KM385BT ㌫ࡇḤ⋩ᵪ䈤᰾Җ

DIESEL ENGINE MODEL KM385BT SERIES

OPERATION MANUAL

ኡьॾⓀ㧡ࣘ޵⟳ᵪᴹ䲀‫ޜ‬ਨ
SHAN DONG HUA YUAN LAI DONG ENGNE CO..LTD
 PREFACE

Please read the manual of operation carefully before opefrate the engine ,and the operator
should maintain it strictly as required.
The engine is improved from time to time ,so the manual of operation may be different from
the engine ,please draw attentions to it .The engine NO.is engraved in the central position of
cylinder-block upper end by the side of the fly wheel.

PRECAUTIONS

To ensure the availability and a long service-life, the engine should be operated and
maintained strictly as required .
Never let the engine run in overload ,or the engine will be damaged .To avoid premature
wearing of the engine parts ,do not allow to run the engine with high speed in the period of
commissioning.
If not necessary ,don’t run the engine with high speed . While running with low ger ,the
engine should keep running in low speed .Cooling water should be soft-water.
Do not allow to frequently work in the condition of boiling or in high temperature water
(over 95ć).
Please choose the real parts supplied by our works or appointed one by our works.
Wellkeep the manual of operation and transfer it with the engine.
 CONTENTS
CHAPTER I engine ntroduction……………………………………………….. 1
1. Main specifications
2. Main accessories specifications
3. Fitting clearances and wearing limits of the main moving parts
4. Main bolts tightening torque
CHAPTER Ċ engine operation and precautions…………………………….5
1. Engine operation
2. Precautions when operating
3. Assembling air filter

CHAPTER ċ engine maintenance………………………………………...7

1. Daily maintenance
2. Maintenance after 100 hours
3. Maintenance after 500 hours
4. Engine preservation storage

CHAPTER IV the structure of engine……………………………………10

1. Cylinder block assembly
2. Cylinder head assembly
3. Crankshaft and flywheel assembly
4. Piston-connecting rod assembl y
5. Driving mechanism
6. valae system
7. Fuel suppl y system
8. Lubrication system
9. Cooling system
10. Electric systsem

CHAPTER V engine trouble and remedy……………………………………17

A. Engine can not be started
B. Engine power declines
C. Engine stops suddenly
D. Enigine running with knocking sound
E. Oil pressure too low
F. Engine over heat
G. Encine exhausts abnormal smoke
H. Troubles and remedies of the fuel injection pump
I. Starter is out of order
J. Alternator is out of order
 CHAPTER I ENGINE INTRODUCTION
1. MAIN SPECIFICATIONS

Dynamic Norm of the Engine(the power of each type is show on the nameplate)
KM385BT Diesel Engine
order Rated Power/Speed(KW/rpm) Max Torque/Speed(Ngm/rpm)
1 18.4/2350 86 /İ1762
2 17.8/2400 81.5/İ1800
3 17.6/2350 82.3/İ1762
4 18.3/2350 85.5/İ1762
5 18.4/2400 84.2/İ1800
6 17.4/2350 81.3/İ1762

Main Paraments of the Diesel Engine

MODEL
KM385BT
SPECIFICATION
Type In---Line,water—cooling, direct injection
No.of Cylinder 3
Cylinder bore(mm) 85
Piston stroke(mm) 90
Compression ratio 18:1
Displacement(L) 1.532
Cylinder working sequence 1ü3ü2
Lowest steady speed without load(rpm) İ850
Lowest fuel consumption at full load(g/KW.h) İ248
Oil consumption at full load(g/kw.h) İ0.8%
At idle speed(kpa) ı50
Oil pressure
At rated speed(kpa) 200~400
Crankshaft rotating direction counterclockwise
Injection advance angle(T.D.C) 18~22
Fuel injection pressure(kpa) 20000f500
Valve timing Intake valve open 14.5ebefore T.D.C
phase Intake valve close 37.5eafter B.D.C
Exhaust valve open 56ebefore B.D.C
Exhaust valve close 12eafter T.D.C
Valve Intake valve(mm) 0.20~0.30
clearance Exhaust valve(mm) 0.25~0.35
Valve sinkage Intake valve(mm) 0.7~0.9
Exhaust valve(mm) 0.7~0.9
Steady speed adjusting ratio at rated conditon İ8%
Oil sump capacity(L) 5
Temperature(ć) Water outlet 75~85
Oil 85~95
Exhaust pipe İ600
Starting method Electric starting
Lubricating method Pressure & splash
Cooling method Water cooling
Overall dimension (L×W×H) (mm) 569×525×604
Net weight (kg) 234
Tractor, engineering
Applications
machine

2. MAIN ACCESSORIES SPECIFICATIONS

Model KM385BT

Model IW or BQ
Injection
Type Plunger˄3I344˅
pump
Plunger diameter (mm) Ï7
ZCK154S425
Nozzle tip model
or ZCK154S423
QDJ1332A or QDJ1309J1
Starter
(12V, 2.5kW or 3kW)
2JF200
Alternator
(14Vǃ350W)
Water pump Centrifugal
Oil pump Rotary type
Model CX0706
Fuel filter
Type Rotary
Model WB178
Oil filter
Type Rotary
),77,1*&/($5$1&(6$1':($5/,0,762)7+(0$,1029,1*3$576
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STANDARD NEW ENGINE L1MIT
No. NAME FITTING
SIZE FITTING CLEARANCE ALLOWANCE
0
Main journal and Shaft¶58h6–0.019 Clearance
1 0.07~0. 138 0.25
main bearing hole +0.119 fit
Hole¶58+0.07
-0.075
Axial clearance of 29-0.165 Clearance
2 0.075~0. 265 0.50
crankshaft +0.10 fit
29 0

Crankshaft journal 0
Shaft ¶50h6 –0.016 Clearance
3 and connecting rod 0.04~0.102 0. 20
+0.086 fit
bearing hole Hole ¶50+0.04

Connecting rod big -0.115

31b11-0.22 Clearance
4 end facing 0.115~0.32
+0.10 fit
clearance 310

Piston pin & Shaft¶26h4–0.006

0

connecting rod Clearance

5 0.025~0.044 0.10
small end bushing +0.038 fit
Hole¶26+0.025
hole
0
Piston pin & piston Shaft¶26 (–0.006)
6 Interim fit -0 0045~+0. 0105
pin seat hole +0.0045
Hole¶26JS5–0.0045

-0.106
Piston skirt & Skirt ¶80-0.13 Clearance
7 0.106~0. 160 0.4
cylinder liner +0.030 fit
Hole ¶80h7 0

Piston ring opening First ring 0.30-0.50

8 2.2
clearance Third ring & oil ring 0.25-0.45

0
First ring and its Ring 2.5-0.012 Clearance
9 0.06~0.092 0.20
slot +0.080 fit
Slot 2.5+0.060
0
Second & third ring Ring 2.5-0.012 Clearance
10 0.04-0. 072 0.18
and its slot +0.06 fit
Slot 2.5+0.04
0
Oil scraper ring and Ring 4-0.012 Clearance
11 0.03~0.067 0.18
its slot +0.055 fits
Slot 4+0.03
No NAME STANDARD FITTING NEW ENGINE LIMIT
SIZE FITTING CLEARANCE ALLOWANCE
12 Camshaft journal -0.050 Clearance
Shaft¶44c7(–0.075 )
and its bushing fit 0.08~0.130 0.20
+0.055
Hole¶44+0.03

13 Camshaft axial -0.070 Clearance

¶5C11-0.145
clearance fit 0.07~0.245 0.60
+0.10
¶50

14 Valve tappet -0.016 Clearance

Shaft¶13f6(–0.027 )
and its hole [it 0.016~0.045 0.25
+0.018
Hole¶13H70

15 Rocker arm shaft -0.016 Clearance

Shaft¶16f7(–0.034 )
and shaft hole fit 0.016~0.052 0.20
+0.018
Hole¶16H70

16 Intake valve and -0.025 Clearance

Shaft¶7e8(–0.047 )
valve guide hole fit 0.025~0.069 0.15
+0.022
Hole¶7H80

17 Exhaust valve and -0.040 Clearance

Shaft¶7d7 (–0.055 )
valve guide hole fit 0.040~0.077 0.15
+0.022
Hole¶7H80

18 Idle gear shaft -0.025 Clearance

Shaft¶44f7(–0.050 )
journal and fit 0.025~0.075 0.20
+0.025
bushing hole Hole¶44H70
-0.095
19 Idle gear end facing 17c9-0.138 Clearance
clearance +0.138
fit 0.19~0.276
17C9+0.095

20 Gears engaging Clearance

0.11~0.18 0.30
side clearance fit

4. MAIN BOLT TIGHTENING TORQUE

Cylinder head bolt 135~150 N.m
Main bearing cover bolt 115-130 N.m
Connecting rod bolt 50~60 N.m
Fly wheel bolt 50~60 N.m
 CHAPTER Ċ
ENGINE OPERATION AND PRECAUTIONS
1. ENGINE OPERATION
Fuel, oil and cooling water

1) Fuel and oil:

Fuel and oil selected subject to local ambient temprature.
2) Cooling water:
Water of rain or clear river water is always preferably selected as cooling water. You are
always suggested to fill some anti-frozen liquid in cooling system in cold winter. Heat the cooling
water up to 80ć before filling it into the water tank, if the engine is hard to start, when the
ambient temperature is below 0ć.

Inspection and preparation before starting:

1) Check each connection for tightness, check operation levers such as fuel supply lever, engine
stop lever whether they are running freely.
2) Running the crankshaft several turns, check each part for running smoothly.
3) Check the oil level in oil sump and injection pump to ensure that the oil level is at the upper
side of the oil dipstick mark.
4) Check water tank for full of cooling water and whether there is any leakage on water pipe
connections.
5) Check fuel tank for full of fuel and fuel pipes for smooth flowing and its leakage.
6) Check each attached parts for correct connection as injection pump, fuel filter, oil filter, water
pump, fan, generator and its bracket, fan belt, starter and water tank etc.
7) Check each connector of electrical system for correctness, tightness.
Check alternator for sufficient voltage.
Check alternator for negative electrode bonding and the accumulator for negative electrode
bonding.

Engine starting

1) Set speed adjusting level at middle position.

2) Loosen the air exhaust screw on fuel filter, continuously press the hand – operated fuel delivery
pump to discharge the air inside fuel system, especially for new engine or engines stocked for long
time.
3) To start the engine first turn the switch to “pre-heat” position to heat the engine for 25-30
seconds.. Then turn to “pre-heat” position to start the engine. Repeat as above procedures in 2
minutes, if you failed to start the engine.
4) After startingˈimmediately adjust fuel supply to make the engine running at idle speedˊ
Care should be taken to ensure that the oil pressure is up to50kPaˈthen gradually increase speed to
warm up the engine without 1oadˊ
 Engine running

1) Engine is only a11owed working with 1oad when the coo1ing water temperature is up to
50ºC. Running at rated power when the coo1ing water temperature is about 80ºC.
2) Increasing or decreasing the 1oad and speed should be smoothly and gradually carried
outˊNormally is not a11owed to increase or decrease the 1oad suddenly.
3)During engine operationˈcare must be taken to see whether the meter is normalˈthe
co1our of exhaust air and the sound of running. Should any abnormal appearsˈstop the engine and
check.

Engine stopping

1)Before stopping the engineˈ1ower the speed to the idle condition and gradually discharge
the 1oad until the water temperature comes down below 70ćˈthen the engine can be stopped by
stopü1everˊ
2)After the engine stoppedˈturn the switch to middle positionˊ
3)After the engine stoppedˈdraining the cooling water by opening the water cock on both
cylinder block and water tank while the cooling water temperature comes down below 60ć.
When ambient temperature below 5ćˊDraining is not necessary when anti-frozen 1iquid is
fi11edˊ

2. PRECAUTIONS WHEN OPERATION

Engine should be maintained and adjusted according to the stipulation in the operation
manualˊ
Full speed and full 1oad operation is not a11owed for the new or repaired engine. First
wearing-in should be carried out for 45 hours in 1ow speed and 1oadˊThen the engine could be
put in normal 1oad operationˊ
Engine fuel should be precipitated and filtered cleanˊ
Keep normal water temperature at 75ć-85ćˈnormal oil Pressure at 200-400kPaˊ

3. ASSEMBLING AIR FILTER㸬

Air filter should be correctlyˈreasonably and tightly assembled at a suitable place on back or
front of the chassis of cabinˈand connected to intake pipe by rubber wave pipe which both ends
should be tightened with clipsˊThe dirt discharge port should be downwardsˊ
 CHAPTER ċ ENGINE MAINTENANCE
To ensure a longer service life, the engine should be maintained according to the following
procedure.

1. DAILY MAINTENANCE

Check the oil level in oil sump, to ensure the oil level be between the two marks on the oil
dipstick.
Check water quantity in water tank.
Check the oil level in injection pump and speed adjustor, refill to specified position when
insufficient.
Check and remove any oil, fuel, water and gas leakage.
Check for the tightness of each attached parts.
Check for the tightness of engine bracket.
Keep the engine clean,and remove dirt and mud. Special care must be taken to ensure the
electrical equipments dry and clean. After 45 hours wearing - in of new engine with light load, oil
should be replaced and the oil filter cartridge should be cleaned in time.
Remove other troubles and abnormals.

2. MAINTENANCE AFTER 100 HOURS

Replace oil in oil sump

Clean or replace oil filter cartridge.
Clean or replace fuel filter cartridge (or after 200 hours)
Check for tightness of cylinder head bolts.
Check valve clearance and adjust when necessary.
Check fan belt tightness and adjust when necessary.
Remove dirt in intake pipe and air filter.
Check injection and injection pressure after 200 hours. Clean and adjust when necessary.
Check tile accumulator voltage. The specific gravity of electrolyte should be 1.28 - l.
29, when air temperature at 15°C. It is normally not lower than 1.27.
Check whether the electrolyte level is 10 to l5mm higher than polar plates. Otherwise fill in
vaporized water.
Replace cooling water when not clean.
Take out thermostat, assemble water outlet pipe, start the engine and change the engine speed
alternatively so as to change the cooling water flow speed to wash out sediment. Then stop the
engine and open the water cock both on cylinder block and water tank to drain water.
While fill clean water into the water tank, restart the engine and run in idle to make water flow.
Close the water cocks as soon as the drained water is clean. Stop the engine and reassemble the
thermostat.
To ensure the parts disassembled for maintenance are reassembled correctly.

3. MAINTENANCE AFTER 500 HOURS

 Carry out the follow procedure besides item 2.
Check full injection pressure and atomization quality. Clean and adjust when necessary.
Check injection advance angle and adjust when necessary.
Dismount cylinder head; Remove carbon deposit; Check valve sealing and lap when necessary.
Check connecting rod bolts, main bearing bolts and flywheel bolts for tightness.
Re-tighten the cylinder head bolts according to the sequence shown in Fig. 1, and adjust the
valve clearance.
Clean or replace air filter cartridge (may proceed earlier according to working condition)
Replace oil in injection pump and speed adjustor.
Clean cooling system. Cleaning fluid is mixture of 150g NaOH and 1 liter water completely.
Drain out the cooling water before cleaning, then fill in cleaning fluid and run the engine after
8-12 hours. Stop the engine when working water temperature is achieved, drain out cooling fluid
immediately to prevent the inflow scale depositing, finally clean the cooling system with clean
water.
Check thermostat working.
Check each electrical starting equipment to ensure all tightness and wiring connections are
tighten. Replace those burned out.
Check all engine parts, repair or adjust when necessary.

Fig.1 cylinder head bolts tighten sequence

Besides the above mentioned procedures, you may carry out more detail maintenance according to
your, own condition.
4 . E NG I NE P RE S E RV AT I O N A N D S T O R AG E .

To store the engine for long time, immediately drain out oil, cooling water and fuel after
engine stops. Clean oil sump and oil filter cartridge.
Carry out maintenance procedure accordingly.
Disassemble intake and exhaust pipes. Fill 50g dewatered clean oil into air port and turn
crankshaft to make the oil smoothly cover the valves, cylinder head, cylinder liner, piston and
piston rings etc.
Remove all dirt from engine surface; brush the unpainted parts with butter except rubber and
plastic parts.
Cover the mouths of air filter and silencer, wrapped in plastic paper.
 Engine should be stored in place of dry, clean and good ventilation.
Chemical medicine is strictly prohibited nearby.
The above preservation method could store the engine for 3 months, if the preservation is overdue,
the engine should be preserved as above again.

CHAPTER IV THE STRUCTURE OF ENGINE

1. CY L I NDE R B L O CK AS S E MB L Y .

The cylinder block is planer-type with the full supporting bearing and dry cylinder liner,
which the shoulder is 0.02 - 0.10mm higher than the cylinder block upper surface. The height
difference of adjacent liner is not more than 0.03mm.
Dismounting cylinder liners must use the special tools and should keep the cylinder bore inner
surface and the cylinder liner outer surface dry and clean, coating grease is prohibited.
The water cavity of cylinder block is tested by 400kpa water pressure for 2 minutes. The oil
channel should be tested by 600kpa oil pressure for 1 minute, and leakage is not allowed.
Cylinder block have valve tappet cavity opener, a connecting pipe on the cover plate connects
with breather. The oil filter and water drain cock is assembled on the cylinder block by the side of
injection pump.

2 . CY L I NDE R H E AD AS S E MB L Y

Cylinder head is a unitary one, and is made of HT200 cast iron plus to cuprum chromium or
HT250 cast iron.
Cylinder head water cavity is tested by 400kpa water pressure for 3 minutes. No leakage is
allowed. Valve guide is pressed into cylinder head leaving a protruding of 10mm,shown as Fig.2.
The cone angles of intake and exhaust valve are respectively 90°and120ć. The width of
contacting surface is 1.2--1.7mm. The sinkage of intake and exhaust valve is 0.7-0.9 mm shown as
Fig.2.3.

ig.2 Valve guide mounting dimension Fig.3 Valve sinkage diagram

There is an oil hole on the cylinder head cover, which is designed for filling in oil. While
mounting cylinder head gasket, pay attention to the position of oil hole, water hole and screw hole.
Incorrectly mounting is not allowed. Before mounting cylinder head, pour 20g lubrication into
each cylinder liner surface.
Cylinder head is positioned on block by positioning bushing and tightened by cylinder head
bolts. Tightening torque is 135~150N.m which should be effected twice.
CRA NK S H AFT AN D FL Y W H E E L AS S E M B L Y

Crankshaft is made of QT900-2 nodular cast iron. Main bearing is made of steel back 20%
alloy with high tin and aluminum which can't adhere oil while mounting to avoid affecting its
radiating efficiency and damaging bearings. The thrust plate is of the same material as main
bearing. They are mounting on two sides of the last main bearing and positioned by the convex tail
of the lower thrust plate. When mounting, the oil channel of thrust plate should face to crankshaft
thrust surface. Reverse mounting is not allowed.
Main bearing cover is machined in couple with cylinder block. Cylinder block No. and
sequence No. are engraved on main bearing cover. The forth-main bearing cover is positioned by
positioning bushing. When mounting, the top arrow on main bearing should back- face to the side
of camshaft and compile the number from front end.
Reverse mounting is not allowed. Tightening torque of main bearing bolts is 115~130N.m. when
tightening, firstly tighten the central one, then the two sides alternatively. After tightened, the
crankshaft should run freely.
Flywheel is positioned by pin and tightened by bolts on the crankshaft rear end. Bolts are
tightened at a torque of 50 - 60 N. m alternatively on diagonal line. The belt pulley is positioned
by starting paw, tightened at a torque of 160-170 N.m on the crankshaft front end. Pounding or
beating is strictly prohibited when mounting or dismounting.
Crankshaft, flywheel and belt pulley, have been balanced. Care must be taken of ensuring its
balance when replacing parts. Both flywheel housing and gear case cover are mounted with oil
seal. Do not damage them when mounting or dismounting.

4 . PI S T O N A ND CO NNE CT I NG RO D AS S E MB L Y

The piston is made of aluminum alloy ZL109, which has tow air--compression rings and one
oil scraper ring.
The first compression ring is of chrome- plated barrel shape; the second one is of taper shapes.
The oil scraper ring is spiral spring expanding ring with the inner cylinder face, inner round face
and outer cylinder edge face plated by chrome, pay attention that the spring connecting point
should space out 180° apart from the oil scraper ring gap.
It is advised to install the piston ring with special expander; excessive expanding is not
allowed to avoid breaking. The ring should turn easily in the slot and can fall into the slot
supporting face by itself. The piston concave should be poured lub.oil.
The piston ring shape and its opening direction, please refer to Fig.4 and Fig.5

Fig.4 Piston ring shape Fig.5 Piston ring opening direction

 The connecting rod is made of 35CrMoA. There is coupling mark on the body and cap. You
must install according to the mark; wrong installing should be avoided. The tightening torque
of the connecting rod bolts is50 – 60N.m.
The connecting rod bearing is made of steel back alloy with aluminum, tin, silicon and
cuprum.
While mounting the piston pin, the piston should be heated to 100°C, while mounting the
connecting rod, the piston top face to the installer, the tub concave is on the upper side, and the
bearing positioning slot in the connecting rod big end hole should also be on the lower side.
The weight of connecting rod big end & small end has a strict distribution portion; the weight
difference of piston and connecting rod assembly of each engine should be limited to below 20g.

5. DRIVING MECHANISM

The gear driving system of the engine, please refer to Fig.6.

When installing the gears, pay attention to the timing mark on the gear faces to ensure good
phasing and fuel delivery.
After installing the idle gear, check axial clearance. Each gear should turn easily without
clicking.
6 . V AL V E S Y S T E M

V a lv e me c ha nis m:
The mechanism is top - mounted valve type. The camshaft is made of No. 45 steel choicely. The
surfaces of camshaft and gear are high frequency quenched. There is a thrust plate in front of first
shaft journal. Axial clearance of camshaft is 0.07-0.245 mm.
Valve tappet is made of chilled casting iron. There is a position deviation between tappets
center and cam center, so that the tappet could continuously turn for smooth wearing during
operation to prevent seizing. Push rod is made of steel; one end is bail structure, the other end is of
bowl structure. Rocker arm shaft is fully supported for high rigidity. Rocker arm and shaft are
lubricated by pressed oil from cylinder head.
Valve and valve seat are made of alloy steel and alloy cast iron and lapped to fit. To check its
fitting, pour kerosene into air port and wait for 2 minutes, no leakage is allowed. Air leakage of
the valve may affect engine technical performance or even burn to damage valve and seat. So
leakage check should be carried out according to technical requirement when in operation. Lap it
when necessary.
A chamfer is designed on valve guide to prevent oil flowing back into cylinder liner and
burning.
 Valve clearance adjustment:
Valve clearance shall affect engine performance. It should be checked and adjusted according
to technical maintaining stipulation. The intake valve cooling clearance is of 0.20-0.25mm,the
exhaust valve cooling clearance is of 0.25-0.30mm. The adjusting procedure as following:
Make the first cylinder piston stop at T.D.C. position when the "0" mark on crankshaft pulley
is aligned with the arrow mark on gear case cover, then check and adjust valve clearance of the
first valve (count from the engine front end) by inserting a valve clearance gauge. Turn the
crankshaft 180° subject to the cylinder working order 1 – 3 - 2 to adjust every valve clearance.

7 . FUE L S UP PL Y S Y S T E M

The fuel supply system consists of delivery pump, injection pump, speed adjustor, fuel filter,
injector, delivery pipe and injection pipe etc. Fuel is delivered to fuel filter from fuel tank by
delivery pump where the fuel is filtered and transferred to injection pump by a high pressure and
atomized, then injected into chamber through injection pipe.
1) The fuel delivery pump is of piston type and assembled on the side of injection pump.
When in normal operation it is driven by the eccentric camshaft gear of' injection pump. Air inside
the system can be discharged by manual pump when necessary after the engine stopped.
2) Fuel filter cartridge is made of paper, which should be mounted correctly to ensure
completely sealing. To keep fuel clean, replace and clean the cartridge as instruction, otherwise
some elements might be choked or worn out to cause trouble or shorten service life.
3) The injection pump is BQ pump or IW pump, and the plunger diameter of injection pump is
6 or 6.5mm for swirl type engine. Lubrication oil is filled into injection pump from right upper
side until oil drop out from side pipe for complete lubrication. Oil refilling should be carried out
periodically.
I nj e c t io n p u mp d is a s s e mb li ng :
Try not to turn the crankshaft after the pump is disassembled so that to ensure the fuel supplies
timing. Otherwise the marks on idle gear and pump gear should be aligned again by turning tile
crankshaft.
Ad j us t f ue l s up p ly t i mi ng :
To adjust the angle, firstly discharge air in fuel system, crank the crankshaft to let injection
pump fill fuel. Dismounting injection pipe on first cylinder. Blow off the air in the hole of delivery
valve seat connector, then crank the crankshaft slowly and inspect the fuel level in delivery valve
seat connector, stop cranking immediately when fuel level waves. Check the mark on crankshaft
belt pulley to see whether the advance angle is in comply with the above mentioned specification.
Larger or smaller advance angle can be adjusted by loosening three bolts on pump connecting
plate. If the angle is larger, turn the gear seat counter clockwise a proper angle, If tile angle is
smaller, turn it clockwise for a proper angle, then tighten three bolts and check the angle again.
Adjust injection pump:
Injection pump was already adjusted, checked and lead sealed before ex--works. If
readjustment is necessary, it should be made on special testing machine at repairing workshop.
Injection pipe: inner diameter x outside diameter x length=¶l.5׶6×283mm
Injector:
Open pressure of injector and injector nozzle of every model engine refers to operation manual
page 4 and page 2.
Higher or lower injection pressure shall affect normal injection. When the part is damaged,
the engine shall exhaust black smoke, lower power and speed, raise exhaust temperature or knock
the cylinder. To check the trouble injector, loosen injection pipes one by one, stop injection, and
inspect the color of exhaust smoke. Only the trouble injector stop injection can make the engine
no smoke, crank the crankshaft slowly to check injection sound of each injector, the trouble
injector shall be no sound injection.

I nj e c t o r a d j us t me nt :
Set injector on testing machine; slowly increase pressure to pressure required in main
technical specification table. Check to ensure no fuel drops or leakage, otherwise clean or lap the
nozzle and try again.
Then check atomization at a speed of one injection per second. Atomized injection should be
smooth and fog shape without split, drops, uneven or partial injection but with obvious and
melodious sound when fuel supply is cut off. Generally speaking, an abnormal injection is caused
by unsmooth movement of plunger and barrel. While fuel drops in injection hole is caused by
damaged sealing surface, and uneven injection is caused by heat deflection due to carbon deposit
on head.
Injector dismounting:
When dismounting injector, firstly clean outside surface. Clamp it on bench vice with nozzle
toward upside. Note that the vice mouth should be covered with copper plates. Screw out the
tightening nut, pull out plunger and barrel and put in clean diesel. Turn the injector upside down
and clamp again. Screw out pressure adjusting screw and nut, then take out pressure adjusting
spring and push rod. Clean the plunger and barrel when they are seized or effect poor atomization.
Sink it in diesel for a while when seized, clamp it with cloth covered clipper and lightly turn out
the plunger. To clean plunger and barrel, scrap with wooden sheet dip in gasoline or diesel, metal
sheet is strictly prohibited. If plunger can't move smoothly in barrel, lap it with clean diesel, then
clean to remove all dirty and metal chips.
Speed adjustor:
Speed adjustor is well adjusted and lead sealed when ex-works. Don't adjust it unless necessary.
Adjust speed controller only on pump testing bench to prevent damaging.

8 . L UB RI C AT I O N S Y S T E M

Lubrication system which effect pressure and splash lubrication consists of oil pump, oil filter
and oil channel.
Oil pump is of rotor type and is driven by camshaft gear. The gear shaft and camshaft gear are
lubricated by splashed oil. Oil filter is of paper cartridge type, which should have a good sealing.
While installing the cartridge, care must be taken to prevent leakage or short-way. The system
working pressure is 200-400kpa.
To ensure a longer service life, maintain the lubrication system completely and in time.

9 . CO O L I NG S Y S T E M

Cooling system is of closed, forced water-cooled, which consists of water pump, thermostat, fan,
connecting pipe and radiator etc.
The cooling water in radiator is pumped into cylinder block water cavity, then to cylinder head.
Some water directly flows up to cylinder head and accumulated near thermostat. Some water holes
in cylinder block and head are very small, so care must be taken not to block them especially those
holes between cylinder bores and the triangle area where injection nozzle located to prevent
trouble caused by overheating. Water pump is centrifugal type. If there is trouble in water seal,
water may leak out from overflowing hole, repair it in time. Alter long time operation, some
deposit shall be left in cooling system which can be removed by the following procedure:
Pour the mixture of 700-800g NaOH and 150g kerosene into water cooling system. Run the
engine for 5-10 minutes, then stop for 10 - 12 hours. Restart the engine for 10 – 15 minutes, drain
out the mixture and clean cooling system with clear water.

1 0 . E L E CT RI C S Y S T E M

Electric system consists of generator, starting motor, regulator, accumulator, oil pressure
sensor, glow plug and connecting wire etc. Engine normal voltage is 12v.
The negative pole of accumulator and generator should be earthed; positive and negative pole
can't be short circuit to prevent damage.
 CHAPTER V ENGINE TROUBLES AND REMEDY

A: ENGINE CAN NOT BE STARTED

Trouble Cause Remedy

1. Fuel System

1) No fuel in fuel tank or fuel cock not opens. 1) Fill in fuel or open fuel cock.

2) Air in fuel system 2) Discharge air by manual delivery pump.

Check each connection for leakage.

3) Fuel pipes or fuel filter blocked. 3) Clean pipes and filter cartridge or replace cartridge.

4) Poor atomization 4) Clean nozzle; Adjust injection pressure.

5) Lever not return to max.fuel supply position. 5) Pull the speed adjustor lever with force when starting

to force the lever to max. fuel supply position.

2. Electrical System

l) Improper circuit contact 1) Tighten the circuit connecting screw.

2) Lower voltage of accumulator 2) Charge the accumulator.

3. High oil viscosity to lower the engine starting 3. Cranking the crankshaft for several turns with cranking

speed. handle, or fill in preheated oil.

4. Ambient temperature too low. 4. Fill in hot water to pre- heat starting

5. Lower Compression Pressure in cylinder.

1) Cylinder liner, piston and piston rings worn out. 1) Replace new parts.

2) Valve and valve seat fitting not good.

3) No valve clearance. 2) Lap valves.

4) Valve stem blocked in valve guide. 3) Adjust clearance according to technical requirement.

5) Air leakage from cylinder head gasket. 4) Clean it in kerosene or diesel.

5) Check cylinder head nuts torque. check whether the

6) Air leakage from injector seat. gasket is broken .

7) Valve timing incorrect. 6) Check nuts and packing for tightness and damage

7) Check and adjust.

6. Fuel supply advance angle not correct. 6. Check and adjust it.

B: ENGINE POWER DECLINE

Trouble Cause, Remedy

1. Air filter or intake pipe blocked 1. Clean it.

2. Exhaust pipe blocked 2. Clean it.
3. Insufficient fuel supply.
1) Delivery pipe & fuel filter blocked. 1) Clean it.
2) Nozzle tip worn out. 2) Replace nozzle tip or injector.
4. Water in fuel 4. Replace fuel.
5. Incorrect fuel supply advance angle. 5. Adjust
6. Too much carbon deposit in chamber. 6. Disassemble cylinder head and remove carbon
deposit.

C: ENGINE STOP SUDDENLY

Trouble Cause Remedy

1. No fuel supply.
1) No fuel in tank. 1) Fill in fuel.
2) Air in fuel system 2) Discharge air.
3) Fuel filter blocked 3) Clean it.
4) Water in fuel. 4) Replace fuel.
2. Piston blocked 2. Replace it.

3. Air filter blocked. 3. Replace filter cartridge.


D: ENGINE RUNNING WITH KNOCKING SOUND.

Trouble Cause Remedy

1. Fuel supply too early or too late. 1. Readjust fuel supply advance angle.
2. Valve clearance to big 2. Readjust valve clearance.
3. Too big clearance between piston and cylinder liner. 3. Check and replace piston or
cylinder liner when necessary.
4. Too big clearance between piston pin and connecting 4. Check and replace connecting rod bushing when
rod bushing, having beating sound. necessary.

5. Too big clearance of main bearing or connecting rod 5. Check and replace connecting rod bearing or main
bearing, having ramming sound. bearing when necessary
6. Valve knock with piston top. 6. Adjust timing phase.


E: OIL PRESSURE TOO LOW.

Trouble Cause Remedy

1.Insufficient oil in sump. 1. Fill in oil.

2. Oil pipes or oil filter cartridge blocked. 2. Clean and replace when necessary.
3. Oil viscosity too low. 3. Replace oil according to technical requirement.
4. Cylinder head gasket, water pump packing or gear
case cover packing damaged to induce water into oil. 4. Replace damaged gasket ,packing and oil

5. Suction fuel pipe connector leakage 5. Check and repair it

6. Oil pump rotors seriously worn out. 6. Replace rotors and adjust clearance.
7. Too large clearance between main bearing and 7. Check and replace when necessary.
connecting rod bearing.
8. Improper adjustment of pressure adjusting valve on 8. Readjust it
oil filter.
9. Oil pressure gauge damaged 9. Replace it
10. Wrong assembling of oil filter seat packing 10. Reassemble it

F: ENGINE OVER HEAT

Trouble Cause Remedy

1. Cooling system out of order

1) No water in radiator 1) Fill in water
2) Too much deposit in water passage 2) Add alkaline solution (750g alkaline in I0 L water),
operating 4 - 8 hours and discharged, then use clean
water to clean the passage.
3) Fan and water pump belt too loose. 3) Adjust the tension of belts or change belt when
necessary.
4) Space between radiator and fan is not suitable. 4) Adjust it.
5) Water inlet and outlet pipe deformed or blocked 5)Replace it.
2. Fuel injection delayed or nozzle leaks fuel. 2.Adjust the fuel delivery advance angle or repair
nozzle.

3. Oil insufficient causes oil pressure too low and 3. Add oil.
temperature too high.

4. Valve phasing is incorrect. 4. Adjust it.

5. Thermostat out of order. 5. Replace it.

6. Engine running overload for a long period. 6. Reduce load.


G: ENGINE EXHAUST ABNORMAL SMOKE.

Trouble Cause Remedy

1. Exhaust blue smoke (oil in cylinder)
1) Piston rings, cylinder liner worn out or piston rings jammed. 1) Repair or replace it.
2) Intake or exhaust valve guide hole worn out. 2) Replace it.
3) Too much oil in oil sump. 3) Drain out some oil.

2. Exhaust white smoke (Engine in cold condition with bad fuel

atomization in low load condition. ) 1) Adjust fuel delivery.
1) Fuel injection pump delivery too much fuel. 2) Inspect injection pressure or replace fuel
2) With bad fuel atomization, fuel pressure is too low injector when necessary.
3) Fuel delivery too late 3) Adjust fuel advance angle
4) Cylinder compressing pressure is low. 4) Refer to a-5
5) Fuel with water 5) Replace fuel.
3. Exhaust black smoke (bad combustion) 1) Reduce the load.
1) Engine overloaded 2) Adjust or replace the nozzle.
2) Nozzle with bad atomization or leak fuel 3) Adjust the fuel delivery advance angle.
3) Fuel delivery too late 4) Clean air filters and air intake pipe or
4) Air filter blocked replace filter cartridge.
5) Too much fuel delivery 5) Adjust the fuel delivery.

H: FUEL INJECTION PUMP OUT OF ORDER

Trouble Cause Remedy

1. No fuel delivery
1) Delivery valve burn out or with dirt I) Replace or clean delivery valve.
2) Delivery valve spring or plunger spring deformed or broken. 2) Replace it.
3) Adjusting arm broken down. 3) Tighten the adjusting arm.
4) Adjusting arm and fork jammed 4) Inspect and repair it.
5) Delivery pump stem jammed 5) Inspect and repair it.
2. Fuel injection pump supply fuel all the time ,causes running away of
the engine.
1) Adjusting arm and fork jammed 1) Inspect and repair it.
2) Adjusting arm come down. 2) Replace or tighten it.
3) Governor sleeve burn out because of bad lubrication. 3) Inspect and repair it.
4) Pulling bar stroke not enough. 4) Adjust its stroke.
5) Flyweight loosen 5) Tighten it.
6) Pulling bar spring come down 6) Adjust it.
3. Speed governing rate too high
1) Governing spring deformed or worn out. 1) Replace the spring
2) Calibrator works too early. 2) Adjust it.

4. Unsteady fuel delivery.

1) Air or water in fuel. 1) Discharge air or water.
2) Delivery pump damaged. 2) Repair or replace it.
3) Plunger spring broken. 3) Replace plunger spring.

5. Unsteady operating of the engine

1) Governor internal friction too high. 1) Inspect and solve it.
2) Camshaft axial clearance too big 2) Adjust the clearance.
3) Governing spring deformed or rigidity too small 3) Replace it.
4) Fly weight loose 4) Tighten it.
5) Too much lub.oil 5) Add lub.oil as requirement
6. Insufficient fuel supply,
1) Pump element or delivery valve worn out. 1) Replace it.
2) Calibrator out of order. 2) Adjust it.
3) High speed limit abnormal 3) Adjust it.
7. Uneven fuel delivery of each cylinder
1) Adjusting arm loosen. l) Tighten it.
2) Plunger spring broken, 2) Replace it,
3) Delivery valve or nozzle with dirt. 3) Clean it.
8. Engine unsteady in low speed.
1) Idle speed screw not correct. 1) Adjust it.
2) Uneven fuel supply in low speed. 2) Adjust it,

I. STARTER IS OUT OF ORDER

Trouble cause Remedy

I. The starter can't work.

1). Connecting wire is broken or bad connection. l). Weld it or replace new wire.

2). The fuse is broken 2). Replace it.

3). The accumulator is no power or insufficient power. 3). Recharge or replace it.

4). The electric brush can't connect with the commutator. 4). Adjust brush and spring pressure.

5). The starter is short circuit. 5). Check and resolve the short.

6). The bearing sleeve is worn out. 6). Replace it.

7). The clutch is sliding. 7). Adjust it,

2.The starter can run in empty load, but not start the engine.

1). The shaft bushing is worn out, the armature rubs with the 1). Replace new bushing.

magnetic pole.

2). The electric brush badly connects with the commutator. 2). 2). Clean brush and commutator surface.

3). The surface of commulator is burnt out or with oil dirt. 3). Clean oil dirt and polish it.

4). The armature coil seal off with the commulator. 4). Weld it.

5). The wire connection is bad. 5). Screw down the nuts,

6). The electric-magnetic switch's connection spot is burnt out and 6). Check the switch connecting spot and

causes a bad connection. polish it.

7). The accumulator is insufficiently recharged or the voltage is not 7). Recharge or replace the accumulator.

in conformity with the requirement.

3, Loosen the switch, but the starter continue to run.

1). The electric-magnetic switch connecting spot has been melted 1), Check and polish the connecting spot.

together.

2). The eccentric screw is not adjusted in proper position. 2). Adjust eccentric screw (frontward).

4. The starter's gear badly mesh with the flywheel gear ring 4. Adjust eccentric screw (rearward).
 J. ALTERNATOR IS OUT OF ORDER
Trouble cause Remedy

1. The alternator can not generating power.

1). The wire is broken or wrong connection. 1). Check and repair it.
2). The stator and rotor coil is broken or short circuit. 2). Repair or replace it.
3). Silicon rectifier damage to cause breaking or short circuit. 3). Replace it.
4). Electric brush is bad connection, sliding ring is dirty and 4). Clean and repair it.
alternator v-belt is too loosened.
5). The regulator's regulating voltage is lower, its connecting 5). Repair and replace it.
spot is burnt out or oxygenated, the relay coil is burnt out.

2. The charged power is insufficient.

1). Some of alternator's silicon elements is broken circuit. 1). Repair or replace it.
2). The alternator's electric brush is bad connection, spring 2). Clean and repair it.
pressure is lower, the sliding ring is dirty.
3). The regulator's regulating voltage is lower; its connecting spot is 3). Repair or replace it.
burnt out.
4). The accumulator's electrolyte is less 4). Fill the electrolyte or replace it.

3. The charged current is unstable.

1 ). The stator and rotor coil will be short or broken circuit. I). Repair or replace it.
2). The alternator electric brush is bad connection; spring pressure is 2). Clean, repair or replace it.
lower, the sliding ring is dirty.
3). The alternator v-belt is loosened. 3). Adjust or replace it.
4). The regulator's connecting spot is dirty 4). Clean it.
5). The regulator is out of order. 5). Repair or replace it.

4. There are abnormal sounds in the alternator.

1). The alternator installing is not correct, bearing is damaged. 1). Repair or replace it.
2). The alternator’s stator coil or silicon elements are short. 2). Repair or replace it.
3). The alternator's moving parts knock or rub with the fixed parts 3). Repair it.

5. The charged power it excessive

1). The regulator's regulating voltage is higher or it is out of order. 1). Repair or replace the regulator.
6. The alternator is burnt out and damaged.
1). The alternator's silicon elements is short circuit or its stator knocks 1). Repair it.
the rotor.
2). The regulator's coil is burnt out and damaged or the connecting spot 2). Repair or replace it.
is burnt out and melted Together cause it is out of order.
3). The regulator's voltage coil or resistance wire is broken. 3). Repair it.
Add : 40,Wulong North Road,
Laiyang City ,Shandong , China
FAX:0086-535-7215149
E--mail : ldworks@ec . com . cn
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