Forward 4jb1 Series

Forward 4JB1 series diesel engine maintenance manual
INTRODUCTION
This manual includes the detailed main technical specifications, structure, operation,
maintenance, adjustment and troubleshooting, sealing and unsealing, etc., of Forward
4JB1 series diesel engine, thus serving as a reference for the operation, maintenance and
repair of Forward 4JB1 series diesel engine.
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TABLE OF CONTENT
CHAPTER 1 TECHNICAL INFORMATION

1.1 Main technical parameters
1.2 Tightening torques of the important nuts and bolts
1.3 Main adjustment data
1.4 Temperature and pressure ranges
1.5 Fitting clearances and wear limits of the main components
CHAPTER 2 OPERATION AND TECHNICAL MAINTENANCE

2.1 Preparations before starting
2.2 Starting
2.3 Running
2.4 Stopping
2.5 Running-in
2.6 Sealing and maintenance
2.7 Fuel, oil and coolant
2.7.1 Fuel
2.7.2 Oil
2.7.3 Coolant
2.8 Maintenance
2.8.1 Daily maintenance
2.8.2 First-grade technical maintenance
2.8.3 Second-grade technical maintenance
2.8.4 Third-grade technical maintenance
2.8.5 Air-filter maintenance
2.8.6 Fuel-filter maintenance
2.8.7 Oil-filter maintenance
CHAPTER 3 STRUCTURE AND ADJUSTMENT

3.1 Components of the diesel engine
3.2 Cylinder-block components
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3.3 Cylinder-head components

3.4 Crank and connecting-rod mechanism
3.5 Valve mechanism
3.6 Lubrication system
3.7 Cooling system
3.8 Fuelsupply system
CHAPTER 4 PROBLEMS AND TROUBLESHOOTING

4.1 Diesel engine is difficult to start
4.2 Diesel engine doesn't operate at full power
4.3 Diesel engine runs with abnormal noise
4.4 Diesel engine exhaust contains unusual gas
4.5 Diesel engine oil over-consumption or lower oil pressure
4.6 Diesel engine cooling system With unusual temperature
4.7 Starter cannot run, starts noisily and with a lack of power
4.8 Alternator runs without output, doesn't charge engine
4.9 Battery capacity is insufficient, starts difficultly, self-discharges excessively
APPENDIX PARTS CATALOGUE
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CHAPTER 1 TECHNICAL INFORMATION
1.1 Main technical parameters
Table 1-1 Main technical parameters of Forward 4JB1 series diesel engine
Main technical parameters of Forward 4JB1 series diesel engine for genset
Model 4JB1 4JB1T 4JB1TA
Fuel injection system Inline pump with GAC electronic governor
Configuration In-line, forced water cooling, 4-stroke
Cylinder number 4
Bore x stroke- mm 93x102
Rated speed - rpm 1500 1800 1500 1800 1500 1800

Prime power - kW 24 28 28 34 36 44
Standby power - kW 27 32 32 38 40 48
Dimension - mm 855x667x795 855x590x799 885x590x799
Fuel consumption g/kW.h 226 223 226 224 223 221
Net weight - kg 225 241 241
Rated voltage - V 12
Main technical parameters of Forward 4JB1 series diesel engine for pump
Model 4JB1-P 4JB1T-P 4JB1-C 4JB1T-C
Fuel injection system Inline pump with mechanical VE pump with mechanical
governor governor
Configuration In-line, forced water cooling, 4-stroke
Cylinder number 4
Bore x stroke- mm 93x102
Rated speed - rpm 3000 3000
Prime power - kW 45 62 45 62
Dimension - mm 882x605x818 882x603x818 882x605x818 882x591x818
Fuel consumption g/kW.h 243 245 243 245
Net weight - kg 248 253 248 253
Rated voltage - V 12
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1.2 Tightening torques of the important nuts and bolts

The tightening torques of the important nuts and bolts of the Forward 4JB1 series diesel
engine are shown in Table 1-2.
Table 1-2 Tightening torques of important nuts and bolts

Nuts and bolts Tightening torque Nuts and bolts Tightening torque
Camshaft & upper idle gear 80-90 N·m Cylinder-head bolt 98-108 N·m
Rocker-shaft bolt 45-59 N·m Crankshaft-pulley bolt 260-300 N·m
Main bearing cap bolt 160-180 N·m Flywheel bolt 113-123 N·m
Connect-rod nut 80-90 N·m
● Note:
The important nuts and bolts of the diesel engine must be tightened with special spanner.
1.3 Main adjustment data
1.3.1 Valve clearances
Intake-valve clearance (cold state): 0.4mm±0.05mm
Exhaust valve clearance (cold state): 0.4mm±0.05mm
1.3.2 Pressure of injector valve (open): 18.6-19.6MPa
1.4 Temperature and pressure ranges
The range of temperature of the Forward 4JB1 series diesel engine is shown in Table 1-3.
Table 1-3 Temperature range of the Forward 4JB1 series diesel engine
Item Value Item Value
Coolant outlet temperature 75-85 ℃ Oil pressure 0.30-0.55MPa
Oil temperature ≤95 ℃
● Note:
The temperature of outlet of closed, high-pressure radiator reaches 100-105℃ in a short time.
The temperature of oil in the main path is 125-130℃.
1.5 Fitting clearances and wear limits of the main components
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Table 1-4 Fitting clearances and wear limits of the main components
No. Fitting parts Clearance (mm) Limits of clearance
1 Valve guide hold and inlet valve stem 0.039-0.071 0.20
2 Valve guide hold and outlet valve stem 0.064-0.096 0.25
3 Rocker arm and rocker shaft 0.010-0.050 0.20
4 Cylinder liner inner diameter and piston skirt 0.047-0.065
5 Tappet hole and tappet outer diameter 0.010-0.041 0.10
6 1st compression ring and piston ring groove 0.090-0.125 0.15
7 2nd compression ring and piston ring groove 0.050-0.085 0.15
8 Oil ring and oil cup height 0.030-0.070 0.15
I 0.2-0.4 1.5
9 Width of the piston pin II 0.2-0.4 1.5
III 0.1-0.3 1.5
10 Connect-rod little end bushing hole and piston pin 0.008-0.020 0.05
11 Piston pin hole and piston pin 0.002-0.015 0.03
12 Axle clearance of connecting rod journal and big end 0.0175-0.290 0.35
13 Camshaft bearing and camshaft journal 0.015-0.085 0.12
14 Connect-rod big end bore and crank pin journal 0.029-0.075 0.10
15 Main bearing bore and main crankshaft journal 0.033-0.079 0.11
16 Axle clearance of crankshaft 0.05-0.20 0.30
17 Clearance of timing gears 0.10-0.17 0.30
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CHAPTER 2 OPERATIONS
2.1 Preparations before starting
(1) Before starting a new diesel engine, check tightness of all parts, accessories and control
mechanisms.
(2) Please check the coolant level only when the diesel engine is not operating. Check the oil
level, which should be between the marks "L" and "F" on the dipstick. Check the oil pipe and
water pipe for leakage, deterioration and tightness.
● Note:
The mark "L" is warning level. Do not run diesel engine at this level. Check oil level 5 minutes
later after adding oil.
(3) Air must be expelled from the pipe before starting a new engine and an engine that has not
been used for a long time or has just been repaired. Do as follows: First, loosen the exhaust
coupling bolt on the fuel filter, and pump fuel with the hand pump until no bubbles are in the
discharged fuel. Secondly, tighten the exhaust coupling bolt. Thirdly, loosen exhaust coupling
bolt on the fuel pump, and do as described above until no bubbles are in the discharged fuel.
(4) Check the connectors of the electric equipment and check the electrolyte level ofthe battery.
2.2 Starting
(1) Turn switch key to the "Start" position.
● Note:
In order to protect the starter and battery, each time you start the diesel engine, should not be
longer than 15 seconds. If the first could not start the diesel engine, restart the diesel engine
at least two minutes later. If you fail to start up for three times, check the fuelsupply system and
wiring system.
(2) After starting, please check oil pressure immediately.
2.3 Running
(1) It cannot run with a full load immediately after starting. The engine needs to warm up free
of load. It runs with a full load only after the coolant’s temperature reaches 60°C.
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● Note:
For new and overhauled diesel engine, full load can be applied only after 60 hours' running-in.
(2) Confirm whether the coolant temperature is appropriate while diesel engine is running.
(3) Confirm whether there is abnormal noise, confirm if there is leakage in the fuel supply,
coolant system and air system while diesel engine is running. Otherwise, it may result in
serious problem.
● Note:
If the indicator of oil pressure or the indicator of coolant temperature is in the warning state
while diesel engine is running, stop the engine and check. It can only be restarted after the
problem is solved.
2.4 Diesel engine stopping
(1) The load on the diesel engine must be reduced gradually before stopping. It only can stop
after engine coolant is below 70℃.
(2) Do not stop engine by closing the fuel tank to prevent air from mixing into the fuel-supply
system, as this will make it difficult to start next time.
2.5 Running-in
A new or overhauled diesel engine (including a replaced piston, piston ring, cylinder liner, main
bearing and connecting-rod) must be running-in for certain time before normal operation. The
load should be added gradually. During running-in process, the friction surfaces of diesel
engine parts will fit well to avoid abnormal wear. Experience shows that the life, reliability and
economy of diesel engine mainly depend on the running-in of initial stages.
The running-in process should exceed 50h.
Table 2-1 Running procedure for new diesel engine

Load (%) Running time Load (%) Running time
25 10 75 30
50 15 100 5
First, running-in with 25% load in 10 hours; then running-in with 50% load in 15 hours and
running-in with75% load in 30 hours; finally, running-in with 100% load in 5 hours. The load
must be added gradually.
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● Note:
Maintenance must be taken after running-in.
(1) Replace oil in the oil sump.
(2) Replace oil filter element.
(3) Adjust clearance of the valve and fuelsupply advance angle. Tighten the bolts and nuts.
2.6 Sealing and maintenance
If diesel engine will not be running for long time (over 3 months), it should be sealed with the
instruction as follows:
(1) Drain fuel and oil from diesel engine and drain the coolant from radiator.
(2) Remove preheating plugs, dispense 30g engine oil into the cylinder and then rotate the
crankshaft for 15-20 circles before reinstalling preheating plugs.
(3) Clean the surface of diesel engine, add industrial Vaseline to the points and contactors of
the electric devices as well as the unpainted metal surfaces.
(4) If diesel engine will be sealed for long time, it should be checked every 2-3 months. In order
to prevent engine parts from rusting, diesel engine should run for an hour under the procedure
for starting and running. Seal diesel engine again according to engine sealing instruction.
2.7 Fuel, oil and coolant
2.7.1 Fuel
Forward 4JB1 series diesel engine should use light diesel fuel. According to the season and
temperature, the fuel should be selected as follows:
Table 2-2 Fuel grade of Forward 4JB1 series diesel engine

Temperature Grade of diesel fuel Temperature Grade of diesel fuel
Above 5℃ 0# light diesel fuel Above -25℃ -35# light diesel fuel
Above -5℃ -10# light diesel fuel Under -25℃ -50# light diesel fuel
Above -10℃ -20# light diesel fuel
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Table 2-3 Specification for light fuel oil
Temperature of distillation Viscosity (20℃)

Moisture
Cetane
Flash Condens content
number Sulfur Ash
50% 90% 95% % Point ation %
No. not Kinematic % %
not not not ≤ ℃ ℃ not
less °E viscosity ≤ ≤
higher higher higher ≥ ≥ more
than 10-6 m2/s
than than than than
10 50 300 355 365 1.2-1.67 3-8 0.4 0.2 0.025 60 10

0 50 300 355 365 1.2-1.67 3-8 0.4 0.2 0.025 60 0
10
-10 50 300 355 - 1.2-1.67 3-8 0.3 0.2 0.025 60 -10 No Trace
-20 45 300 355 - 1.15-1.67 2.5-8 0.3 0.2 0.025 60 -20
-30 43 300 - 350 1.15-1.67 2-7 0.3 0.2 0.025 60 -35
To limit problems and maximize the life of diesel engine, diesel fuel must be clean.
Keep the fuel clean by means of the procedure for fuel transport and dispensation.
● Note:
(1) Fuel cannot be mixed with water and impurities.
(2) Do not dispense fuel when the engine is running. Keep the area around the mouth of the
fuel tank clear. Fuel cannot be allowed to overflow.
2.7.2 Lubrication oil
Use high quality lubrication oil to relevant specification as shown in the table below.
Attention: The type of lubricating oil to be used may be affected by the quality of the fuel which
is available. For details, see "Fuel Specification."
Always ensure that the correct viscosity grade of lubrication oil is used for the ambient
temperature range in which the engine will run, as shown in the chart below:
0W
5W20
10W30
15W40
-30 -20 -10 0 10 20 30 40 50℃

-22 -4 -14 32 50 68 86 104 122°F
Diesel Engine Operation Temperature
Figure 2-1 Lubrication oil standard according to local temperature
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● Note:
(1) Confirm that the oil is free of water and impurities.
(2) Oil of different grades or different manufacturers can not be mixed. Used oil and new oil
can not be used together.
Table 2-4 Specification for lubrication oil

Specification
Engine API CD/SE

API CC/SE
CCMC D4
Naturally aspirated ● ●
Naturally aspirated engines in heavy-duty earthmoving equipment ●
Turbocharged ●
※ Not recommended for first 20/40 hours operation, nor for light-loadapplication
2.7.3 Coolant
The diesel engine's cooling system should use coolant that has the capability of antifreeze,
antirust, anti-stain and high boiling point.
● Warning:
Coolant is poisonous;it must be kept in its original container.Do not make contact with the skin
or splash into the eyes.If water is ofhigh mineral content, which will change into furring at high
temperature and adhere to water pipe and high-temperature parts. Thiswill clog them and
result in overheating to diesel engine.
● Note:
(1) Do not add water if the coolant is insufficient, as it will affect the coolant performance.
(2) If the coolant is insufficient due to leakage, once the diesel engine is cool the same grade
of coolant should be added.
(3) Do not mix different coolants together. Please use the same grade of high-quality coolant.
Otherwise the life of the diesel engine will be shorted due to erosion and furring.
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Table 2-4 Formula for liquid antifreeze
Solidifying
Description Unit of
Ethylene Alcohol Glycerin Water point ≤
composition
60 40 -55
Ethylene liquid 55 45 -40
antifreeze 50 50 -30
40 60 -22
2.8 Maintenance
During engine operation, engine performance will get worse due to the wear of parts. It is
necessary to take maintenance. There are four grades of maintenance:
(1) Daily maintenance to be performed after running 8-10h.
(2) First maintenance to be performed after running 100h.
(3) Second maintenance to be performed after running 200h.
2.8.1 Daily maintenance
(1) Confirm whether there is oil leakage, coolant leakage or air leakage, and tighten every nut
and bolt.
(2) Confirm whether or not coolant and oil is enough, refill if necessary.
● Note:
Check if there is mixture of oil and coolant in theradiator. If coolant is determination. It is
necessary to confirm whether there is abnormal noise, vibration, exhaust.
2.8.2 First-grade technical maintenance
(1) Perform the daily technical maintenance.
(2) Check the tightness of fan belt, and adjust ifnecessary.
2.8.3 Second-grade technical maintenance
(1) Perform the first-grade technical maintenance
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(2) Replace the oil (including the oil in the fuel pump).
● Note:
To lubricate every part, it is necessary to run without load for some time after the oil is
replaced.
(3) Replace fuel filter element.
(4) Replace oil filter element..
(5) Clean air filter.
● Note:
It is necessary to ensure the sealing of the air filter.
It can avoid air get into cylinder block directly.
(6) Check fuel pump advance angle, adjust it if necessary.
(7) Check valveclearance and adjust it if necessary.
(8) Check overflow hole of water pump. If there is leakage from the overflow hole, replace the
water pump.
(9) Check the connector of electric equipment. A burnt wire must be replaced.
2.8.4 Air filter maintenance
It should be maintained after diesel engine has been operating for 200 hours. Remove any
dust from the shell filter element.
(1) Clean air filter box: Wipe the dust from air filter box and sealing gasket surface (see Figure
2-2).
(2) Clean air filter element if the filter is in dry condition, clean it with compressed air (see
Figure 2-3). Turn filter element by hand, blowing off the dust with compressed air. The
pressure of compressed air should be lower than 490KPa.
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Figure 2-2 Clean air filter Figure 2-3 Clean air filter
● Note:
Do not clean the air filter with compressed air from outside because it will make dust enter into
filter.
Air filter element should be replaced at the following case:
The filter element is polluted by carbon deposits and oil stains.
The oil stains on the filter aren't easy to remove.
Air filter element is distorted or damaged.
2.8.5 Fuel-filter maintenance
The maintenance of fuel filter should be done as below:
(1) Clean the surface of fuel filter element. Nip oil-intake tube.
(2) Unscrew the filter box and dissemble it with a spanner.
(3) To ensure the reliability of connecting, it is necessary to cleanfilter seat.
(4) Lubricate sealing ring with a little fuel. Install the filter box to seat it by hand, and then
ensure that the screw connection is reliable.
(5) Unscrew the filter element with a spanner and loosen the oil-intake tube to confirm whether
there is leakage.
(6) Expel air from the fuel filter.
2.8.6 Oil filter maintenance (Figure 2-4, 2-5)
(1) Place a container under oil filter to catch overflowing oil.
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(2) Dissemble oil filter element by turning it counter-clockwise with a spanner.
Figure 2-4 Replace oil filter element Figure 2-5 Replace oil filter element
(3) Check and clean oil filter seat to ensure a proper connection.
(4) Place a little oil on sealing ring of the new filter. Screw the oil filter box onto the seat by
hand until resistance is felt, then continue 3/4 of a circle by turning clockwise with a spanner.
(5) It is necessary to ensure there is enough oil in oil sump.
(6) Star tengine to confirm whether there is leakage, and then stop the engine to check the
oil-level indication on dipstick. Add oil if necessary.
● Note:
(1) Oil filter element is not recyclable.
(2) Replace oil filter element according to the maintenance procedure.
(3) The output pressure is limited to 0.45±0.02MPa by a valve. Do not dissemble or adjust
under normal conditions, as it has been adjusted as default by manufacturer.
(4) To ensure the sealing of the filter, take care of the sealing ring. Replace the filter if the
sealing ring is damaged.
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CHAPTER 3 TECHNICAL MAINTENANCE
3.1 Components of diesel engine
Diesel engine is a complicated machine that converts thermal energy into mechanical energy.
There are various mechanisms and systems present in different kinds of diesel engines.
3.1.1 Cylinder head and cylinder block
The function of the cylinder head is to close the upper side of the cylinder and form a
combustion chamber between upper side of the cylinder and the top of the piston. An intake
valve, exhaust valve, rocker arm and injectors are mounted on the cylinder head. Additionally,
the cylinder head has intake and exhaust ports and a cooling jacket. The cylinder block is one
of the most important parts of the diesel engine. There are various mechanisms and systems
mounted on cylinder block.
3.1.2 Crank and connecting-rod mechanism
The crank and connecting-rod mechanism transmit the reciprocating motion of the piston into
the rotating motion of crankshaft, thereby transmitting the push force on the piston caused
by burned gas into torque at the crankshaft. It can also transmit the rotating motion of the
crankshaft into the reciprocating motion of the piston, whereby it transmits the torque of the
crankshaft into the push force of the piston. Through these motions, a diesel engine performs
its working process and outputs energy via the crankshaft. The mechanism of the crankshaft
and connecting rod is comprised of the piston, connecting rod, crankshaft, flywheel, etc.
3.1.3 Valve mechanism and intake/exhaust system
The function of valve mechanism and intake/exhaust system is to open the intake valve and
close the exhaust valve at a precise timing to ensure that fresh, clean air can be drawn into the
cylinder at the exact instant it is needed, so that the exhaust gas can be pushed out of cylinder
most efficiently. The mechanism consists of the intake and exhaust valves, transmission
mechanism (drive gears, camshaft, tappets, pushrods, rocker shaft, rocker arm, etc.), air filter,
intake and exhaust pipes, etc.
3.1.4 Fuel-supply system
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The function of the fuel-supply system is to inject fuel into the chamber at a precise timing,
using a fixed quantity and pressure according to the condition of the diesel engine so that
diesel fuel be burnt completely. At the same time, the fuel supply should be adjusted
automatically according to the load of the diesel engine thereby ensuring the constant speed
of diesel engine. The fuel-supply system mainly consists of a fuel tank, oil filter, transfer
pump, fuel-injection pump and fuel injectors.
3.1.5 Lubrication system
While diesel engine is working, the surfaces of the crankshaft, connecting-rod mechanism and
other moving parts will incur friction and wear. So, the main function of the lubrication system
is to lubricate the surfaces of moving parts, reduce friction resistance and wear, prevent the
overheating of such parts, clean the friction surfaces and preserve the seal surfaces. The
lubrication system is mainly comprised of the engine-oil strainer, oil pump, oil filter, oil cooler,
etc.
3.1.6 Cooling system
The function of cooling system is to remove excess heat from parts during operation and
maintain the normal working temperature of the diesel engine. The cooling system is mainly
comprised of the radiator, water pump, and fan etc.
3.1.7 Starting system
The function of the starting equipment is to rotate the static crankshaft by outside power until
the crankshaft can move independently. It includes the start motor, battery and other
equipment.
3.2 Cylinderblock components
Forward 4JB1 series diesel engine is designed with a thin-walled dry liner made of steel. When
the liner is worn, replace it if necessary.
● Note:
In order to choose the right piston, it is necessary to measure the liner’s diameter after
replacing the liner. The clearance is controlled 0.047-0.065mm.
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There are five main bearings on the cylinder block. Each is tightened onto the cylinder block
with two M14 bolts. The tightening torque is 160-180N.m. Tighten three times (first to
40-50N.m, then 90-100N.m and then 160-180N.m) via the procedure shown in Figure 3-1.
Because the main-bearing cover is machined with the cylinder block, it cannot be installed in
the opposite direction. For correct installation, it is marked with "1", "2", etc., and an arrowhead
on each main-bearing cover points to the front of diesel engine (see Figure 3-1).
Arrow
Front
Lubricating with oil the diesel engine
Figure 3-1 Figure 3-2
Tighteningsequence of main bearing cap bolts Installation of crankshaft thrust washers
The third main bearing supports the thrusting force of crankshaft. There are half-round thrust
washers on the two sides of the third main bearing. Each thrust washer comprises a steel liner
and aluminum-alloy layer. When installing the thrust washer, position the surface with the oil
groove toward the rotational position of the crankshaft (see Figure 3-2).
The thrust clearance of the crankshaft is Upper bush with oil groove and hole
Correct installation
0.05-0.02 mm.
Each upper bearing has an oil groove and a

hole (see Figure 3-3). Place upper bearings
on cylinder block, the lower bearings on cylinder
block and a lower bearing on the main bearing
cap during installation. Align the bearing claw
with the claw groove of the cylinder blockand Lower bush without oil groove and hole
the main bearing cap separately.
Figure 3-3
Upper &lower main bearings & installation
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There are three cam-bearing bores on the upper right sides of the main bearing holes. A
bearing, which is made of high tin-aluminum alloy with a steel liner, is pressed into each
bearing bore. When reassembling the camshaft, match the bearings to the oil holes on the
cylinder block.
3.3 Cylinder-head components
The cylinder head is installed on the cylinder block with 18 M11 bolts, and tightening torque is
98-107.8N.m. First lubricate the bolts with lubricating oil and then tighten them at two passes
in the sequence shown in Figure 3-4 (first, 49-78N.m; second, 98-108N.m).
Figure 3-4
Tightening sequences of cylinder head bolts
The valve guide that is pressed into the cylinder head is made of power metallurgy with an iron
base or is made of cast-iron alloy. It is highly resistant to wear, but it cannot support a larger
pressure force from the side direction. Therefore, do not hit or press it during disassembling or
reassembly.
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Figure 3-5
Cylinder head casket assembly
1. Oil hole 4. Pad board 7. Upper board

2. Coating 5. Wheel circle inserting board 8. Auxiliary board
3. Bottom board 6. Inserting board 9. Steel wire ring gap mark
The cylinder-head gasket is made of 5-layer steel plate. The part ofcylinder hole is warped up
by tinplate, and there is a steel wire ring in it. There are special coatings on and around the
pushrod holes and water holes in order to seal them well (see Figure 3-5).
If there is leakage of air or water from the cylinder-head gasket, check the tightening torque of
the cylinder-head bolts with a torque spanner when the diesel engine is sufficiently cool. The
tightening torque is 98-108N.m, and the tightening sequence is shown in Figure 3-4. When
disassembling the cylinder head to clear away carbon deposits or disassemble the piston, fully
drain the cooling system first and then disassemble other parts mounted on the cylinder head
(the intake and exhaust manifold don't have to be disassembled). Loosen and remove the 18
cylinder-head bolts and then remove the cylinder head gently and carefully, avoid any damage
to the surface of the cylinder head and the cylinder block. Check the cylinder head for cracks
and warping. Check the cylinder-head gasket with damage, oil leakage, gas leakage and water
leakage.
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Table 3-1 Thickness of cylinder head gasket
Cap market of cylinder Protrusion height of piston Free thickness of cylinder

Head gasket (mm) Head gasket (mm)
A 0.617－0.722 1.60
B 0.722－0.827 1.65
C 0.827－0.933 1.70
Measure of protrusion height of piston:
(1) Carefully clean any carbon deposits from the top of the piston and gasket on the top
surface of the cylinder block.
(2) Measure the protrusion height of the piston at spots 1 and 3 of the piston top surface and
at spots 2 and 4 of the cylinder block top surface with an indicator (see figures 3-6 and 3-7).
Each cylinder must be measured.
(3) Record the highest value and then use this value to select the thickness of the cylinder-head
gasket.
● Note:
The highest protrusion of the piston must be 0.617 - 0.933mm.
Figure 3-6 Measurement of Figure 3-7 Measurement points of

protrusion height of piston top piston surface and cylinder block surface
3.4 Crank and connecting-rod mechanism
3.4.1 Piston
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The piston of the Forward 4JB1 diesel engine is made of common–crystal sliming, and is
coated with tin on the outside surface to improve its performance of wearability There are
forward-facing marks on top of the piston. When assembling piston connecting rod to the
cylinder, position the front mark of the piston toward the front of the diesel engine. There is
also a piston diameter mark on the top of the piston, such as "M, N, S, A, B, C, D, E." When
reassembling the piston connecting-rod to the cylinder, make sure the piston diameter mark
matches the cylinder block (see Figure 3-8).
Figure 3-8 structure of piston

1. Inserted ring groove seat
2. Quadrangle shape with shrinkage periphery
and ω model combustion chamber
3. Diameter mark
4. Quantity mark
0.7mm excursion 5. Front towards mark

of piston pin
6. Steel supporter
● Note:
The front mark of piston must face toward front side of diesel engine when reassembling a
piston (see Figure 3-9).
Figure 3-9 Reassembling pistonwith special
piston rings compressor
1. Special piston rings compressor
2. The front towards mark of piston
Measure the amount of wear, and change the piston if the amount exceeds the standard.
Choose the same diameter group as with the old one.
● Note:
Change the piston ring while changing the piston.
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3.4.2 Piston ring
The piston ring includes a compression ring and oil ring (see Figure 3-10). The standard of
the piston ring's hatch clearance is as follows: first compression ring, 0.2-0.4mm; second
compression ring, 0.2-0.4mm; oil ring, 0.1-0.3mm.
Figure 3-10 Structure of piston ring
Place the piston ring in a standard cylinder jacket and use the thickness gauge to measure the
hatch clearance. The clearance will reduce the wear resistance of the piston ring, which
causes higher percentage of air leakage When the clearance value exceeds the standard, it
should be changed.
The clearance between piston ring and groove is called side clearance: first compression ring,
0.090-0.125mm; second compression ring, 0.050-0.085mm; oil ring,0.030-0.070mm.
Place the piston in the relevant groove and use thickness gauge measure the size of side
clearance. Ensure the side clearance and
2nd compression ring Spiral spring ring
hatch clearance when assembling the piston
ring. Otherwise, the groove can be obstructed
and lose seal capability. Reassemble three
piston-rings according to the number with
the piston-ring compressor. The mark "N"
on the ring should be upward, and ring gap
Oil ring
should be staggered (see Figure 3-11).
1nd compression ring
Figure 3-11 Installation positions of piston
24
3.4.3 Piston pin
The piston pin is fixed by an elastic ring that can is easily reassembled and disassembled with
the help of pointed pincers, because there is a gap in the piston pin seat (see Figure 3-12).
Check the piston pin elastic rings for cracking and scarring when piston pin elastic rings are
assembled, then move the opening of piston pin ring away from the gap of the piston.
Figure 3-12
Disassembly and reassembly of
elastic ring with the sharp pincers
3.4.4 Connecting rod and bolts
The connecting rod is forged from steel alloy. There is a lead-bronze alloy liner set in the small
end of the connecting rod, with a small oil groove on the small end for the lubricating piston pin.
There are bearings that made of aluminum alloy in the hole at the big end of the connecting
rod. In order to avoid faulty assembly, there are matching marks on the right side of the
connecting body and the cap. There are protrusion marks on the mid-part of the connecting rod
and the head of the connecting rod cap. During reassembly, ensure that these marks face the
front of the diesel engine (see Figure 3-13).
Figure 3-13 Mark of Connectingrod

1. Front towards marks
2. Couple marks
25
● Note:
Do not install the connecting rod cap inreverse direction. Apply lubricating oil to the screw
thread and piston face of the bolts, and then tighten them two times (first 40-50N.m; second
80-90N.m). (see Figure 3-14.)
Figure 3-14 Tighten connection rod bolts
3.4.5 Flywheel
There is flywheel rim on the edge of the flywheel. It meshes with the rim of the starter.The
flywheel is mounted to the crankshaft by eight bolts to ensure the reliability of installation (see
Figure 3-15).
Figure 3-15 Structure of crankshaft
26
● Note:
(1) When reinstalling crankshaft-pulley bolts, apply lubricating oil to screw threads and tightent
specified torque 167-206N.m.
(2) When reassembling flywheel bolts, apply lubricating oil to the screw thread and contact
plane, and then tighten the according to the intersect order in several passes. The flywheel
bolttightening torque is 113-123N.m.
Figure 3-16 Sketch for the structure of crankshaft
A high-performance frame-type oil seal with a screw groove is used for the crankshaft. Its
structure and installation are shown in Figure 3-16.
3.4.6 Crankshaft pulley
There are timing marks on the edge of the

pulley, such as TDC and BTDC12, 14 and 16
degrees (see Figure 3-17).
● Note:
When checking and adjusting, put timing

marks right toward protrusion on gear-case
cover so you can determine the positionfor
TDC and advance angle of injection.
Figure 3-17 crankshaft pully
27
3.5 Valve mechanism
3.5.1 Intake and exhaust valves The valve is used to control intake and exhaust from
the pipe (see Figure 3-18).
3.5.2 Valve spring
When reassembling the valve spring, put the small-pitch end of the spring (painted) toward the
cylinder head.
● Note:
Valve keepers must be set correctly in the valve-keeper groove. Otherwise, when they drop
away the valve will fall into the cylinder and cause a serious accident.
Figure 3-18 Sketch of valve installation

1. Valve Keepers
2. Upper seat of valve spring
3. Valve spring
4. Valve guide seal
5. Lower seat of Valve
3.5.3 Rocker arm
Screws and nuts on arm rocker can adjust valve clearance.
3.5.4 Adjustment of valve clearance
The clearance of intake and exhaust valves is 0.40±0.05mm in the cold state. If the valve
clearance is too big, it may cause serious knocking, and if it's too small itmay prevent the valve
from closing completely. Consequently, the valve could burn out due to excessive heat. Meth-
ods of valve-clearance adjustment listed below:
(1) Turn the crankshaft so that the piston of cylinder No. 1 reaches the TDC piston (Figure
3-19). The "TDC" mark on edge of the pulley should be right toward the pointer on the
gear-case cover. In this condition adjust 1st, 2nd, 3rd and 6th valve clearances (see Figure 3-20).
28
(2) Loosen the rocker-arm nut, and then insert the feeler gauge between rocker arm and
valve, turn the adjusting screw with the help of screwdriver to make the feeler could move a
little but not smoothly, and then tighten the nut (see Figure 3-21).
(3) After adjusting valve clearances of 1st, 2nd, 3rd and 6th, turn the crankshaft one cycle to let
the piston of the No. 4 cylinder reach the TDC position and then adjust 4th, 5th, 7th and 8th valve
clearances in the same way (Figure 3-22).
Turn crankshaft to 1# piston at TDC Adjust 1st ,2nd, 3rd, and 6th Valve Clearances
of compression stroke
Check valve clearance with Feeler Gauge Adjust 4th,5th,7th and 8th Valve Clearance
3.5.5 Hand-lap the valve and check the valve for sealing
After the diesel engine has worked for 1000 hours, check the valve and seat for burnt or worn.
29
If necessary, lap the valve. If the diesel engine works under a heavy load for a long time, if the
fuel-supply system is not in good condition, the air filter is damaged or dirty air is allowed
through the intake, the valve sealing will worsen quickly. Therefore, check it on a routine basis.
(1) Hand-lap the valve.
If the valve and seat are slightly worn, you may retrieve them by hand-lapping the valve as
follows: First, clean the carbon on valve, seat and guide. Then, place lap cream on valve face.
Polish it by lapping and rotating, making each rotating angle smaller than 90°. Do so until there
is a ring (the width is 1.5-2mm) on the valve face. If the ring is too wide, it will be difficult to seal.
If the ring is too thin, it will be difficult to cool and valve will become damaged due to high
temperatures. Please choose right lap cream according to the condition of wear and burning.
Often, lapping begins with grit and proceeds to fine paste in the final round.
After lapping the valve, clean the valve face, seat and guide hole completely. Finally, check
sealing capability of the valve.
(2) Check the sealing capability of the valve.
Draw 8-12 evenly spaced lines with a pencil on the valve face (see Figure 3-23). Reassembly
the valve (do not rotate the valve), beat the valve plant and then check the valve to confirm that
all of the lines break off at the midpoint. This shows that the valve is sealing well. Finally, check
by dispensing coal oil into the intake and exhaust ports. If there is no leakage within three to
five minutes, the sealing capability of the valve is appropriate.
Figure 3-23
3.5.6 Rocker shaft
When reassembling rocker arm shaft components, tighten the bolts of the rocker shaft
according to the order shown in Figure 3-24. The tightening torque is 49-59N·m.
30
Figure 3-24
Tighten bolts of rocker armshaft

according to the order
3.5.7 Camshaft
The clearance between camshaft journal and bearing is 0.015-0.085mm. The thrust clearance
of the camshaft is ensured by the difference in thickness between the thrust washer and the
thrust flange of the camshaft. The thrust clearance of the camshaft is 0.05-0.14mm (Figure
3-25).
Figure 3-25 Measurement of thrust clearance

of camshaft
1. Feeler gauge
2. Camshaft gear
3. Thrust washer
4. Camshaft
3.5.8 Gear case
There are 5 gears mounted in the gear case: crankshaft gear, camshaft gear, injection-pump
gear, upper idle gear and lower idle gear. There are coupling marks on each gear, such as "X",
"Y", "Z" or "V" (see Figure 3-26). When assembling, adjust the marks to ensure the correct
supply of fuel and air. The lower idle gear is driven by a camshaft gear set mark as "X" on both
the lower idle gear and crankshaft gears. The camshaft gear and upper idlegear are driven by
lower idling gear set marks as "Y" and "Z", and the injection-pump gear is driven by upper idle
gear set mark as "V".
31
Figure 3-26 Gear transmission &marks

1. Gear of camshaft
2. Gear of fuel pump
3. Upper idle gear
4. Lower idle gear
5. Gear of crankshaft
● Note:
(1) Accurately check the signs of the gear

when assembling. Otherwise, the diesel
engine cannot be started or its power wou
decrease and oil consumption would
increase. Moreover, the parts of the valve
mechanism will be damaged. If the sign of
gear is not clear or gear is worn, change the
gear mechanism according to its condition.
(2) Be sure that the oil-lubrication hole on

Figure 3-27
lower idling gear shaft faces upward during
reassembly (see Figure 3-27). Lower idle gear assemble
3.6 Lubrication system
3.6.1 Construction
See the figures 3-28 and 3-29.
32
Figure 3-28 Lubricating system of diesel engine
Figure 3-29 Oil flow of lubricating system
33
3.6.2 Oil filter
The oil filter element should be replaced with the engine running. Replace the oil filter
elementand oil every 200 hours (see Figure 4-30).
The open pressure of the relief valve on the filter seat is 0.55±0.02MPa. This is properly adjusted
as default value. Please do not change it. When reassembling the oil filter, properly position
sealing ring or oil leakage may occur.
● Note:
(1) Check the contact surface of the oil filter and oil filter seat for oil leaking, check parts for
damage.
(2) Perform technical maintenance as directed by maintenance manual. Parts will be worn and
oil pipe may be jammed due to impurities in the oil.
3.6.3 Oil pump
The technical regulations for oil-pump installa-

tion:
(1) After the oil pump is assembled, it should

rotate freely and smoothly.
(2) No leakage between oil pump and cover.
(3) The opening pressure of safety valve is

0.62-0.78MPa.
(4) The opening pressure can be adjusted by

increasing or reducing adjustable gasket in
safety valve.
(5) Tightening torque of 4 bolts of oil pump

cover is 20±5N.m
● Note:
Figure 3-30 Oil filter
If oil pressure is low, the pressure indicator will
issue a warning. It means trouble has occurred 1. Oil filter element
in the lubrication system and the diesel engine 2. Sealing ring
3. Oil cooler
needs to be checked and maintained.
4. Oil filter seat unit
34
3.6.4 Oil sump
The function ofoil sump is to seal up the crankshaft case, thereby collecting and storing oil.
After the oil sump is installed, start the diesel engine for some time. Under the hot condition,
check the oil sump for oil leakage. If there is leakage, tighten the bolts of the oil sump or
replace the gasket if necessary (see Figure 3-31).
Figure 3-31 Oil sump unit

1. Sealing ring
2. Oil sump
3. Tightening bolt
3.6.5 Oil dipstick
The oil dipstick is a tool used to check the oil level of the lubrication system (see Figure 3-32).
There are higher and lower holes for checking the level on the dipstick.
Figure 3-32 Oil dipstick
3.7 Cooling system
3.7.1 Structure and operation of cooling system (Figure 3-33).
35
Figure 3-33 Cooling system
3.7.2 Water pump
Do not run water pump when there is no water in water jacket, in order to prevent damage to
water seal due to heating. There is a water spill hole at the bottom of the pump housing. If the
water seal is damaged, coolant will overflow through the spill hole. Do not block the hole in
order to prevent water from leaking into pump bearing and causing damage (Figure 3-34).
Figure 3-34 Structure of water pump

1. Fan pulley flange
2. Water pump shaft with bearing
3. Pump housing
4. Water pump impeller
5. Water sealing unit
6. "O" sealing ring
36
3.7.3 Thermostat
The initial opening temperature of the thermostat is 77℃.
The full opening temperature is 90℃., Fully opening lift is not less than 8mm.
Thermostat inspection:
Immerse the thermostat in the container with water, and heat the water gradually. Check the
valve's opening temperature with a thermometer and valve lift (see Figure 3-35).
Figure 3-35 Check thermostat

1. Thermometer
2. Hot water
3. Thermostat
3.7.4 Fan drive belt
The deflection of the fan drive belt must be a propriety. If the belt is too loose, there will be
slippage between the belt and the pulley. In this case the cooling effect will be insufficient, the
coolant temperature will raise and the belt will become worn in a short time. If the belt tension
is too great, the bearing of the water pump and belt will quickly become worn or damaged. In
this case the fuel consumption will also increase.
When installing the belt, first place it into the grooves in the generator pulley and water pump
pulley, and then place it into the groove in the crankshaft pulley. Pry the alternator with a
crowbar to tension the belt, and then tighten the bolt.
Check the drive-belt deflection: Press the belt with the force of 68.6-98N and check belt
deflection (new belt, 5-7mm; used belt, 7-8mm).
● Note:
Stop engine before checking, adjusting or changing belt.
37
3.8 Fuel-Supply System
3.8.1 Structure of PL in-line fuel-supply system (Figure 3-36)
3.8.2 PL in-line fuel injection pump
● Note:
(1) Please perform technical maintenance on the fuel filter and replace it as directed by the
maintenance manual.
(2) Perform maintenance according to the manual. Routinely check the oil in the fuel pump
with the oil-level stick.
3.8.3 Injector
The injector is a multidirectional type, and injection open pressure is 18.6-19.6MPa.
Trouble in the injector will cause the diesel engine to be unstable in operation and emit black
smoke. In order to find the faulty injector, set the throttle at the most obvious position at which
the diesel engine is unstable. Then, loosen the connecting nut of each high-pressure fuel line
on the pump, one by one, in order to cut off fuel delivery to the corresponding cylinder. If the
speed of the diesel engine dose not change significantly and smoke is less when cutting off
fuel delivery to a cylinder, it means the problem has occurred in that injector. Remove it for
repair or replacement.
Figure 3-37 Check injection spray of injector
38
3.8.4 Inspection for injection spray
Set injector on the test device and check the injection spray of injector (see Figure 3-37). Clean
and adjust injector if bad atomization, fuel faggot injection, leakage or abnormal injection noise
were found, replace it if necessary.
The normal injection spray of an injector is as follows: It injects fuel as a fine mist with an
injection prick angle of 4-12 degree, doing so with a "ping, ping" sound. Under abnormal
conditions the fuel is cut completely, whereby no fuel mist is delivered. There should be no
leakage after injection, but dampness at the end of the injector is acceptable.
3.8.5 Inspection and adjustment for injection timing
The diesel engine's normal, reliable operation is related to the correct adjustment of injection
timing. Although there may be only a slight change in the injection timing, the fuel consumption
may increase and the power will decrease to an obvious extent. Therefore, the injection timing
must be adjusted carefully.
Adjust the injection timing as follows:
Thebest injection timing is adjusted by the manufacturer, whereby the injection timing of
Forward 4JB1 series diesel engine is 12CA°.
If it’s necessary to adjust injection timing, please follow:
(1) Check the injection timing Loosen the

screwcap of high-pressure pipe of 1# piston on
the pump, and turn the crankshaft clockwise
until there is no fuel overflow from the plunger
of the No. 1 piston on the pump. Now, the
timing mark of the pulley corresponds to the
timing mark of the gear-case cover, and the
value isfuelsupply advance angle (see Figure
3-38).
(2) Adjust the injection timing.

Figure 3-38 Check injection timing
If the fuel-supply advanced angle does not
1. The timing mark of pulley
match fixed value, adjust injection timing as
2. The timing mark of gear case cover
follows:
39
Loosen the three nuts in the fuel pump flange.
Adjust fuel-supply advance angle:
Adjust to delay by rotating the injection pump in the direction of the diesel engine.
Adjust to advance by rotating the injection pump in the direction the opposite of diesel engine.
40
CHAPTER 4 TROUBLE AND TROUBLESHOOTING
After the diesel engine has run for a long time, some of its parts will become worn or damaged,
thereby diminishing its technical specifications. When the technical specifications aren't within
their respective ranges, it indicates that the engine is in trouble. The failures should be
resolved promptly when this occurs. If the diesel engine is operated despite malfunctions, not
only will the power and economic capability decrease but also the operation performance will
change. Even the parts and accessories will wear quickly, and the diesel engine could suffer
damage.
Some failures, such as the presence of air in the oil system, filter clogging, the looseness of
belts, etc., can be resolved through adjustment and maintenance. Other failures, such as an
excessively worn piston ring or a damaged cylinder gasket, cannot be resolved through
adjustment or maintenance due to the limitations of the diesel engine. Instead, the operator
must disassemble the engine or change parts in order to resolve such failures.
● Note:
(1) Usually, failure is caused by inappropriate operation or deferred maintenance. The operator
should confirm whether the engine is being operated according to the specified procedures
and that maintenance is performed to prevent and correct failures.
(2) Resolve failures in time. First, check out the reason of the failure. Then go to service
station if need disassemble.
(3) For complicated failures, the technician should perform professional process with
professional instruments and equipment. If clients aren't qualified to adjust or maintain the
engine, please contact nearest service station.
(4) Never run diesel engine with "sickness". Engine working with "sickness" will not only
damage the parts and decrease the life span of the engine but could also cause an accident.
Please check following troubleshooting solution for your reference:
41
4.1 Diesel engine is difficult to start
Troubleshooting Cause Solution
Circuit connection fault or Check the electrical circuit and secure

insufficient connection connections where necessary.
Electrical fault
Insufficient battery voltage Charge the battery.
Starter fault Repair or replace the starter.
Check the fuel pipe linkage for looseness:

Loosen the return valve of the fuel-injection
pump and the air-release bolt of the fuel
Air in the fuel system filter. Pump the fuel via the fuel-water
separator pump until no more air is evident
in the fuel. Tighten the bolt and secure the
fuel-water separator pump.
Plugged fuel-system pipe Check the fuel pipe.
Plugged fuel filter Replace the fuel filter.

Fuel-system fault
Check the fuel-intake pipe for air leakage.
Check the strainer of the fuel-intake pipe for
Fuel pump fails to pump fuel or plugging. Make the switch on and off, and
fuel supply is uncontinuous check the magnetic fuel-supply valve for
movement. If the magnet valve doesn't
move, replace it.
Check the injector for atomization quality.

Fuel atomization isn't in good Remove the injector, clean the needle
condition valve and seat, and replace the injector if
necessary.
Replace the piston ring and replace the

Worn or damaged piston ring
cylinder liner if necessary.
Low chamber
pressure Check the valve clearance. Check the valve
Valve leakage sealing performance, and repair or lap the
valve if necessary.
42
4.2 Diesel engine doesn't operate at full power

Drain off the air from the fuel pipe as in the
Air in fuel pipe
above-described method.
Plugged fuel filter or fuel pipe Replace the fuel filter or clean the fuel pipe.
Insufficient fuel supply or Check the fuel-injection pump, and repair

Fuel-system fault:
fuel-injection pump operation or replace it if necessary.
power or speed
doesn't increase Insufficient fuel atomization Check the injector.
with throttle almost
Adjust the pressure with the adjustment
fully open Low fuel-injection pressure
gasket.
Damaged injector Replace injector.
Improper advance angle of Check and adjust the fuel-injection

fuel injection advance angle.
Intake and exhaust Clean the filter with high-pressure air, and
Plugged air filter
system fault: replace it if necessary.
exhaust temperature Clean the carbon from exhaust pipe; replace
is high and exhaust Exhaust pipe is plugged or
the exhaust pipe with a sufficiently large
gas is unusual exhaust resistance is high
section (maximum number of elbows is 3).
Check the cooling system. Clear away any

Excessive temperature of scaling, and check and adjust the deflection
liquid coolant of the belt. Check the thermostat and
replace it if necessary.
Diesel engine
overheating High oil temperature Check the oil level. Add oil if necessary.
Check and adjust the fuel-injection advance.

High exhaust-gas temperature Check the pressure and atomization of the
injector.
Loose cylinder-head bolt or Tighten the cylinder-head bolt to meet the

Cylinder head unit
damaged gasket specification or replace the gasket.
fault: in this case,
not only the power Intake and exhaust valve Check intake and exhaust valve, and lap the
is low, but also leakage seal face of valve and seat if necessary.
there are air Adjust the valve clearance to meet the
Improper valve clearance
leakage, black specification.
smoke, and
Injector leakage or damaged Disassemble the injector, and repair or
unusual noise
copper washer replace the damaged parts if necessary.
43
Disassemble the oil pump and confirm

Crank and Copper bearing of connector's whether connector big end can move
connecting-rod little end clutching the piston axially. It it cannot, disassemble the piston
fault pin connecting-rod unit in order to check
and/or repair it.
4.3 Diesel engine runswith abnormal noise
Troubleshooting and cause Solution
Injecting timing is very early or injector is blocked; Adjust the inject timing (Part 3.8.5) and
metallic sound can be heard from cylinder. check the injector (Part 3.8.4).
The injection time is very late. There is a slight sound,

Adjust the inject timing (Part 3.8.5) and
and for the same time there are puffs of dense smoke in
check the injector (Part 3.8.4).
the exhaust gas.
There is a clearance between the connecting rod's little

end hole and the piston pin, and there is a slight but shill Replace the connecting rod's little-end
sound with the diesel engine running. This sound could copper bearing, making sure the
be heard easily at idle, and it grows louder when accel- clearance is within the specified range.
erating.
The clearance between the piston and the cylinder liner

Replace the piston, and replace the
is very big. A sound can be heard at the outer side of
cylinder liner if necessary.
the cylinder, and it grows louder when accelerating.
There is a clearance between the bearing and the

Check the bearing and replace it if
crankshaft. A sound can be heard at the crankshaft
necessary, making sure the clearance
case, and a big sound could be heard upon a sudden
is within the specified range.
decrease in speed.
The valve touches the piston when diesel engine is Find the case, check the valve timing
running, and a big, beating sound can be heard at the and adjust the valve clearance (Part
cylinder head. 3.5.4).
The transit gear is worn. The clearance between gears

has increased, there is unusual sound from the gear Check the gear clearance and replace
case, and the beating sound can be heard when the the gear if necessary.
speed is suddenly reduced.
The clearance between the valve and the rocker arm is

Readjust the clearance of valve (Part
very big, so a louder, more rhythmic sound can be heard
3.5.4).
at cylinder head.
44
4.4 Diesel engine exhaustcontains unusual gas

Diesel engine overloading in
Reduce the load ofdiesel engine.
operation
Inconsistent supply of fuel to Adjust fuel pump so that fuel supply is

cylinders evenly distributed.
Valve-stem clearance isn't

correct; the valve cannot seal, Adjust the valve stem clearance, and check
resulting in exhaust-valve the seal surface of the valve (Part 3.5.4).
Exhaust gas with leakage
black smoke
Fuel supply is too late. some
Adjust fuel supply advance (Part 3.8.5).
fuel burns in exhaust manifold
Air intake not sufficient, air

cleaner blocked or intake Clean air filter and replace it if necessary.
manifold blocked
Worn cylinder liner or piston

Replace the cylinder liner or piston ring.
ring
Water in cylinder or fuel Remove water by hand pump
Exhaust gas with Cylinder temperature is low at

white smoke the beginning of start, and oil Increase the speed or load appropriately
is not burned in some cylin- for a certain time.
ders
Piston ring is locked, has

excessive wear or deficient
flexibility; the piston cutting Check the piston ring and replace it if
angle is reversed, causing necessary.
engine oil to enter combustion
chamber
Exhaust gas with
blue smoke Running with low load for a
long time; the clearance
Increase the load appropriately, and check
between piston and cylinder
or repair it.
jacket is big and engine oil
enterscombustion chamber
Supply engine oil according to the indicator

Excessive oil in oil sump
marks on the dipstick.
45
4.5 Diesel engine oil over-consumption or lower oil pressure
Oil not in compliance with the

Replace the oil.
regulation
Sealing gasket and oil seal

Replace sealing gasket and oil seal.
malfunctioning or leaking
High oil
consumption Worn piston ring and groove Replace piston ring or piston.
Worn valve-guide tube seal, Replace the oil seal, valve or valve guide
valve-guide tube or valve lever tube.
Worn of cylinder Repair or replace cylinder jacket.
Engine oil not in compliance

Replace the engine oil.
with the regulation
Locked safety valve Replace the safety valve.
Clogged oil pump filter Clean or replace oil filter.
Worn driving gear and driven

Replace oil pump.
gear of oil pump
Low oil pressure
Oil pipe is cracked or the
Check or replace it.
coupling is loose
Oil pump failure Replace oil pump assembly.
Excessively worn main bearing Replace the main bearing or connectingrod

and connecting-rod bearing bearing.
Damaged oil-pressure gauge Repair or replace it.
Clogged oil holes on the cylin-

Clean or repair it.
der block and cylinder head
Clogged oil hole on rocker-arm

Engine oil doesn't Clean or repair it.
shaft
reach valve system
Clogged oil hole on rocker-arm
Clean or repair it.
bracket seat
Clogged oil hole on rocker arm Clean or repair it.
● Note:
If there is no oil pressure from lubrication system or oil pressure is very low, the diesel engine
shouldn't be operated continuously. Diesel engine must be stopped to solve the problems
once above-mentioned occurs.
46
4.6 Diesel engine cooling system with unusual temperature
Supply cooling liquid; confirm whether there

Cooling fluid level is too low
is leakage and repair if necessary.
Fan belt is loose or has

Adjust or replace the fan belt.
ruptured
Overheating of Thermostat main valve cannot

Replace the thermostat assembly.
diesel engine be opened
Water-pump failure Replace the water-pump assembly.
Incorrect oil-supply timing Adjust the oil-supply timing.
Clogged radiator core Clean the radiator.
Thermostat valve won't close

Replace the thermostat.
Overcool of diesel fully
engine Water temperature gauge Replace the coolant temperature gauge or
inoperative the water temperature gauge.
Radiator leakage Repair or replace the radiator.
Radiator hose coupling is

Tighten the coupling or replace the hose.
loose or the hose is damaged
Lack of water
Water-pump leakage Replace the water-pump assembly.
Heater hose coupling is loose

Tighten or replace the hose.
or the hose is damaged
● Note:
(1) When diesel engine is overheat, do not stop it suddenly or supply cooling fluid immediately.
The operator should keep engine running with no load for a while until coolant temperaturedrops,
then stop engine for checking.
(2) When the diesel engine is still hot, do not touch the water inlet cover. Adding cooling fluid,
the operator should be careful.
(3) If the clients cannot find the reason of overheat, they should go the professional service
station immediately, otherwise, other accessories will be damaged.
47
4.7 Starter cannot run, starts noisily and with alack of power
Start switch or other

Check to make sure the circuit is tight.
control-circuit breakage
Bad contact of carbon brush Adjust the carbon brush spring pressure
Starter not working
and commutator and clean the commutator.
Starter's interior circuit is
Check the starter.
broken or shorted
Deficient battery capability Charge the battery.
Faulty wire connection Tighten the wire connection.
Loss of commutator surface Grind the commutator surface or remove

due to burning the stain.
Starter cannot drive Excessive wear of carbon

Replace the carbon brush or adjust its
the engine brush, causing poor connec-
spring pressure.
tion with commutator
Main contact of solenoid
switch has burning loss or Use 0-grit nonmetal sandpaper.
poor contact
Excessively worn bearing Replace the bearing.
Copper plate sticking with two Cut off the power immediately, check the
After diesel engine contacts circuit and adjust the electrical contact.
starts, starter still Starter armature axle is bent Cut off the power immediately and replace
works and makes or broken the starter.
noise Cut off the power immediately and adjust
Gear is locked
the gear surface.
48
4.8 Alternator runs without output, doesn't charge engine

Incorrect, broken or bad
Check the circuit.
connection
Rotor coil is broken Repair or replace alternator.
Alternator is not
working Commutator diode is damaged Change the commutator diode.
Poor contact of carbon brush Clean or replace the carbon brush.
Damaged regulator Repair or replace regulator.
Loose pulley Adjust the pulley.
Poor contact of carbon brush
Adjust and clean it.
or stain on the ring
Deficient charge
Regulator is damaged Replace the regulator.
Lack of electrolyte or serious Supply electrolyte to specified level or
sulfidation of pole plate replace the battery.
4.9 Battery capacityis insufficient, starts difficultly, self-discharges excessively

Supply distilled water and/or dilute sulfuric
Electrolyte level too low
acid at ratio of 1:1.
Electrolyte isn't Shorted pole plate Clean out the deposit or replace the electrolyte.
enough and
Repeat charging and discharging ofbattery
engine is difficult Sulfidation of pole plate
to clean off the sulfidation.
to start
Poor contact of circuit
Tighten the contact and clean away the
coupling; Much oxide on
oxide.
terminal and deficient charge
Impurities present in electrolyte Use the specified electrolyte.

Excessive battery Shorted battery wire Check the circuit and resolve it.
discharged
Electrolyte overflows from battery, Use alkalior warm water to clean the termi-
shorting the anode and cathode nal ends, and keep the battery clean.
Metal lever or tool shorting Do not place a metal lever or tool on the
the anode and cathode battery.
The flaking of active substance

shorts the pole plate; damaged
clapboard shorts the pole plate; Repair or replace the battery.
bent pole shorts the anode and
cathode
49
Cylinder head assembly - 1
1
12
11
10
9 13
5
8
7
4
18 15
6
16
3
2
18
3
19
24 21
23 20
22
50
Cylinder head assembly - 2
29
28 30
27
31
32
26
25
51
Forward 4JB1 diesel engine cylinder head assembly
No. Drawing No. Part Name and Standards 4JB1 4JB1T 4JB1TA
1 E049301000003 Rocker arm unit 1 1 1
2 E049301000007 Front hoisting ear of diesel engine 1 1 1
4 E049301000015 Clamp plate, injector 4 4 4
5 E049301000016 Spherical bolt 4 4 4
7 E049301000009 Valve spring seat, lower 8 8 8
8 E049301000006 Oil seal of valve guide pipe 8 8 8
9 E049301000008 Valve spring 8 8 8
10 E049301000010 Low seat 8 8 8
11 E049301000011 Valve keeper 16 16 16
12 E049301000060 Connecting plate, heater plug 1 1 1
13 E049301000061 Positive pole joint of heater plug 1 1 1
14 E049301000012 Cylinder head bolt 8 8 8
16 E049301000062 Glow plug 4 4 4
17 E049301000019 Rear hook 1 1 1
20 E049301000014 Exhaust valve 4 4 4
22 E049301000013 Intake valve 4 4 4
25 E049301000042 Sealing gasket; head cover 1 1 1
26 E049301000177 Head cover unit 1 1 1
27 E049301000043 Cover, oil filling hole 1 1 1
28 E049301000046 Ventilator valve, crankcase 1 1 1
29 E049301000017 Head cover nut 3 3 3
30 E049301000018 Sealing ring, head cover nut 3 3 3
31 E049301000045 Ventilating tube clip, head cover 2 2 2
32 E049301000159 Crankcase bleed pipe unit 1 1 1
E049301000002 Cylinder head assembly 1 1 1
3 E049301000027 Bowl plug 12 5 5 5
6 E049301000023 Inlet and exhaust valve guide pipe 8 8 8
15 E049301000025 Bowl plug 45 1 1 1
18 E049301000024 Bowl plug 22 7 7 7
19 E049301000113 Exhaust valve seat 4 4 4
21 E049301000021 Intake valve seat 4 4 4
23 E049302000046 Bowl plug 18 6 6 6
24 E049301000020 Cylinder head ※ ※ ※
● Note:
1. Cylinder head assembly contains 3, 6, 15, 18, 19, 21, 23 and 24.
2. ※means it cannot be offered individually, must choose Cylinder head assembly
52
Cylinder block assembly
53
Forward 4JB1 diesel engine cylinder block assembly
No. Drawing No. Part Name and Standards 4JB1 4JB1T 4JB1TA Remark
5 E049302000011 Oil plug 3 3 3
6 Q5221020 Parallel pin 2 2 2
7 E049302000088 Left strengthening plate 1 1 1
8 E049302000236 Water inlet pipe welding part 1 1 1
9 E049302000035 Packing for water inlet part 1 1 1
10 E049302000017 Dowel bush, cylinder block and cylinder head 1 1 1
13 E049302000140 Cylinder head gasket 3 3 3
14 E049302000013 Oil plug 1 1 1
15 E049302000025 Copper washer 14 1 1 1
16 E049302000050 Bowl plug 56 1 1 1
17 E049302000023 Hexagon head bolt 1 1 1
19 E049302000022 Fixed bolt, rear connecting plate 1 1 1
20 E049302000212 Crankshaft oil seal,rear 3 3 3
21 E049302000012 Rear cover plate of cylinder block 1 1 1
23 E049302000650 Bowl plug oil return pipe welding part 1 1 1
26 E049302000019 Double head stud 1 1 1
27 E049302000024 Nut M8 8 8 8
28 E049302000018 Gasket for screw plug 2 2 2
29 E049302000130 Seat for oil pressure sensor 1 1 1
30 E049302000283 Inductor head for oil pressure sensor 1 1 1
31 E049302000072 Copper washer 3 3 3
32 E049302000143 Screw plug
33 E049302000089 Right strengthening plate 1 1 1
34 E049302000007 Crankshaft bush, upper 5 5 5
35 E049302000008 Crankshaft bush, lower 5 5 5
40 E049302000010 Thrust bearing 2 2 2
41 E049302000053 Sealing ring 1 1 1
42 E049302000193 Oil dipstick socket unit 1 1 1
43 E049302000049 Bowl plug 38 1 1 1
E049302000256 Cylinder block assembly 1 1 1
1 E049302000138 Cylinder block ※ ※ ※
2 E049302000169 Bowl plug 16 2 2 2
3 E049302000044 Camshaft bush, front 1 1 1
4 E049302000045 Camshaft bush, middle and rear 2 2 2
11 E049302000046 Bowl plug 18 2 2 2
12 E049302000048 Bowl plug 36 6 6 6
22 E049302000139 Cylinder liner 4 4 4
54
24 E049302000047 Bowl plug 32 1 1 1
25 E049301000025 Bowl plug 45 2 2 2
36 E049302000042 5th main bearing cap ※ ※ ※
37 E049302000040 1st, 2nd and 4th main bearing cap ※ ※ ※
38 rd
E049302000041 3 main bearing cap ※ ※ ※
39 E049302000043 Bolt,main bearing cap 10 10 10
● Note:
1. Cylinder block assemblycontains1, 2, 3, 4, 11, 12, 22, 24, 25, 36, 37, 38 and 39.
2. ※ means it cannot be offered individually, must choose Cylinder block assembly
55
Crankshaft, flywheel assembly & piston

Connecting rod assembly
8a
8
9 12
12a
10
7a 6a
7
6 13a
11a 13
6a 11
6
3
14
2 15
16
56
Forward 4JB1 diesel engine crankshaft, flywheel & piston connecting rod assembly
1 E049304000056 Bolt for crankshaft pulley 1 1 1
2 E049304000074 Crankshaft pulley unit 1 1 1
3 E049304000003 Crankshaft timing gear 1 1 1
4 E049304000006 Flat key for crankshaft 1 1 1
5 E049304000057 Crankshaft 1 1 1
6 E049303000005 Snap ring for piston pin 8 * *
6a E049303000025 Snap ring for piston pin * 8 8 Turbo engine
7 E049303000029 Piston 4 * *
7a E049303000024 Piston * 4 4 Turbo engine
8 E049303000002 1st compression ring 4 * *
8a E049303000022 2nd compression ring * 4 4 Turbo engine
9 E049303000003 2nd compression ring 4 * *
10 E049303000009 Sustaining spring and oil ring 4 4 4
11 E049303000004 Poston pin 4 * *
11a E049303000023 Poston pin * 4 4 Turbo engine
12 E049303000008 Connecting rod unit 4 * *
12a E049303000021 Connecting rod unit * 4 4 Turbo engine
13 E049303000007 Bush of connecting rod 8 * *
13a E049303000027 Bush of connecting rod * 8 8 Turbo engine
14 E049304000004 Bolt for flywheel 8 8 8
15 E049304000007 Gasket foot flywheel bolt 1 1 1
16 E049304000076 Flywheel & flywheel ring gear 1 1 1
● Note:
1. Item 8 (or 8a), 9, 10 must be offered together
57
Camshaft assembly
3 11
10
2
15
9
14
19
18
17
13
13
12
16
17
18
2
20
58
Forward 4JB1 diesel engine camshaft assembly
1 E049305000018 Bolt, camshaft gear 1 1 1
2 E049305000006 Thrust place for upper idle gear shaft 1 1 1
3 E049305000016 Timing gear for camshaft 1 1 1
4 E049305000019 Thrust place for camshaft 1 1 1
5 E049305000017 Flat key of camshaft 1 1 1
6 E049305000015 Camshaft 1 1 1
7 E049305000002 Tappet 8 8 8
8 E049305000013 Push rod welding unit 8 8 8
9 E049305000014 Oil piping assembly for timing gear case 1 1 1
10 E049305000011 Idle gear unit, lower 1 1 1
11 E049305000003 Idle gear shaft, lower 1 1 1
12 E049305000008 Pipe connecting bolt 1 1 1
13 E049305000009 Washer, copper 2 2 2
14 E049305000056 Bolt for lower idle gear 2 2 2
15 E049305000004 Thrust place for lower idle gear 1 1 1
16 E049305000022 Idle gear, upper 1 1 1
17 NZS60/28N Rolling bearing-Deep groove ball bearing 1 1 1
18 E049305000023 Snap ring for bearing 2 2 2
19 E049305000005 Idle gear shaft,upper 1 1 1
20 E049305000007 Bolt for upper idle gear 1 1 1
59
Gear housing assembly
4
3
11
10
60
Forward 4JB1 diesel engine gear housing assembly
1 E049307000106 Cover plate for timing gear chamber 1 1 1
2 E049307000009 Rubber gasket, timing gear chamber 1 1 1
3 E049307000007 Timing check hole cover 2 2 2
4 E049307000008 Gasket, timing check cover 1 1 1
5 E049307000105 Timing gear chamber cover 1 1 1
6 E049307000006 Sealing ring for timing gear chamber cover 1 1 1
7 E049307000030 Crankshaft oil seal, front 1 1 1
8 E049307000002 Timing gear chamber case 1 1 1
9 E049307000003 Packing for timing gear chamber case 1 1 1
11 E049302000024 Hexagon nut Mx8 1 1 1
61
Oil pump, oil sump & oil filter assembly
1
4
2
62
Forward 4JB1 diesel engine oil pump, oil pan & oil filter assembly
1 E049341000006 Oil pump unit 1 1 1
2 E049302000053 Sealing ring 1 1 1
3 E049341000003 Oil outlet pipe unit, oil pump 1 1 1
4 E049309000055 Oil sump welding unit 1 1 1
5 E049309000004 Bolt for oil sump 1 1 1
6 E049309000003 Gasket, oil sump 1 1 1
7 E049343000090 Oil filter element and sealing ring 1 1 1
8 E049343000091 Oil filter unit 1 1 1
9 E049309000003 Sealing ring for oil filter 1 1 1
63
Intake & exhaust assembly
1
1
64
Forward 4JB1 diesel engine intake & exhaust assembly
1 E049323000050 Exhaust manifold 1 * *
1a E049323000062 Exhaust manifold * 1 1 Turbo engine
2 E049323000034 Pacing unit for exhaust manifold 1 1 1
3 E049322000003 Gasket, intake manifold 1 1 1
4 E049322000002 Intake pipe 1 * *
4a E049322000044 Intake pipe * 1 1 Turbo engine
5 E049322000004 Pacing for inlet manifold 1 1 1
6 E049322000072 Intake manifold unit 1 1 1
65
Fuel pump & high pressure pipe assembly
5a
5
66
Forward 4JB1 diesel engine fuel pump & high pressure pipe assembly
1 E049334000064 High pressure fuel pipe unit1 1 1 1
5 E049331000255 Electrical injection pump assembly 1 1 1
5a DFT200-FR-12 Actuator, integrated with control unit 1 1 1
6 E049334000038 Injection pump gear 1 1 1
7 E049331000004 Sealing ring for injection pump flange 1 1 1
● Note:
1. Item 1, 2, 3 and 4 must be offered together
67
Injector & low pressure pipe assembly
7
5
5
6
5
5
6
5
6
5
5 1a
1
4
2
3
68
Forward 4JB1 diesel engine injector & low pressure pipe assembly
1 E049332000064GC Injector 4 * *
1a E049332000015GC Injector * 4 4 Turbo engine
2 E049332000002 "o"-sealing ring 4 4 4
3 E049332000003 Injector washer 4 4 4
4 E049335000035 Oil return pipe unit, injector 1 1 1
5 E049335000005 Clip for fuel return pipe 9 9 9
6 E049335000002 Cap for oil return pipe, injector 3 3 3
7 E049335000003 Low pressure pipe 1 1 1
8 E049335000143 Fuel return pipe unit part 1 1 1
69
Cooling system
6
5
1
2
70
Forward 4JB1 diesel engine cooling system
1 E049351000071 Fan unit 1 1 1
2 E049351000033 Fan connecting flange 1 1 1
3 E049351000070 Pulley, water pump beet 1 1 1
4 E049351000077 Belt, fan 1 1 *
4a E049351000149 Belt, fan * * 1 Turbo engine
5 E049351000052 Water pump unit 1 1 1
6 E049351000002 O-sealing ring 1 1 1
71
Alternator & electric starter assembly
5
3
72
Forward 4JB1 diesel engine alternator & electric starter assembly
1 E049362000007 Link arm for adjust fanbelt 1 1 1
2 E049362000086 Alternator 1 1 *
2a E049362000128 Alternator * * 1 Turbo engine
3 E049362000025 Bracket, alternator 1 1 1
4 E049361000013 Electric starter 1 1 1
5 E049362000032 Alternator bolt 1 1 1
73
Thermostat assembly
1
2
5 8
6 7
74
Forward 4JB1 diesel engine thermostat assembly
1 E049363000009 Screw plug 1 1 1
2 E049363000002 Water outlet pipe 1 1 *
2a E049363000002 Water outlet pipe * * 1 Turbo engine
3 E049363000381 Thermostat 1 1 1
4 E049363000003 Gasket, water outlet pipe 1 1 1
5 E049363000031 Bypass hose 1 1 1
6 E049363000009 Screw plug 1 1 1
7 E049363000115 Thermostat housing 1 1 1
8 E049363000006 Gasket, thermostat housing 1 1 1
9 E049363000185 Water temperature sensor 1 1 1
75

Forward 4jb1 Series

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Forward 4jb1 Series

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Forward 4JB1 series diesel engine maintenance manual

CHAPTER 1 TECHNICAL INFORMATION

CHAPTER 2 OPERATION AND TECHNICAL MAINTENANCE

CHAPTER 3 STRUCTURE AND ADJUSTMENT

3.3 Cylinder-head components

CHAPTER 4 PROBLEMS AND TROUBLESHOOTING

APPENDIX PARTS CATALOGUE

CHAPTER 1 TECHNICAL INFORMATION

1.1 Main technical parameters

Model 4JB1 4JB1T 4JB1TA

Fuel injection system Inline pump with GAC electronic governor

Configuration In-line, forced water cooling, 4-stroke

Bore x stroke- mm 93x102

Rated speed - rpm 1500 1800 1500 1800 1500 1800

Model 4JB1-P 4JB1T-P 4JB1-C 4JB1T-C

Configuration In-line, forced water cooling, 4-stroke

Bore x stroke- mm 93x102

Rated speed - rpm 3000 3000

Dimension - mm 882x605x818 882x603x818 882x605x818 882x591x818

Fuel consumption g/kW.h 243 245 243 245

Net weight - kg 248 253 248 253

1.2 Tightening torques of the important nuts and bolts

Table 1-2 Tightening torques of important nuts and bolts

Connect-rod nut 80-90 N·m

1.3 Main adjustment data

1.3.1 Valve clearances

Intake-valve clearance (cold state): 0.4mm±0.05mm

Exhaust valve clearance (cold state): 0.4mm±0.05mm

1.3.2 Pressure of injector valve (open): 18.6-19.6MPa

1.4 Temperature and pressure ranges

Coolant outlet temperature 75-85 ℃ Oil pressure 0.30-0.55MPa

Oil temperature ≤95 ℃

1.5 Fitting clearances and wear limits of the main components

1 Valve guide hold and inlet valve stem 0.039-0.071 0.20

2 Valve guide hold and outlet valve stem 0.064-0.096 0.25

3 Rocker arm and rocker shaft 0.010-0.050 0.20

4 Cylinder liner inner diameter and piston skirt 0.047-0.065

5 Tappet hole and tappet outer diameter 0.010-0.041 0.10

6 1st compression ring and piston ring groove 0.090-0.125 0.15

7 2nd compression ring and piston ring groove 0.050-0.085 0.15

8 Oil ring and oil cup height 0.030-0.070 0.15

9 Width of the piston pin II 0.2-0.4 1.5

III 0.1-0.3 1.5

11 Piston pin hole and piston pin 0.002-0.015 0.03

13 Camshaft bearing and camshaft journal 0.015-0.085 0.12

15 Main bearing bore and main crankshaft journal 0.033-0.079 0.11

16 Axle clearance of crankshaft 0.05-0.20 0.30

17 Clearance of timing gears 0.10-0.17 0.30

2.1 Preparations before starting

(1) Turn switch key to the "Start" position.

(2) After starting, please check oil pressure immediately.

2.4 Diesel engine stopping

The running-in process should exceed 50h.

Table 2-1 Running procedure for new diesel engine

(1) Replace oil in the oil sump.

(2) Replace oil filter element.

2.6 Sealing and maintenance

2.7 Fuel, oil and coolant

Table 2-2 Fuel grade of Forward 4JB1 series diesel engine

Above -10℃ -20# light diesel fuel

Temperature of distillation Viscosity (20℃)

10 50 300 355 365 1.2-1.67 3-8 0.4 0.2 0.025 60 10

2.7.2 Lubrication oil

-30 -20 -10 0 10 20 30 40 50℃