HUAFENGDONGLI 495 Series Diesel Engine OPERATION AND MAINTENANCE MANUAL Shandong Weichai Huafeng Power Co.
Preface' HUAFENGDONGLI brand 495 series diesel engine is a four - stroke, vertical, water - cooled., swirl combustion chamber, four - cylinder diesel engine. In 1980', our company adopted the comet V combustion system and diesel design ·technique of Ricardo Consulting Engineers Company and have make great improvement in design. Thus, the power, economy and tiability reached a advanced level among the same kind products all over the world.
the customers. This operation manual mainly introduces common usage type. For the products is changing and improving continually, there may be some slight difference. between the produces and that described in this manua'i arid the. users are advised to notice it kindly. The rrtanual is complied by Zhao Ruian, Wang Jinghai ,Sun. Chuanhai, Yu Caihong, .' Yang Lin, Li Zhiyong, advised'by Li Peiyan, Chen Ling, and finally examined and approved by Li Huaiqing.
Attention 1..The diesel engine operators must familiarize themselves with this manual as well as engine construction and strictly follow· the .procedures of operation and maintenance especially' the regulations for safety 0tJeration described in this manual. 2. Before operating an engine at full load, the 60 hours running in should be carried out as specified in the manual. . 3.
- 2004 495 series diesel en-gine enterprise standard. 11. The No. of production license of this series diesel engine is: XK06' - 205 - 00160, XK06 - 205 - 00161, XK06~ - 205 -. 00279. 12. The 'position of safety warning marks: (1) Theres a guard aga.inst burning mark at' the end of the cylinder cover which is beside the exhaust manifold of the diesel engine. (2) Theres a guard against fire mark at the oil filler. (3) There S a guard against twinning mark on the inlet manifold.
Contents 1" Longitudinal sectional drawing for 495 diesel engine (Fig. la) ... ~................. 1 Cross sectional drawing f9r 495 diesel engine (Fig. Ib) .....................•........ 2 2" Outline drawing for 495, 495G, K4100 diesel engine (Fig. 2) 3 3" Outline drawing for 495T diesel engine (Fig. 3) 4 4 ,,·Outline drawing for 495Gl, 495G9, K4100Gl diesel engine (Fig. 4) 5" Outline drawing for 495G3 diesel engine (Fig. 5) 5 6 6" Outline drawing for 495GI0, 495G14 diesel engine (Fig.
5. Matched- clearances and wear limit of 495 main parts 6. Matched clearances and wear limit of K4100, ZH4100 main parts 7. Ma.in adjusting. data ofZH4100 diesel engine CHAPTER II. Main structure and replacing and repairing method of diesel engine 31 1. Cylinder block assembly 2. cylinder block and, related assembly 3. Piston and connecting rod asse-mbty 4. Crankshaft and flywheel assembly 5. Intake and exhaust system and turbocharger 6. Fuel system 7. Lubricating system 8. Cooling system 9.
1. Start failures 2. Unsteady running 3. Output is instfficient of drops suddenly 4. Abnormal noise during engine iperation 5. Abnormal exhaust smoke 6. Insufficient oil pressure 7. Oil temperature too high. 8. The temperature of used cooling water too high 9. Trouble in the injection pump 10. Insufficient fuel supply of the fuel delivery pump 11. Injector in trouble 12. Governor in trouble 13. Engine stops suddenly 14. Charged dynamo out of order 15. Starting motor be in trouble 16.
Fig.
Fig.
o00 00 694 40° _ - . . -_____ - ~a ~ [' z [' ~ 10° 10° • ~Q Cit :c ~ N 27° {: ~ :c \0 • •;; 27° 18.5 ± 0.5 -+10-4-- 445 Fig.
893 212 182 158 152 60 N N N 90 ~~ I" 99 N 0 ~ ~ S ~ N Z l"'- ~o too • "l:t :x: -...0 0'\ ~ • N 00 ~ 0 N N 36 320 420 Fig.
8-M12 50 605 20 825 316 268 9-MJ2 Thread depth 19 12-MIOeven distributed Thread depth 20 22.5° 445 90 Fig.4 Outline drawing for 495Gl , 495G9, K4100Gl diesel engine * The air cleaner, exhaust manifold & oil gauge of 495G9 are the same as those of 495 (see Fig.
242 189 o~ 00 615 844 212 182 158 N N N 30 90 60 79 N N 0 ~ 0 'I") ~ 12-.12.5 Il-M12 even distributed Thread depth 25 4 36 r 436( ± 0.03) 218 ± 0.03 466 ± 0.05 Fig.
8-M12 Thread depth 316 605 50 20 268 874 9-M12 Thread depth 19 ± 0.5 22.5 0 22.5 0 445 90 Fig.6 Outline drawing for 495GIO, 495G14 diesel engine * The length dimension of 495G14 is the same as 495Gl (see Fig.
836 32 253 969 The connecting dimension of The connecting dimension of the diesel engine the clutch shell 228 4-M14 836 114 Fig.
318 694 6-M8 6 Thread depth 16 9-MJ2 ( 00 :c ~ • ":t 90 +: 0.5 445 Fig.
675 4 32 848 949 The installing dimension of The connecting dimension of ~he the clutch shell diesel engine 846 2- 13 Fig.
The installing dimension of The connecting dimension of the diesel engine the clutch shell 786 32 Fig.
318 694 even 6-4> 36~i III distributed Both sides 22.5° 22.5° 445 Note: The dimension in the brackets is the length of 41000 Fig.
V) 00 N 686 9-\1'2 even 6-.36~(;il(, distributed Both sides §o ..................1-- ~ ":f ~ • Q5 • ~ 27': 6 445 Fig.
OPlt O£:6 00 rr. Fig.
g I kW • h , 1\: '~ 450 , 1500r I min ~ l;/v I 420 I , l " \~ \I 390 ~ V V ~~ V / V Iw 1800r I min /' \\ K v ~ \ \~ ~/ V , Ivr\ '\\~ \ \~ ~ V VI \. X\" 7 \~ \ ~/ \~ \ I 360 \ 330 300 ~ V " ~ ~ ~~ 270 2000r I min A ~ '~ '- ~ ~ '~ "- ~ . ~ , '~ ~ ~ ~ r---. ~ '" ~ ~ ........... ~~ 240 5 10 15 20 ........ 25 ~ 10... -- 30 ,. -~ 35 - 40 Pe kW Fig.
\ g/kWeh 450 , l 420 390 1\ \ \ \ ~ v y [\, , ~ 360 ~ 1500r I min v ~ v 1800r1 min ~ V~ '\, \-, 330 ~ ../' ~ V ~ \ \ r\. r\. ~~"~ 300 ~ 270 ~~ '"~ ~ !IllI... ~ 240 10 15 20 25 It ~ ~ ~ r---.. ......... 30 35 Fig.
n r/min 2000 1600 }V 1200 ~~ 800 ~ - ~ ~ '/ " II / '" Me .. N-m \ ~ \ ~ g / kW • h \ \ ~'vV , ,~"'", ~ 300 \ 280 260 ~ 240 ~ ~ ~ ~ ". / ~ ............. , ~ ~~ / ~ - ~~ ~~ I) :/ V ) / 200 I 'r--'- ~ ~ ~~ / ~ -... ~ '-. i'~ --....- .......... ........... 11III..- 15 80 ~~ ~ 20 ............. ......... 160 120 ~ I"'" 'i\v v l / ~ ~ V~ 10 ~~ -:> 25 "'" ~ --- 30 40 ,) 35 o Pe kW Fig.
Me ~.". ~ ~ .".", ~~ V" Pe - ."..,. ~ "", ~ """""""" - --- -- N · ~ -,..."""" --- ~ " "..,... lIII""""'" "-= ~~ ~ " . . -- ,",, , \ 'l;- ~ II'" 40 ,/ ~" ./ ~ ./ / " / 30 ~~ ~~ ~ ~ / I / v/ V ~ ~ ..A ~ ~ ~ ~ "'"" '" ~\I "\ kW 20 "~ ~, \ ", 200 ........ '" "-. ~ - ....... ~ 160 - ,\ ~ L \ ."."", ,rr \ , ~ - \1 ' ~ , ,, 12U I' , 1\ , I ~ \ .\ 1\ ,I \ 1 "1 \ 'l \ \ 1\ 1~ V ,\ \ 1\, 10 J ", l , 1000 ~ -- 1200 .......
Me ~~ Nm ...-- --.. .......... .......... ~ v~ / / ';' 200 ~ ""' ~ 180 I 160 pe kW 45 ./ 40 / 30 V ~v ~v V V "" V.- ~~ ~ ~ l \ ~v \ I \I I \~ I~ I ge g/kWh 20 ~ 240 / '- v~ ~ ~~ -~ ~ 230 "",...- 220 1000 1200· 1400 ·1600 1800 2000 2200 2400 2600 n r I min Fig.
Me ........ ~ ~ .............. Pe ,. " N em 200 ~ '-. '"' 160 kW 55 120 ....... .",.,.... ~ 45 / ~ / ", ~ 35 25 15 / V v ~ ~/ ~ g/kW • h 300 270 '" 800 ~ ......-.. ....... 1200 ---1600 2000 ~ / 2400 / 240 2800 Fig.
CHAPTER 1 Main Technical Specifications and Data of Diesel Engine 1 Main Technical Specifications No. 495T 495 Item 495T3 1 Type Four strokes, Water Cooling, Inline , Swirl combustion chamber 2 Cylinder No. -Bore x Stroke ( mm) 4-95 x 115 3 Total Displacement of Piston ( L) 3.26 4 Pressure Ratio 19: 1 5 Firing Order 1-3-4-2 6 Air Intake Mode Naturally Aspirated 15min Output/Speed ( KW/r/min) 7 Rated Working Condition Ih Output/Speed ( KW/r/min) 38.
495T4 495T5 495Gl 495GI0 495G2 495G14 Four strokes, Water Cooling, Inline, Swirl 495G 495G3 495G5 495G9 No. 1 combustion chamber 4-95 x 115 2 3.26 3 19: 1 1-3--4-2 5 Naturally 6 Aspirated 7 40.4/2400 36/2000 26.5/1500 ::::;2160 ::::;1650 35.3/2000 ::::;2640 ::::;2200 ::::;550 198/1500 662 650 ::::;258.4 9 186/1680 194/1500 10 620 650 11 ::::;266.6 ::::;258.4 12 ::::;2.
No. 495G6 Item 495G7 495Gll 1 Type Four strokes, Water Cooling, Inline, Swirl combustion chamber 2 Cylinder No. -Bore x Stroke ( mm) 4-95 x 115 3 Total Displacement of Piston ( L) 3.26 4 Pressure Ratio 19: 1 5 Firing Order 1-3-4-2 6 Air Intake Mode Naturally Aspirated 15min Output/Speed ( KW/r/min) 7 Rated Working Condition 51.
4950 495Y -1 4950 495Yl -1 49502 495Y4 Four strokes, Water Cooling ,Inline, Swirl 49501 49505 49501 495Z0 1 combustion chamber 4-95 x 115 2 3.26 3 17 :1 19: 1 1-3-4-2 Naturally Turbocharged 6 51.5/2800 40.4/2400 ~2200 ~3080 ~2640 29/1500 33/1800 39.6/1500 26.5/1500 30/1800 36/1500 ~1575 ~1890 ~1575 8 ~500 ~550 ~500 9 ~550 197/1400 197/1960 201/1960 186/1680 690 677 677 620 ~253.0* 650 266.6 ~650 613 ~258.4 903 11 ~251.
No. Item 49ZD -1 495ZD2 495ZDl 1495ZDl - 1 495P 495ZD3 Four strokes, Water Cooling, Inline, Swirl 1 Type 2 Cylinder No. -Bore x Stroke ( mm) 4-95 x 115 3 Total Displacement of Piston ( L) 3.26 4 Pressure Ratio 5 Firing Order 6 Air Intake Mode combustion chamber 19: 1 17:1 1-3-4-2 15min Output/Speed ( KW/r/min) 7 Rated Working Condition Aspirated I Ih Output/Speed ( KW/r/min) 39.6/1500 44/1800 38.8/2000 12H OutputiSpeed( KW/r/min) 36/1500 40/1800 35.
K4100 K4100D K4100G1 Four strokes, Water Cooling ,.Inline, Swirl combustion chamber ' 'ZH4100 ZH4100G1 ZH4100D ZH4100L Four strokes, Water Cooling, Inline, Direct injecting combustion chamber No. 1 ", 4-100 x 115 2 3.61 3 19: 1 43/2000 33/1500 39/2000 30.1/1500 ~2160 ~1575 4 17 :1 45/2400 ~2640 1-3-4-2 5 ] Naturally Aspirated 6 7 45/2400 44/2000 40/2000 31/1500 ~2160 ~1575 43/2200 ~2640 ~2380 ~550 215/1500 650 650 ~258.4 9 206/1680 220/1500 620 660 ~266.
2 Various temperature and pressure range Lub oil temperature ~95OC (the TC Engine ~ 1ooOC) Outlet cooling water temperature ~90OC(the TC Engine~98OC) 0.20 -- O. 40MPa Lub oil pressure ;:::0. 5MPa,when at idling speed Fuel injection pressure 12+1.0MPa 3 Main bolts tightening torque Cylinder head bolt 120 --140N. m Main bearing bolt 140 --160N. m Flywheel tightening bolt 100 --120N. m Connecting rod bolt 100 --120N. m Gear case bolt 30 --40N. m Flywheel housing bolt 50--60N.
5 Matched clearances and wear limit of main parts No 1 Matched parts Standard size Crankshaft main journal neck and main Shaft <1>750_00019 bearing Hole <1>75 :~:~~~ 2 Crankshaftr thrust ring and crankshaft 3 Crankshaft & connecting rod journal neck Shaft <1>650_0.
No Matched parts 17 Idler shaft and idler shaft bushing 18 Air intake valve and valve guide 19 Exhaust valve and valve guide 20 Rocker arm shaft and bushing 21 Idler and idler shaft 22 Standard size Shaft «1>26 =~: ~~ Holet «1>260+0.021 Shaft tJ)9 =~:~~~ Holet <1»90+0.022 Shaft <1»9 =~:: Holet tJ)90+0.022 Shaft «1>16 =~:~~ Holet «1>160+0.018 Matched clearance Wear limit 0.020-0.062 0.20 0.030 -0.072 0.25 0.040 -0.082 0.25 0.016 -0.052 0.25 axial clearance 0.10 -0.
6. ~H41oo, K4100 matched ~Iearances and wear limit of main parts No. Matched parts Matched Standard size Shaft
Chapter II Main Construction, Adjustment and Maintenance of the Di.esel Engine 1. Cylinder Block Assembly Cylinder block is of a rectangle gantry type. Cylinder liners of wet type are fitted in the cylinder block and rested at its upper shoulder. The top surface of the liners should be higher than the top surface of the block 0.03 -0. 08mm.
should be kept, and the cylinder head should be heated integrally to about 2000C when assembly. Then the valve seat can be in -laid, and ream and lap it at the contact area to make it at 1.3 -·1. 5mm in width, valve setting value is 0.6 -1. Omm down. Fig. 1 Dlagram of reconditioning valve seat There are cylinder heat gaskets between the cylinder and the cylinder block. And the cylinder head is fastened to the cylinder block by 18 bolts.
ton pin, connecting rod, connecting rod bearing and connecting rod screw. Each piston of diesel engine has three compression rings and one scraper ring. The first compression ring is barrel chrome - plate ring of modular cast iron, to improve the abrasive resistance under high temperature. The second ring is taper - face ring with the word II topll on the side which should be upward when assembled. The third compression ring is distorting ring. The side with distorting groove should be faced downward.
hole on the bushing should be right aligned t~ the oil gathering hole at the top of connecting rod small end, to lubricate piston pin and bushing. Connecting rod bolts are self - locked by friction force. The mass difference of connecting rod for one same diesel engine is less than 20g, and that of piston and connecting rod assembly for one same diesel engine is not bigger than 30g. The connecting rod bearing is usually made of thin steel - backed aluminum alloy material, so it cant be lapped.
The outside of flywheel is marked TDC point, and also the scale range of 10 - 30 o advanced. Each scale means 2°crankshaft angle of turn. 5. Intake & Exhaust System and Turbocharger The turbocharger is of HIA, H2B or J65 type. In the process of using, the whirl shell and the vane ~roove of the turbocha!ger are easy to accumulate greasy dirt and charcoal, so We should clean them regularly.
a. Fuel injec Uon pump fuel return i ng A 4 b. Fuel filter fuel returning Fig. 5 Fuel System 1. Fuel filter 2. Fuel filter inlet pipe 3..Governor 4. Fuel delivery.pump inlet pipe 5. Fuel injection pump 6. Fuel delivery pump 7. Fuel injection pump 8. Return pipe 9. High pressure fuel pipe 10. Injector 11. Injector fuel return pipe 12. Fuel ring 13. Fuel supply 14.
sealed before delivery. The customers shouldnt adjust it privately. The injector is Model PB35S and of a single hole shaft needle type. The fuel should be atomized evenly after being sprayed, and the fuel stopping should be functioned at once, no fuel late drops of leakage. When the fuel atomized not well, the injector shoul.d be tested and adjusted on the injector test 'bench. The needle valve mate is matched mate, never exchanged when dismantled.
To low down the oil temperature, an engine oil radiator or cooler can be added to the diesel engine. There'S a II Winter & Summer" valve on the connecting panel of the oil filter. When the oil temperature goes too high, we should turn the valve to Summer" end, and when the oil temperature is normal, we should turn it to II II Win- ter" end. The engine oil enters into the main oil passage through the oil filter without cooling. The oil pump is of a internal and external rotor type, JZ x 2578 Model.
battery and the starting motor to avoid the voltage drop too hard when the engine starting, the section area 36mm2 low voltage connecting cable should be adopted. When the staring current is highest, for 12V and 24V starting motor, the voltage drop should be less than o. 5V and 1V respectively. The battery with the diesel engine hasnt been charged before delivery, it-should be first charged as the battery"s requirement before used.
Fig. 7 Electric System 1. Battery 2. Starting motor 3. Electric plunger 4. Preheating - starting switch 5. Ammeter 6. Key switch 7. Pressure gauge 8. Temperature gauge 9. Voltage regulator 10. Silicon rectified generator 10. Transmission System The transmission system includes the common V belt transmission and the gear transmission in the gear housing. The crankshaft belt pulley drives the water pump belt pulley and the alternator belt pulley through the II 8" type V belt.
Fig. 8 Transmission system 1. Oil pump transmission gear (Z = 17) 2. Oil pump middle gear (Z = 25) 3. Crankshaft timing gear (Z = 20) 4. Oil pump gear (Z = 16) 5. Camshaft timing gear (Z =40) 6. Hydraulic pump gear (Z =20) 7. Alternator belt pulley 8. Water pump belt pulley 9. Common V belt 10. Idling gear 11. Fuel pump gear 12. Timing gear 13.
11. Power Take Out Equipment The diesel engtne takes out power through the flywheel and clutch or spring coupler. We cant adopt the steel connection of belt pulley and flywheel in case the crankshaft inherits additional pressure and the crankshaft break. 495, K4100 adopt the dry, one piece and close type clutch, which is shown in Fig. 9. 23 22 Fig. 9 Clutch assembly 1. Pressure disc 2. Supporting disc 3. Adjusting hole cover 4. Control lever 5. Release lever & adjusting bolt 6. Return spring 7.
A. The clearance between the release lever and the release shaft should be 3mm. The diesel engine takes out power through flywheel, supporting disc, pressure disc and driven plate putout shaft. A flat belt pulley, V - belt pulley or a coupler can be installed at the output shaft end. The front end of the clutch output shaft is supported on the' flywheel bearing, the rear end is supported on the two bearings inside the clutch housing. The release bearing and the seat are installed on the front bearing cover.
CHAPTER mOPERATION OF THE DIESEL ENGINE 1. Transportation & installation When the diesel engine is transported, the front and rear lifting bracket should be used to lift the engine and close attention should be paid to protect the appearance, accessories and oil pipes of the diesel engine from being damaged. If the diesel engine will be transported for a long distance, the air filter and silencer should be dismantled, use plugs .
Winter In.Cold Area All Year In Common Area Summer In The South TEMPERATURE( OC) - 5 - - 15 0 - 30 > 30 OIL BRAND 20W/40 30 40 AREA The lubricating oil must be filtered before it is filled into diesel engine, other brand lubricating oil is forbidden to be used for engine so as to protect the parts such as bearing and piston ring from being darmaged. 2.3 Cooling Water The diesel engine should adopt clear soft water such as tap water, rain water and river water ,etc..
(2) When the engine is working, the temperature of the antifreeze mixture doesn't exceed 90°C so as to avoid the alcohol volatilize. (3 ) test the volume of the antifreeze mixture each 25 - 30hrs ,compensate it if not enough. ( 4 ) the volume of antifreeze nixture should be 6 % less than the water, because the antifreeze mixture preventive liquid will exqands at high temperature. 3. Preparation for starting 3.1 The diesel engine should be thoroughly checked before starting.
4.4 For the protection of the starting motor and battery, the starting time shouldn't exceed lOs. If need to start continucously, the interval time should be more than 2min. If can't start for continuous 3 times, the~ don't start until the trouble is found out and elininated. 4.5 As soon as the engine starts, turn the starting switch back to the previous position. Set the control handle of the fuel valve to the idel speed. position, turn the circuit key switch counterclockwise to the charging position. 4.
6. Stopping 6. 1 Before stopping the engine, unload first, decrease the engine to the idling speed gradually, when the water temperature falls down below 70°C, turn the stopping lever to stop. After the engine stops, take out the switch ,key and close the fuel thak valve. 6.2 It is forbidden to stop the engine suddenly at high water temperature. 6.3 It is not permitted to stop the engine by shutting off the valve of the fuel tank so as to preventiong the air from entering· .into the oil passage. 6.
CHAPTER IV Technique maintenance of the diesel engine Periodic technique maintenance is an important content of using engine normally, in order to remain the engine in good technique state and to prolong it's service life, the technique maintenance system must be seriously performed as standard.
two - maintenance period. 2.3 Clean the dust on the air filter element and inside the dust deposit set. Replace the oil inside the oilbath type air filter. 2.4 Check and adjust t~e tension of the fan belt. 2.5 Fill the lubricating grease into the weater pump bearing. 2.6 Check all parts of the engine, to do the necessary adjustment if need. 2.7 when the maintenance is finished ,start the engine and test it's working appearance,eliminate the trouble and abnormal appearance. 3.
4.5 Dismantle and check the cylinder head. Test the valve seal, wipe off the carbon deposit, burnish the. valve according. the conditions. 4.6 .Check the fasten situation of the cylinder head bolt, main bearing boa, connecting rod bolt. For the bolts which tightening torque is insufficient, then tighten it to the set point value. 4.7 Check the water pump, replace the lubricating grease, if necessary, replace the water seal. 4.8 Check the dynamo ,starting motor,clean,repair and fill new lubricationg grease.
( 2 ) Air trapped in the fuel system (2) Vent the air from the system withe the fuel delivery pump, check whether ther is leakage of fuel and air in the fuel pipes (3 ) Delivery pump fails in delivering (3 ) Check and repair fuel or delivers brokienly ( 4 ) Injector sprays abnormally ( 4 ) Check and adjust or replace the nee- dle valve mate 1. 2 insufficient compress pressure ( 1 ) Piston ring and cylinder liner 1.
(5 ) Cylinder blows by ( 6) Uneven fuel delivery to each ( 4 ) Check and adjust the governor (5 ) Check the tightening torque of the cylinder head bolt and the seal of cylinder (DUneven fuel delivery to each cylinder in injection pump (2)lnjector sprays not well or the ma- thecylinder head gasket ( 6 ) (DCheck and adjust (2)check the spray quality of the injector, replace the mate if necessa- te be choked ry @The plunger of the injection pumpworn out or the spring broken @Check and replace 3.
cause the rhythmic and clear metal- aAgle lic pounding noise be heard inside the cylinder. (2) Injecting time is too late to cause 2. adjust the fjel delivery advance angle the grave and unclear noise is heard inside the cylinder. (3) Pounding noise can be heard inside 3. Check the cylinder clearance, replace the cylinder after the engine starts be- the piston or cylinder liner cause of too large gap between the piston a,nd cylinder liner, this noise gets lower along mith the warming of the engine.
5. Abnormal exhaust smoke When the engine works normally, the smoke color is light grey, when the load is higher at low time, it color is onlt dark grey, when the exhaust smoke is blue, white or black, then the smoke color is abnormal. Blue means burning oil; white means fuel fog no burns thoroughly inside the cylinder or water trapped inside the cylinder; black means injecting fuel too much to burns thoroughly. Thouble cause and its feature 5.
(2)Fuel sprays too much ( 2 ) Adjust the fuel delivery amount of the fuel injection pump (3 ) Injecti~g time is too late, late burning ( 3 ) Adjust the fuel delivery advance an- is heavyp gie (4 ) Valve lash is incorrect or valve seal is ( 4 ) Adjust the valve lash and seal, elimi- not good nate the fou It (5) Air filter choked (5 ) Clean the filter element 6. Insufficient oil pressure Trouble cause and its feature Remedy 1. Oil pressure gauge is in trouble or the 1.
deposited outside, influence the heat radiating efficiency 8. The temperature of used cooling water too high Trouble cause and its feature 1. Water temperature gauge Remedy or 1. Inspect and replace inductor be in trouble 2. Cooling water is not enough 2. Fill cooling water and get rid of the air from the water passage 3. Flow of cooling water is too small 3.
( 6) Pressure of inlet fuel is uneven 3. Insuficient fuel delivery (6) Inspect fuel de~ivery pump and filter 3. (1) Replace parts ( 1 ) Fuel cock leaks (2) T.ighten the connector .( 2) Connector of fuel pipe leaks (3) Replace parts (~) Plunger worn out 10. Insufficient fuel supply of the fuel delivery pump 1. Non - return spring broken or seal of 1. Replace spring or repair no - return the valve seat is not good valve 2. Piston worn out 2. R·eplace piston 3.
(4) Fuel inlet and outlet· connector ( 4 ) Tighten, replace parts screw· is loose 5. Fuel atomized not well 5. ( 1) Needle valve is distorted or worn (1) Replace out (2) Bad seal of the needle valve (2) Repair or replace ( 4 ) Needle valve blocked ( 4 ) Clean or replace 12. Governor malfunction Trouble cause and its feature Remedy 1. Unsteady speed 1. .
13. Engine stops suddenly Trouble cause and its feat Remedy 1. Crankshaft can't be rotated after the 1. engine shtops ( 1 ) Crankshaft jammed with bushing ( 1) Inspect, replace parts (2) Piston jammed with cylinder liner (2) Inspect, replace parts 2. Crankshaft can be rotated easily 2. ( 1) Air trapped in fuel systemp ( 1 ) Blowout air (2 ) Fuel system choked (2)Clean (3 ) Air filter choked (3 ) Maintenance the air filter 14.
15. Starting motor malfunction Trouble cause and its feature Remedy 1. Starting motor no works 1. ( 1) Vonnecting 'electric wire con - ( 1) Clean and tighten the contacting tacts badly point (2) Insufficient charging of the bet - (2) Recharging tery (3 ) Clean the contacting surface of the (3 ) Brush contacts badly commutator (4) Repair ( 4 ) Open circuited inside the start - ing motor itselt 2. Starting motor rotates weakly 2.
(1) Too low of adjusting voltage (2) Too dirty of contacting point 3. Overchargine ( 1 ) Adjusting v'oltage too high or unadjusted , uncontrolled 17. Turbocharger in tro~ble Trouble cause and its feature Remedy 1. Engine output drops 1.
(3 ) Over - heating causes parts be (3) Replace transmuted ( 4 ) Precision of running balance t09 (4) Replace low 18. Air com.pressorin trouble Trouble cause and its feature Remedy 1. Efficiency gets worse because of 1. Clean off carbon deposit ,replace parts carbondepositedonexhaustvalve, valvespringbrokenorcylinderliner worn out 2. Oil mixes because of piston ring 2. Clean and repair, replace parts broken, cylinderlinerwornoutoroil return pipe choked 3. Abnormalsoundcanbeheardwhen 3.
APPENDIX: The wearing in of the diesel engine The time of wearing in should not less than 60 hours. The load and time of wearing in is as follows: Load Operation time Idling speed 10 minutes Check the pressure of lubricating oil and whether there is abnormal noise etc. 250/0 2 h 500/0 15 h 750/0 30 h 100 % 15 h During the period of wearing in, the throttle should be fully opened.
Shandong Weichai Huafeng Power Co., Ltd Add: No.337, Beigong East Street, Weifang, Shandong, P.R.China Postal Code: 261009 Tel: (0536) 8192800 8192735 Fax: (0536) 8192711 Web: http://www.huafengdongli.com E-mail:scb@huafengdongli.
