starter motor. After starting the engine, decrease the engine speed. If
the operation is normal at a short time , and then stopped or unstable operation, in this case check
the fuel system whether there is air existing. If so, the low-pressure pipe will leak.

4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
Engine fluids 5
Fuel specification .……………………………………………….……….… 5.02

Lubricating oil specification……………………….…….……….……….……5.03

Coolant specification…………………………….…….……….……….……5.04

5.01
5.02
5.03
. 5.04
Fault diagnosis 6
Problems and possible causes……………………………….……….………… 6.02

Code list of possible causes……………………….…….……….……….…… 6.03

6.01
6.02
6.03
Engine preservation 7
Introduction……………………………….……….…………………………7.02

Procedure ………………………………….……….……………………… 7.02

7.01
7.02
Parts and service 8
Introduction………………………………….……….………………………8.02

Service literature …………………………….……….……………………… 8.02

Training…………………………………….……….………………………8.02

8.01
8.02
Engine data 9
Engine…………………………………….……….………………………9.02

9.01
9.02
Supplement 10
PB pump ………………………….……….……………………………… 10.02

Major Technical Data of PB Pump……………….……….………………………10.02

Structure of PB Pump ……………………….……….………………………10.03

Notices on Adjustment and Use of PB Pump………….……….……………………10.04

Structure of RSV Governor…………………….……….………………………10.05

Theory of RSV Governor …………………….……….………………………10.06

Electronically Controlled Governor …………….……….………………………10.07
Adjustment of Static Fuel Supply Advance Angle of Inline Pump.……………………… 10.08

10.01
PB fuel pumps, RSV governors and electronically controlled governors are applied on

the diesel engines manufactured by Perkins Lovol Engines (Tianjin) Co., Ltd., which

are used on the electric generating sets.

Characteristics of PB pumps:
1. The basic geometric data of PB pumps and A type pumps are the same, so the two types can be
counterchanged.
2. The plunger are integrated with discreteness housing, so it can bear larger pressure.
3. The integral sealing is waterproof and dustproof.
4. The rectangular drawbar of P pumps is applied.
5. The pump body, camshaft and bearings are specially reinforced to bear larger pressure.
6. Moving parts as discreteness and tappet stem can be uninstalled from the top of the pump.
Disassembling of the camshaft is not necessary when changing the vulnerable parts.

Major Technical Data of PB Pump

cylider number 4-8
plunger diameter 9-12 mm
camshaft lift 10 11 12mm
maximum delivery quantity 230 mm/cycle
maximum speed 1800 rev/min
maximum pressure at pump outlet 950 bar
suitable engine power output 45kW/cylinder (max)

10.02
Structure of PB Pump：

10.03
Notices on Adjustment and Use of PB Pump
1. Important adjustment of the pump should be carried out on special test bench according to the
technical documents. And wrong adjustment may cause heavy accidents.
2. When adjust the pump, the temperature of proving oil and diesel should be kept with the range of
35℃ and 40℃.
3. When adjusting the pretravel, washers of the same thickness should be placed on either side of the
plunger. Otherwise the drawbar will not move smoothly and vibrate, and other malfunction will
also occur.
4. The plunger, fuel outlet valve and nozzle coupling elements are of special accuracy, which may be
destroyed by any dust in the fuel. Therefore, the fuel filter and fuel tank should be cleaned
periodically to keep the fuel clean. Forced or splashing lubrication system is applied on the PB
pump. In the former case, lubricant need not be filled at the pump side. However in the two cases,
before running the pump (before being mounted on the test bench or engine), lubricant specified by
the engine manufacture should be filled into the pump body until it begin to flow out of the
overflow outlet. If the lubricant is not filled, the bearings, camshaft and pushing rods may be
destroyed.

10.04
Structure of RSV Governor:

10.05
Theory of RSV Governor
RSV governor is of mechanically eccentric type. The governor drawbar device can be simplified into a
crank block device, and the brake device can be simplified into a rolling guide rod device. The pulling
force of the spring can be changed through rotating the spring lever via governor handle, thus the
speed range can be changed. When adjusting the speed, the torque generated by the pulling force of
governor spring on the governor lever is equal to the torque of centrifugal force at the specified speed.
The stroke of governor hand lever and flyweight can be transmitted to the toothed bar through the
lever device. The total fuel quantity limit screw and calibrator are mounted in the governor body. The
idle speed stabilizing device is mounted in the rear housing. The adjusting screw on the spring lever is
used to change the speed governing rate within a certain range.

10.06
Electronic governor(used for 1006TAG)：
Basic system illustration

The principle on electronic speed governing

The solenoid actuator is an actuator of electronic governor which can control the output displacement
of the actuator through controlling a coil current in the solenoid actuator. The electronic actuator drives
directly the high-pressure fuel pump rack on the engine, thus it can control the fuel delivery to the
engine and thereby the speed. The speed controller is a full electronic device which can control the
engine speed with a rapid and accurate response to the instantaneous load variation, its reliability is
high and can stand up to ambient interference around the engine.

10.07
The method of adjusting the static fuel supply advance angle for
in-line fuel injection pump (domestic)
1. Determine the mark position when the piston of number 1 cylinder is at its TDC on the
compression stroke according to the method stated on page 17A0.4 of «WORKSHOP
MANUAL», the mark should be stamped on both timing case cover and pulley respectively.
2. Remove the high-pressure pipe of number 1 cylinder, pull the throttle control lever to the
maximum position of fuel supply, turn the crankshaft, clockwise from the front, set the piston of
number 1 cylinder is at its TDC on the compression stroke.
3. Turn the crankshaft, counterclockwise from the front, to the angle more than 60° from the
beginning then turn it again clockwise slowly, observe the fuel overflow from valve seat, when the
fuel level fluctuation just appears, it indicates that the supply begins at the number 1 cylinder. At
this time stop turning the crankshaft, check is there any deference angle between the marks on
timing case cover and the pulley, thus the fuel supply advance angle can be determined. At this
moment if the mark on the pulley is ahead of the mark on timing case cover, it indicates that fuel
supply is in advance, otherwise, is delaying fuel supply.
4. If the fuel supply advance angle fails to meet the requirement, loosen the nut on pump bracket and
the flange at the side of pump, adjust with the kidney hole on the flange. When moving the pump
body close to the cylinder block it can get the fuel supply advance angle increase, otherwise
decrease.
The periphery of the flange on pump body to be turned for 1mm of arc length, the fuel supply
advance angle can increase or decrease for 1° of crankshaft rotation angle.
After defined value of the fuel supply advance angle set has been reached, the nuts on the flange at
the side of pump and the screws on pump bracket should be tightened to the defined torque. And
then repeat the third step operation and check.
Note: The arc length opposite to 1° of rotation angle of the crankshaft =p D / 360 (mm), D-pulley
diameter.

10.08