g ~ pfa m j~ d lK

INSTRUCTION MANUAL OF

490 SERIES DIESEL ENGINES

R
E
W
O
P
A
ID
S

JIANGSU SIDA POWER MANCHINERY GROUP CO.LTD

WUXI DIESEL ENGINE WORKS

K ~ K ~ ~K
 g ~ pfa m j~ d lK

EDITOR: Zhou hao

CHENKER: Ge mingsheng Shi bingfeng

INPECTOR: Wang xiwu

PPROVER: Wang xingguang

R
E
W
O
P
A
ID
S

K ~ K ~ ~K
 g ~ pfa m j~ d lK

FOREWORD

W serious diesel engines are prime power for light-duty automobiles,

agrioultural transport vehicles from 0.75t to 2t, small-duty construction machinery,
tractors, combines, generating sets and so on.

R
This instruction manual introduces W series diesel engines in aspect of their
main technical specifications, method fo adjusting, demand of operating and

E
maintenance. Operating and maintaining diesel engines correctly are very important
to drive safely and prolong service life. Customers please read this carefully, operate

W
and maintain diesel engines according to the regulations.
During productive practice, we will absorb advanced technology continuously,

O
accumulate practice experience and make some improvements, so the content of the

P
instructions may be different from the actuality of future product. Customers should
pay more attention to this when operating diesel engines.
Since the construction of the engine is subject to frequent improvement and

A
development during production and practice, it is possible that the engine supplied is
somewhere not exactly the same as one described herein. Please pay more attention to

D
this when operating diesel engines.

I
S

K ~ K ~ ~K
 g ~ pfa m j~ d lK

WARNING NOTICE
1.It is strictly forbidden to use inferior or dirty diesel and oil.
2.It is strictly forbidden to leak intake system (air filter, pipe and connection parts).
3.It is strictly forbidden to use hard water (well water & spring water) for cooling, if
have to, please soften the water.
4.It is strictly forbidden to start or work under condition of lack of water or oil.
5.It is strictly forbidden to adjust the fuel injection pump and fuel appliance
arbitrarily.
6.It is strictly forbidden to check whether the generator works by method of
Short-circuit.
7.Control the start time and gap strictly when using electric start.
8.Must keep regular technology maintenance of the diesel engine.

R
9.When ambient temperature is below 0 ℃， drain out the cold water to keep the
machine from frost crake.

E
10.All of the filters (including the air filter) should be maintained or changed in
accordance with requirements.

W
O
P
A WINTER NOTICE

D
To ensure the diesel engines start smoothly in winter, users should pay attention to

I
issues as follows:
1.Please use fuel type -10 light diesels.

S
2.Please use CC or CD 10W/30 or 5W/30 lubricating oil.
3.Please ensure that the access between battery and starter cable is reliable;
Battery capacity should be in accordance with the provisions of instruction manual;
Wire’s cross-sectional area is not less than 40 mm2 when total length of the fire
wire and ground wire is less than 2 m;
Wire’s cross-sectional area is not less than 70 mm2 when total length of the fire
wire and ground wire is less than 2 m.
4.Add hot water and hot lubricating oil when the start ambient temperature is below
-5 ℃.
5.Exclude the air in fuel system.
6.Check whether atomization of the injector is normal or not.

K ~ K ~ ~K
 g ~ pfa m j~ d lK

CONTENTS

FOREWORD .................................................................................... 3
Diesel Engine Appearance and Installation Dimension Diagram............................ 7
I 485、490、493 ................................................................................................................... 7
II 490Z、493Z ..................................................................................................................... 17

Chapter 1 Technical Characteristics of Diesel Engine ................ 15

1.1 Technical Performance Parameters of Diesel Engine.. ........ .............................................15
1.2 Main Technical Data of Diesel Engine.............................................................................. 17

Chapter 2 Operation and Safety Requirements Of Diesel

R
Engines............................................................................................. 18

E
2.1 Fuel, oil and cooling water ............................................................................................. 18
2.2 Examinations and preparations before starting .............................................................. 18

W
2.3 Starting of diesel engines ............................................................................................... 19
2.4 Operating of diesel engines ............................................................................................ 19

O
2.5 Stopping of diesel engines ............................................................................................. 19
2.6 Safety requirements of diesel engines ............................................................................ 20

P
Chapter 3 Technical Maintenance of Diesel Engine ................... 21
3.1 Routine maintenance ...................................................................................................... 21

A
3.2 Maintenance after every 100 accumulated operating hours ........................................... 21
3.3 Maintenance after every 500 accumulated operating hours ........................................... 22

D
3.4 Preservation and storage of engine................................................................................. 23

Chapter 4
I Adjustment of diesel engine ..................................... 24

S
4.1 Adjustment of valve lash ................................................................................................ 24
4.2 Adjustment of injection timing ...................................................................................... 24
4.3 Adjustment of injector.................................................................................................... 25
4.4 Adjustment of lube oil pressure ..................................................................................... 26
4.5 Adjustment of injection pump ........................................................................................ 26

Chapter 5 Construction of Diesel Engine..................................... 27

5.1 Cylinder head ................................................................................................................. 27
5.2 Cylinder block ................................................................................................................ 28
5.3 Piston and connecting-rod .............................................................................................. 29
5.4 Crankshaft and flywheel ................................................................................................ 31
5.5 Camshaft ........................................................................................................................ 31
5.6 Gear transmission system............................................................................................... 32
5.7 Fuel and governing system............................................................................................. 32
5.8 Lubricating system ......................................................................................................... 34

K ~ K ~ ~K
 g ~ pfa m j~ d lK

5.9 Cooling system ............................................................................................................... 35

5.10 Electric system ............................................................................................................. 36
5.11 Pressurization、turbocharged system .......................................................................... 36

Chapter 6 Faults and Remedies for Diesel Engine ...................... 38

6.1 Hard or refuse to start..................................................................................................... 38
6.2 Insufficient ..................................................................................................................... 38
6.3 Smoking exhaust ............................................................................................................ 39
6.4 Knocking noise in engine ............................................................................................... 39
6.5 Oil insufficient or no pressure ........................................................................................ 39
6.6 Overheating of engine .................................................................................................... 40
6.7 Engine running-away ..................................................................................................... 40

Appendix:................................................................................................................................ 41
Wearing parts of diesel engine ................................................................................................ 41
R
E
W
O
P
A
ID
S

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Diesel Engine Appearance and Installation Dimension Diagram

I 485、490、493

R
E
W
O
P
A
ID
S
Figure I Right view

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S
Figure II Left view

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S

Figure III Front view

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S

Figure IV Back view

10

K ~ K ~ ~K
 g ~ pfa m j~ d lK

II 490Z、493Z

R
E
W
O
P
A
ID
S

Figure I Right view

11

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S
Figure II Left view

12

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S

Figure III Front view

13

K ~ K ~ ~K
 g ~ pfa m j~ d lK

R
E
W
O
P
A
ID
S
Figure IV Back view

14

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 1 Technical Characteristics of Diesel Engine

1.1 Technical Performance Parameters of Diesel Engine

No. items requirements

1 Model SD485 SD490 SD493

2 Type Wet-sleeve, water-cooled, inline, four-stroke, natural aspiration

Combustion
3 Direct injection
chamber type
Number of
R
E
4 cylinders-bore × 4—85×100 4—90×100 4—93×102
stroke(mm)

5 Work order 1—3—4—2

W
O
6 Displacement（L） 2.27 2.55 2.77

P
7 Compression ratio 17.5±0.5:1
Rated power 17/1500 23/1500 25/1500
8
(kw/r/min) 20/1800 27/1800 28/1800

A
Characteristics
9 fuel consumption ≤245 ≤245 ≤245

10
(g/kwh)

ID
Lubrication mode Pressure and splash lubrication hybrid

11

12
S
Oil, fuel
consumption ratio
Start mode
≤0.3

Electric start
Crankshaft
rotation direction
13 Counter-clockwise
(viewing toward
power out )
14 Outline size(mm) 705×592×702

15

K ~ K ~ ~K
 g ~ pfa m j~ d lK

No. items requirements

1 Model SD490Z SD493Z

Wet-sleeve, water-cooled, inline, four-stroke, natural
2 Type
aspiration
Combustion
3 Direct injection
chamber type
Number of
4 cylinders-bore × 4—90×100 4—93×102
stroke(mm)

5 Work order 1—3—4—2

6 Displacement（L） 2.55 2.77
R
E
7 Compression ratio 17.5±0.5:1
Rated power 29/1500 34/1500

W
8
(kw/r/min) 34/1800 40/1800

O
Characteristics
9 fuel consumption ≤240 ≤240

P
(g/kwh)

10 Lubrication mode Pressure and splash lubrication hybrid

A
Oil, fuel
11 ≤0.3
consumption ratio
12

ID
Start mode
Crankshaft
Electric start

S
rotation direction
13 Counter-clockwise
(viewing toward
power out )
14 Outline size(mm) 705×592×702

16

K ~ K ~ ~K
 g ~ pfa m j~ d lK

1.2 Main Technical Data of Diesel Engine

1.Valve timing
Intake valve opens bTDC 12°±2°
Intake valve closes aBDC 38°±2°
Exhaust valve opens bBDC 50°±2°
Exhaust valve closes aTDC 14°±2°

R
E
W
O
P
A
D
Fig 1 Drawing of port timing

I
1. Valve clearance（cold condition） Intake valve: 0.28～0.33

S
Exhaust valve: 0.28～0.33
2. Tightening torque of main bolt（N.m）
Name 485 490 493 490Z 493Z
Cylinder head bolts 140～150 140～160
The connecting rod bolt 60～70 60～70 60～70 70～80 90～100
Main bearing bolt 160～180
The flywheel bolt 110～130
3. Various temperature and pressure of diesel engine
(1) exhaust temperature (℃) ≤520℃
(2) Lube. oil temperature (℃) （95±5）℃
(3) Cooling water outlet temperature （88±5）℃
(4) Temperature of the diesel （38±5）℃
(5) Oil pressure Rated speed condition（294～490）kPa Maximum
torque point condition≥250kPa，Idle speed condition≥150 kPa。

17

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 2 Operation and Safety Requirements Of Diesel

Engines

2.1 Fuel, oil and cooling water

1. Fuel. Users can select the proper grade of fuel according to local ambient
temperature. In general area in China, selection of fuel grade is on basis of GB252
light diesel fuel. Use grade “0” light diesel fuel in summer, while in winter, use
grade “-10” light diesel fuel. Before being filled into the fuel tank, the diesel fuel
should be settled for at least 27 hours and then draw out the upper part. When
filling the fuel, silk cloth should be used to filter impurity. It will extend service

R
life of fuel injection pumps and injectors by using the well settled diesel fuel.
2. Lubricating oil. You must select lubricating oil according to GB11122 diesel

E
engine lubricating oil. Use grade 40 when the temperature is above 20℃, when it
is 0~20℃, use grade 30 or 20W/40; when it is -20~-10℃ in winter, use grade

W
10W/30, when it is below -20℃in alpine region, use grade 5W/30.
3. Cooling water. It is recommended to use rain water, city tap water or clean river

O
water. It is unsuitable to use tap water coming from well or well water, because
the water has more mineral substance and can produce more scale in the cooling

P
system of diesel engines after using, thus affect the cooling effect and cause diesel
engine failure. So, if have to use well water or spring water, it must be softened
originally. There are two methods to soften the water: (1) boiling up the hot water;

A
(2) add 20g caustic soda (NaOH ) into 30L hard water to make up a solution. In
cold winter, antifreeze can be added to the cooling system to protect it from

ID
freezing. The antifreeze used most widely is ethanediol (glycerol) water solution
or alcohol. When it is hard for the diesel engine to start under low ambient
temperature, heat the cooling water to about 80℃ before filling it into the

S
cooling system.

2.2 Examinations and preparations before starting

1. Check the tightness and reliability of all connecting parts. Check control levers
(speed control lever and stopping lever) to see whether they can be moved freely.
2. Rotate the crankshaft several turns; be sure that all moving parts move freely.
3. Check the oil level in the oil sump and injection pump to see whether it is kept
within two marks on the dipsticks. Make sure that the fuel tank has sufficient fuel
and that the fuel pipelines are unblocked.
4. Open the fuel tank cock. check whether there is air in the fuel system. If necessary,
loosen the vent screws on the fuel filter and injection pump, operate the priming
pump on the fuel delivery pump by hand until the fuel flows out of these screws
without bubbles, and retighten the vent screws. After that, loose the union nuts of
injection pipes on the injectors and rotate the crankshaft to bleed air from injection

18

K ~ K ~ ~K
 g ~ pfa m j~ d lK

pipes, and then retighten the union nuts. Check all fittings of the fuel system to see
whether there is any leakage at all joints.
5. Check the radiator to see whether it is filled fully with water and whether there is
any leakage at all joints.
6. Check the accessories to see whether they are firmly and reliably connected. Check
the electrical system to see whether the battery is fully charged, all wirings are
correct and all connections are tightened.
7. Check the Power Supply switch to see whether the diesel generator is unload.

2.3 Starting of diesel engines

1. Turn the ignition switch to “preheating”position to heat the electrochemical unit

for 20~30s ， when atmospheric temperature is low.(If the engine has

R
electrochemical unit)
2. Turn the ignition switch to “on” position. Press the starting button to start the

E
engine. If it fails to start, release the button immediately. Wait 2~3 minutes before
restarting the engine. If the engine fails to start after 3 attempts, check the cause

W
and remedy the fault.
3. As soon as the engine has been started, release the press button immediately. Then

O
turn the ignition switch to another position to charge the battery. At the same
time ,check the operation of the engine to see whether there is any abnormal noise.

P
Especially pay close attention to the readings of oil pressure gauge, which should
be within specified pressure limits. Then warm the engine up without load .

2.4
A
Operating of diesel engines

ID
1. Do not load the engine until the cooling water temperature is over 50℃ and the
lube oil temperature is over 40℃. The engine should be operated under rated

S
output before the outlet water temperature reaches approximately 80℃.
2. Increase or decrease the engine load and speed gradually and evenly. In normal
case, do not load or unload the engine suddenly , especially engine speed upon
1500r/min.
3. During operation, observe the gauges on the instrument panel frequently where
the readings should be within the specified limits. Pay close attention to the
exhaust gas color and the operating noise. If there is any fault, stop the engine and
inspect it.

2.5 Stopping of diesel engines

1. Before stopping, take off the load and reduce the engine speed gradually. Let it
run at idling speed 900r/min for a while. Do not stop the engine until the outer
temperature falls to below 70℃.
2. After stopping the engine, the ignition switch should be turned to the middle

19

K ~ K ~ ~K
 g ~ pfa m j~ d lK

position.
3. In winter, when ambient temperature falls to below 5℃, after the engine stops and
the cooling water temperature falls to below 60℃, open all drain cocks on the
cylinder block and radiator to drain off all water remnant within the cooling
system, in order to avoid damage of parts due to freezing. If anti-freezer is added
to the cooling water, it is not necessary to drain off.

2. 6 Safety requirements of diesel engines

1. When the diesel engine are used for the unit, all exposed rotating parts and
transmission mechanisms that may pose a risk to the operator is must installed
with protective devices alert tag. Protective casing, partitions and so on should be
sufficiently rigid so that it can not be dismantled except using the tool.

R
2. Working condition for diesel engines must be well-ventilated. In places where
there may be accumulation of flammable, toxic or asphyxiating gas, ventilation

E
facilities should be installed.
3. Operating premises of diesel engine must be accompanied by anti-skid cover.

W
Work access, control platforms, staircases and other operate regions must be
installed with barriers to prevent the operator and goods from falling.

O
4. When the diesel engine is used, it must be equipped with water temperature table,
hydraulic table, and other instrumentation and instruction system which are

P
necessary to ensure the normal operation.
5. During the debugging operation of diesel engines, in the event of abnormal noise,
speed, or a sudden lubrication interruption, or when the exhaust temperature

A
exceeds the set limits in explosive environments, you should quickly cut off the
fuel (press the parking handle, cut off fuel pipes etc.) and air intake (block it) or

D
take other effective measures to stop the engine quickly.

I
6. Outlet position of refueling hole and vents of fuel tank should be away from
high-temperature surfaces and electrical components, and the blocks should be to

S
ensure that the turbulence of the fuel tank will not lead to fuel leaks.
7. Users should set warning signs in eye-catching location when profiling the
radiator, warning the operator not to open the radiator cap immediately when
engine is hot, so as not to burn high-temperature steam.
8. Diesel engine exhaust pipe and muffler have high-temperature surfaces, so the
operator should be careful not to contact the above-mentioned high temperature
surfaces in the hot engine, so as to prevent scalding. If users use insulation
materials as a protective of exhaust pipe’s and muffler’s high-temperature surface,
they should notice that fuel should not infiltrate insulation materials so as to
prevent fire.
9. When diesel engines are used in places as follows, high-temperature surface
should be cooled or effective protection facilities and warning signs should be set,
and the insulation material should be non-combustible, and leaked fuel should not
infiltrate to avoid fire.
①Marine ② Oil industry ③Coal mine④ chemical industry⑤Power generation
⑥ Fix

20

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 3 Technical Maintenance of Diesel Engine

For reliable engine operation with less wear and longer service life, all maintenance
work must be carried out as follows:

3.1 Routine maintenance

1. Check the oil level in the oil sump and it should be between two marks on the
dipstick and near the upper one. For a new engine or the engine reused after
stopping for a long period, the lube oil must be filled to the upper mark, and
operate the engine at lower speed for 5~10 min, then stop the engine and measure
the lube oil level once again.
R
E
2. Check the cooling water level in the radiator.
3. Check the lube oil level in the governor of the injection pump, replenish the oil to
the specified level if need.
4. Eliminate oil, water and gas leakage of the engine.
W
O
5. Check tightness and correctness of all components attached to the engine.
6. Check tightness and reliability of engine foundation bolts and the connection

P
between the engine and the driven machinery.
7. Keep the engine clean. Oil, water and dust gathered on the engine surface should
be wiped away with a dry rag or cloth dipped in gasoline. Especially keep the

A
electric equipment clean and dry and clean out the dust on the fins of the radiator.
8. For the new engine, after 50h trial running, renew the lube oil in the oil sump, fuel

D
injection pump and governor, and flush the oil filter element, oil sump and oil

I
strainer.
9. Promptly eliminate the troubles and faults found.

S
3. 2 Maintenance after every 100 accumulated operating hours

Besides the “routine maintenance” work, it needs the following items:

1. Renew the oil in the sump.
2. Clean the oil filter or renew the paper element if necessary.
3. Clean the fuel filter or renew the paper element if necessary. (It may as well be
replaced after every 200 accumulated operating hours.)
4. Check tightness of cylinder head bolts.
5. Check whether the valve clearance accord with the regulation, and adjust if
necessary.
6. Check tension of the fan belt and adjust if necessary.
7. Inject ZG-4 calcium-based grease into the water pump bearing with oil gun.
8. Remove the dust which is in the dust disk of the intake pipe &air filter and is
attached to the surface of paper element, and remove dust in exhaust pipe and

21

K ~ K ~ ~K
 g ~ pfa m j~ d lK

muffler.
9. Check the pressure and atomization performance of the injector after 200 hours’
running accumulated, clean and adjust if necessary.
10. Check the voltage of the battery, the specific gravity of electrolytic liquid should
be 1.27~1.28 (atmospheric temperature is 20℃). If it reduces to 1.14, it must be
charged. Check up whether the level of electrolytic liquid surpasses the plate
about 10~15mm, and add distilled water when inadequate.
11. To the parts which are disassembled for maintenance, they must be cleaned, and
the correctness and reliability of the mounting position must be guaranteed when
these parts are mounted again. After that start up the diesel engine and check the
operation, exclude the failures and anomaly.

3. 3 Maintenance after every 500 accumulated operating hours

Besides the work of maintenance after every 100 accumulated operating hours, the
R
following items are needed:
E
1. Check the injection pressure and spray pattern of the injector. If necessary,

W
dismantle the injector, clean the nozzle set and readjust the injection pressure.
2. Check fuel delivery of the injection pump, and recalibrate it on a test bench if

O
possible. Check the injection timing, and readjust it if necessary.

P
3. Check the sealing of the intake and exhaust valves. If necessary, grind and lap
the valve seats and readjust the valve lashes.
4. Check the tightness of the connecting-rod, main bearing cap and flywheel bolts.

A
5. Retighten the cylinder head bolts and adjust the valve lashes according to
direction given in Section 4.

D
6. Clean or replace the paper element of air cleaner.

I
7. Clean the cooling system. The cleaning solution can be prepared by adding 150
grams of caustic soda (NaOH) to every litre of water. Before cleaning, drain the

S
system completely and then fill in the same capacity with cleaning solution. Let
it remain in the system for 8~12h. Then start the engine and run it until the
temperature of cleaning solution reaches normal operating temperature. Stop the
engine and drain the system immediately in order to avoid settling of scale
within the system. Finally, flush the system with clean water until all sediment is
flushed out.
8. Check whether the thermostat is in good order. Examine the water dropping out
from a weep hole of the water pump. It is necessary to renew the water seal, if
flowing out too much of water.
9. Check the wiring contacts of the electric equipment to see whether they are
connected firmly and well. Burnt marks should be removed.
10. After every 1,000 accumulated operating hours, add the following items:
(1). Make an overall check on all parts and components. Make necessary
adjustments and repairs.
(2). Dismantle the dynamo and starting motor. Clean out the dirty grease in the
bearings and refill them with clean grease. Check the pinion of starting motor.

22

K ~ K ~ ~K
 g ~ pfa m j~ d lK

11. After every 1,500 accumulated operating hours, add the following items:
(1). Remove the cylinder head; check the valve seats and other parts of cylinder
head assembly.
(2). Remove the carbon deposits on the surface of cylinder head, liner, piston and
piston ring, etc, and wash down them.
(3). Check and measure wear of the pistons and piston rings.
(4). Check and measure wear of the cylinder liner.
(5). Check and measure wear of the crankshaft main journals and crank pins. Clean
lube oil passages of the crankshaft.
(6). Check wear of the main bearing and connecting-rod bearing shells.
(7). Check oil passages of the cylinder block and replace lube oil.

3. 4 Preservation and storage of engine

R
If the engine is to be put out of service for a comparatively long period of time, it is
necessary to preserve it according to the following procedure:
E
1. After the engine stops and still does not cool yet, drain out completely the lube oil,

W
cold water and fuel immediately. Clean the oil sump and oil strainer.
2. Clean out the dust and oil on the engine surface. With antirust oil smear all the

O
unpainted exposed surfaces of engine except rubber and plastic parts.

P
3. Heat the filtered lube oil to 110~120℃, until all bubbles in the surface of oil
disappear. Then pour the dehydrated oil into the oil sump until oil level reaches
upper mark, and turn the engine, in order to make sure that the lube system is

A
completely filled up with this oil.
4. Pour some dehydrated oil into cylinder through injector——assembled holes on

D
the cylinder head, and turn the crankshaft to make sure that the piston, piston ring,

I
cylinder liner and valve seat are all covered with a layer of this oil.
5. Block the outlets of intake and exhaust manifolds (silencer) with wooden plugs or

S
wrap up properly with plastic film in order to prevent any dust from getting in.
6. The engine should be stored in a clean room with good ventilation and low
humidity, and the engine should be covered. Chemicals near it are strictly
prohibited.
The preservation according to the above procedure may be valid for 3 months.
Over this period, repeat the procedure.

23

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 4 Adjustment of diesel engine

4.1 Adjustment of valve lash

When the engine is maintained and repaired, it is necessary to check and adjust the
valve lashes. The recommended method of adjusting the valve system and valve lash
is as follows:
1. Remove the cylinder head cover.
Check and tighten the nuts
fastening the rocker arm shaft

R
stands.
2. Turn the crankshaft to make sure

E
that the piston of 1st cylinder is at
the compression TDC position.

W
The timing mark on the inspection
window of the flywheel housing

O
exactly points to the “o” mark on
the flywheel rim, or the “o” mark
on the crankshaft pulley is aligned
with the pointer on the cover of
timing gear housing.
P
A
3. Slip a feeler gauge between the

D
rocker arm and the tip of the
intake or exhaust valve stems of

I
the 1st cylinder respectively to

S
check and adjust the valve lashes. Since then, four-cylinder machine according to
the working cylinder 1-3-4-2 according to the crankshaft will be 180 °, 3
cylinder machine according to the work in accordance with the 1-3-2 cylinder
crankshaft 240 ° adjust each cylinder valve clearance.

4.2 Adjustment of injection timing

To obtain the most economical specific fuel consumption and to ensure normal
operation of the engine, injection timing should be adjusted properly. Right in front of
the fuel delivery advance Angle shall be the check point on 16 + 1 °
The adjusting method of injection timing is as follows:
1. Vent the air trapped in the fuel system, and turn the crankshaft to fill up the
injection pump with fuel. Disconnect the injection pipe of the 1st cylinder, turn the
crankshafts slowly in the direction of its rotation and at the same time observe the fuel

24

K ~ K ~ ~K
 g ~ pfa m j~ d lK

level in the hole of fuel pipe union. When this fuel level just starts to rise, stop turn
the crankshaft immediately.
2. Check the timing mark on the injection window of flywheel housing to see
whether it aligns with the correct granulated mark of specified advanced injection
angle on the flywheel rim (or on the crankshaft pulley).
3. The advanced injection angle can be adjusted by loosening the three nuts on the
triangular flange of injection pump and turn the injection pump shaft. Facing the
front end of engines, when the injection pump rotates clockwise, the fuel
injection will retard; while the injection pump rotates anticlockwise, the fuel
injection will advance. After turn the injection pump once, it is must to tighten the
three nuts and check the advance injection angle again until the advance injection
angle fits the specified value.

R
4.3 Adjustment of injector

E
Injector test and adjustment must be performed on a injector tester in order to adjust
injecting pressure, inspect spray pattern and remedy faults.

W
Too high or too low injector injecting pressure, and abnormal spray on damaged
injector parts will cause engine troubles, such as black smoking, power and speed

O
dropping, increasing exhaust temperature and diesel knocking, etc. Generally, the

P
“shut off” method is recommended to check a faulty injector, i.e. loosen the nuts of
injection pipe from the injector of every cylinder successively, and observe the
exhaust smoke. When the cylinder with the faulty injector stops firing, black smoke

A
would disappear and engine speed is not appreciably affected or not affected at all. It
may also be checked by listening to the chattering action of the injector of every

D
cylinder with the flywheel rotating. If the distinct clear sharp sound of certain cylinder

I
could not be heard, the injector in this cylinder may be faulty.
1. Procedure of injector testing and adjustment

S
(1). Work the injector tester hand pump until the gauge pressure reaches about
specified injection pressure. Then operate the hand pump slowly and adjust the
injection pressure at which injection begins. The nozzle should not show any signs of
leakage. If fuel drips around the nozzle tip after several tests, the nozzle set must be
dismantled for cleaning and grinding. Then test it again.
(2). Adjust the injection pressure. Remove the pressure regulating nut of the injector,
loosen or tighten the screw to make the injection pressure 13.7Mpa, then tighten the
pressure regulating nut and conduct another retest.
(3). Work the hand pump at a rate of approximately 1 stroke per second and observe
the nozzle spray. The fuel spray should be even and well atomized in a shape of cone.
At any cross section of the cone, the atomized fuel should be finely and evenly
distributed. Fuel droplets and irregular pattern which can be seen by naked eyes
should not be present in the spray. There should be a distinct clear sharp sound at the
end of injection. Generally, irregular pattern of the spray is caused by needle valve
seizure, fuel dripping is generated by damaged conical sealing surface of needle valve
and spray split results from carbon deposits on the tip of nozzle and its heat

25

K ~ K ~ ~K
 g ~ pfa m j~ d lK

deformation.
2. Injector dismantlement and repair
(1). Before dismantling the injector, clean off the dirt gathered on it. Clamp the nozzle
body in a vice lined copper sheets on its jaw with the nozzle upward. Turn off the
nozzle cap nut and take out the nozzle set. Draw out the needle valve from the nozzle
body and soak it in clean fuel oil. Then clamp the injector in the vice upside down
again. Dismantle the adjusting nut, and adjusting screw, and then take out the injector
spring and spindle.
(2). If the nozzle set is seized or emits fuel badly, it must be cleaned. Soak the seized
nozzle in fuel oil for a while, and clamp the needle valve by pliers with cloth lined.
Then rotate and draw it out slowly, just to avoid scratching its surface. Decarbonize
the needle valve and nozzle body with wooden chip soaked in fuel oil. It is forbidden
to clean them with metal chip. If the guiding surface of the needle valve and nozzle

R
body are not smooth enough, it may be lapped with a little bit of clean fuel oil, then
clean off any metal particulates in clean fuel. While lapping of needle valve with

E
nozzle body, never knock the needle valve against the body.

W
4. 4 Adjustment of lube oil pressure

O
See fig.2. Loosen the lock nut and turn the adjusting screw with a wrench to take

P
the lube oil pressure within 200~400kPa (in cold state the pressure may be higher
slightly). After adjustment, the pressure adjusting screw must be locked by the lock
nut.

A
ID
S
Fig.2 Adjustment of lube oil pressure

4.5 Adjustment of injection pump

The injection pump has tested and calibrated at the factory. If it is necessary to
readjust, the readjustment must be performed in an injection pump test bench with a
standard injector and injection pipes of standard length according to the instructions in
Operation Manual of the injection pump.

26

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 5 Construction of Diesel Engine

5. 1 Cylinder head

Intake/exhaust valves，valve seats，valve guide pipe，valve springs，rock arms

and supports are assembled on the cylinder head.
When assembling, cylinder head is fixed on the cylinder block with cylinder
head bolts. A torsion spanner should be during tightening the bolts. The bolts are
tightened several times in sequence shown in Fig. 3 until they reach the specified
torque limit. After dismantling and assembling the cylinder head, it is necessary to

R
shut down the engine when first warming up period is over. Retighten each bolts on
the cylinder head according to the specified value of torque limit and readjust the

E
valve lashes.
Injectors are inclined on the top of cylinder head with a anlge to the centerline of

W
cyclinder. When injectors are assembled, the copper sleeve are put into the injectoe
assembling holes, and the press plate shall be pressed evenly to avoid gas leakage, at

O
the same time, the belve of the plate shall face down.
The intake and exhaust valves are made of different materials. Each couple of the

P
valve and valve seat should be ground in order to prevent leakage.
It is necessary to grind when gas leaks out due to burning out, mechanical pitting
and wear appeared on the sealing face of valve and valve seat. When grinding, apply a

A
grinding paste (fine valve sand) on the conic sealing surface of valve. Then the valve

D
and valve seat are lapped in pair until a even, continuous and lusterless sealing band
appears. It is strictly forbidden that the grinding paste enters the valve guide. After

I
lapping, clean the valve, valve seat and valve guide carefully. Wearing of the valve

S
guide may cause the eccentric wear of valve sealing band which results in abnormal
sealing. Pour some kerosene or diesel fuel into the gas passage, and observe whether
there is any leakage, then check the valve sealing.
The sealing band of valve and valve seat is normally 1.2~1.7 mm in width. After
a long period of service and regrinding many times, the width of valve sealing band
may get wider, this may cause abnormal sealing. Being kept concentrically with
respect to the valve guide hole, the contact band on valve seat is to be refaced by a
reamer. Then gring the valve and valve seat in pair.
After service for a long period and regrinding many times, the sink age will
increase. When it exceeds 2.0mm, replacing the valve seat should be considered.
Check the valve lashes frequently. The recommended adjusting method is shown
on Section 1 of Chapter 4. If the lashes are too large, it may affect the correctness of
valve timing and the noise level of valve device rises. On the contrary, it may cause
leakage or valve burnt out.

27

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Fig.3 tightening sequence of cylinder head bolts

R
E
W
O
P
A
Fig.4 Valve sinkage

5. 2
D
Cylinder block

I
S
The cylinder block uses a typical gantry structure.
Besides the fitting bores for the liner and the cylinder head bolt holes, on the top
plane of the block there are holes leading water to the cylinder head. Near the rear end
of the block there are channels delivering lube oil upwards to the cylinder head.
The water pump is mounted on the upper front face of cylinder block, and the gear
system is on the lower part. The flywheel housing is installed at the rear face of the
block. On the block bottom, there are a lube oil inlet, a hole for the lube oil pump and
tap holes for installing the sump. There are a side cover and a breather on the left side
of the block (facing to the front end). There are the lube oil filter, fuel filter and drain
cock on the right side of this block. The main lube oil line and its branches are
arranged in horizon. The lube oil passage delivering lube oil to the camshaft bushes
are slant. When dismantling and repairing the diesel engine, flush all lube oil passage,
and be sure that they are clean and locked. All passage plugs should be sealed reliably
and leak proof.
The main bearings are of complete suspension-support type. Since the main
bearing caps and cylinder block are matched to bore, the matching marks are both on

28

K ~ K ~ ~K
 g ~ pfa m j~ d lK

the block and main bearing caps. Misplacement or inverted installations, when
dismantling for cleaning, make sure that the upper and lower bearing shells are in
right places (the upper shell with an oil groove). The crankshaft thrust plates are
assembled on the last main bearing with an upper piece and a lower piece on each side.
The thrust plates bear the axial force from the crankshaft. There are oil channels on its
operating surface which should be located against the thrust planes on the crank, and
its back surface if smooth. Never locate them in reverse. When tightening the main
bearing bolts, two bolts on the bearing cap should be tightened several times in turn.
Before tightening the main bearing cap, strike the crankshaft forward and backward in
order to keep the upper and lower thrust plates in the same plane. Then tighten the
bolts until they reach the specified tightening torque. When completing the crankshaft
assembly, turn it at the flywheel end by hand to check whether it can be moved freely.
The liner is slipped into the cylinder bore vertically so that deformation of the

R
liner may be avoided. The liner flange plane should protrude out the top plane of
cylinder block by 0.04~0.12mm to keep an excellent sealing between the cylinder

E
liner and cylinder head, as shown in Fig.5.

W
O
P
A
ID
S
Fig.5 protruding height of the liner flange plane relative to the plane of cylinder
block
Oil sump is stretched by cast aluminum or steel plate. When you clean the inside
of the oil sump, be careful not to leave impurity on the wall, in order to avoid
blockages in the copper wire net of the oil collector and oil filter element.

5.3 Piston and connecting-rod

The piston and connecting-rod assembly comprises the piston, piston rings, piston
pin, retaining rings, connecting-rod, connecting rod cap, connecting-rod bolts and

29

K ~ K ~ ~K
 g ~ pfa m j~ d lK

connecting-rod bearing shells and bush, etc. The mass difference of piston and
connecting-rod assemblies in the same engine should be with in 20g, and that of the
connecting rod assembly not exceed 10g.
Combustion chamber on the top of the pistion is ω type. Skirt of the piston is
machined in a shape of barrel along the height direction and ellipse along the
circumference. There are two compression ring grooves and an oil ring groove
machined in the piston.
All of the compression rings are made of alloy cast iron. The outer circle surface
of the first ring is plated with porous chrome in order to decrease the wear between
the cylinder liner and piston ring. The second ring has a conical surface. When
assembling, the surface marked with a sign “up” should be kept against the top of
piston and be careful to avoid assembling in reverse.
The oil-control ring is of tensioning ring type. The radial force of oil ring is still

R
kept while decreasing the elasticity due to wear. Thus the service lift of oil ring is
prolonged.

E
Check the ring end gap before assembling the piston ring. The method measuring
this gap is recommended as follows: press down the piston ring evenly into the

W
cylinder liner by 15~20mm from the top surface of liner. Measure the clearance with a
feeler gauge. In normal case, the measuring value should be specified value in

O
Chapter 1 (Fig.6). In case the gap value is less, enlarge it by a file. If it is excess,
replace it with anther one. In addition, measurement should be made with a feeler

P
(gauge) to check the side clearance between the piston ring and ring groove. The side
clearance should be specified value in Chapter 1 as shown in Fig. 6.

A
ID
S
Fig.6 measurement of piston ring end gap and side surface gap

When dismantling and assembling the piston ring, a special tool may be used. The
ring end gap of piston rings should be set off with each other by 120℃ to prevent
being in line with the piston pin seat hole.
If the piston ring is seized and could not move when checking, soak it in diesel
fuel (kerosene or gasoline) for 24h or more. Then knock the piston ring slightly to
make it become flexible of itself. On getting out the piston ring, clean it in diesel fuel
or carbon tetrachloride.
Check the piston to see whether there are any cracks or scars. Change the defective

30

K ~ K ~ ~K
 g ~ pfa m j~ d lK

piston and renew its rings.

The cross section of the connecting-rod is 1-shapped, with the splitting surface of
large end being perpendicular to the center line of connecting-rod. Boring the
connecting-rod hole and connecting-rod cap must be mated. Therefore when
assembling, pay close attention to the mating marks on both the connecting-rod and
connecting-rod cap in order to avoid making mistakes. The connecting-rod bearing
shell is made of steel with high tin aluminum alloy. When the clearance between the
connecting-rod bushes and crankshaft journal exceeds the specified value after
wearing or severe stripping and burning occur on their surfaces, they must be renewed
in pair.
During engine overhaul or renewing the connecting-rod, check the axis
parallelism of the connecting-rod small end to the large end, which is specified to be
within 0.01mm/100mm (both in vertical and horizontal direction). If it goes beyond

R
the scope, alignment should be made.
Before dismantling the piston and connecting-rod assembly in cylinder liner or

E
assembling, it is necessary to scrape and clean the carbon deposit and greasy dirt on
the top part of cylinder liner. Before assembling, smear some clean oil on the cylinder

W
liner bore, external surface of piston and piston rings, connecting-rod bearing shells
and crankshaft journal. Then place the piston guide sleeve in the cylinder liner, fit the

O
piston and connecting-rod assembly into the cylinder liner carefully, and tighten in
turn the connecting-rod bolts according to the specified tightening torque limit in

P
several separate times. After finishing the assembly, turn the crankshaft; be sure that it
rotates smoothly.

5. 4
A
Crankshaft and flywheel

ID
The crankshaft timing gear and pulley are fitted on the front output end of
crankshaft. Positioned by the locating pin, the flywheel is fitted on the rear end flange

S
of the crankshaft with six bolts tightened according to the specified torque value. An
angular calibrating line is marked on the crankshaft pulley and a pointer, which is
fitted on the cover of the timing gear housing, indicates the reading of advanced
injection angle.
A flywheel gear ring is bound on the outside diameter of flywheel in shrinking fit.
A calibrating line, which provides observation for advanced injection angle, is marked
on the flywheel.

5. 5 Camshaft

There is a gear driving the lube oil pump in the front of the last set of cams
(facing to the front end). When the camshaft revolves, the cam on the shaft drives the
tappets, push rods, valve rocker arms and valves, which respectively control the
intake and exhaust valves for each cylinder.
There is a thrust flange at the front end of camshaft, and a thrust plate of camshaft

31

K ~ K ~ ~K
 g ~ pfa m j~ d lK

is located at the front end to control the camshaft axial moving. The lube oil is
delivered to the camshaft bushings separately through the main oil line. Before
assembling the front bushing of camshaft, check whether the oil holes on the bushing
and oil passage in the cylinder block communicate with each other.
The axis of the tappet deviates from the center line of cam width. During
operating, the tappet rotates so as to provide an even wearing on the bottom surface
and the cylindrical surface of tappet.

5.6 Gear transmission system

The gear transmission system consists of the crankshaft timing gear, timing idler,
camshaft timing gear, injection pump timing gear and hydraulic pump gear.
Except the hydraulic pump gear, all the timing gears are all marked with timing

R
signs which, when assembling, should align with each other at the meshing position
(the single tooth marked with a sign is inlaid between the two adjacent marked teeth)

E
in order to ensure the movement relationship of all moving parts, as shown in Fig.7.
Special tools are necessary for dismantling or assembling the crankshaft timing

W
gear. The camshaft timing gear can be got out by two bolts M8 on the gear spoke
which are turned staggeringly and evenly. The timing idler is located on the cylinder

O
block by slide fit. The injection pump timing gear is assembled on the timing gear seat

P
which is fixed on the camshaft of the injection pump. Whenever three bolts setting the
injection pump gear are loosened, the injection pump gear can be drawn out. The
injection pump gear is pushed out when the three bolts M8X35 are staggeringly

A
tightened on the gear seat.

ID
S
Fig.7 timing gear meshing signs

5.7 Fuel and governing system

The fuel and governing system is the main operating section of the diesel engine.
It is composed of the fuel delivery pump, fuel filter, injection pump; governor, fuel
injection and fuel return pipes, etc. as shown in Fig.8.
The fuel is pumped by the fuel delivery pump from the fuel tank into the injection

32

K ~ K ~ ~K
 g ~ pfa m j~ d lK

pump through the fuel filter. The diesel fuel is delivered through the injection pipe
under high-pressure produced in the pump, and is then atomized by the injector before
burning in the combustion chamber.
The fuel delivery pump is a single-acting piston type pump located on the outside
of the injection pump. The eccentric cam, which is set on the camshaft of injection
pump, drives the fuel delivery pump, which finally presses the fuel into the fuel cavity
in the injection pump.
The injection pump has been calibrated by the manufacturer. Be sure not to
dismantle it at will. When the dismantlement and adjustment are required, it is
forbidden to interchange the plunger sets and discharging valve sets, and be sure to
keep clean when assembling.
The all speed mechanical-centrifugal governor is applied. The governing handle
can be operated to control the speed of diesel engine. When the governing handle is

R
turned in the direction of tightening the governing spring, the fuel supply would
increase and the engine speed would be up consequently. When this fuel supply would

E
decrease and the relevant engine speed would go down. Do not move either the high
speed or the idling speed set screws or screw the maximal fuel supply set screw on the

W
governor at will during operating.
On the governor housing, a stop handle is mounted which, if necessary, can be

O
operated to stop the engine at emergency.
The needle valve and its body are a precise set lapped in couple, therefore, close

P
attention is paid to that, when dismantling and assembling them. Be sure not to
interchange them and to keep them clean.

A
ID
S

Fig.8 fuel and governing system

1. Fuel return pipe 2. Fuel injection pipe 3. Injector 4. Injection pump
5. Fuel filter 6. governor 7. Fuel delivery pump

33

K ~ K ~ ~K
 g ~ pfa m j~ d lK

5.8 Lubricating system

The lubricating system is composed of the strainer, lube oil pump, oil filter and
pipelines, as shown in Fig.11.
The engine adopts pressure and splash lubrication. The pressure lubrication is
applied to the main bearing, connecting-rod bearing, camshaft bushing. The cylinder
sleeve, piston pin, connecting-rod bushing, cam and its tappet, as well as valve and its
guide are lubricated by splashed oil spray. The bearings for the water pump shaft are
lubricated regularly by adding lubricating grease.
The lube oil is sucked up to the lube oil pump from the oil sump through the
strainer and the oil inlet pipe, and pumped into main oil line through the oil filter. One
path of the lube oil lubricates the main bearing and the connecting-rod bearing
through the oil hole on the crankshaft; other path of the oil lubricates the camshaft
bushing, and also the oil is supplied intermittently to the rocker arm shaft bushing
R
E
through the eccentric oil channel in the rear journal of the camshaft; and the third path
of the oil is fed to the timing idler bearing. The lube oil pump is of slantingly mounted
type. A single stage paper cartridge oil pump is used. The filter element can be

W
replaced regularly. In case of blocking up during operation, the oil flows into the main

O
oil line by opening the safety valve while the oil filter loses the function of filtration,
so it is necessary for the cartridge to be cleaned or replaced regularly according to the

P
maintenance.

A
ID
S

Fig.9 lubricating system

1. Oil sump 2. Strainer 3. Lube oil pump 4. Piston and connecting-rod assembly and
cylinder liner 5. Lube oil filter 6. Gear train 7. Oil pressure gauge 8. Rocker
arm 9. Valve push rod, valve tappet and block hole for tappet 10. Rocker arm shaft
11.Valve and valve guide 12. Camshaft and bushing 13. Oil lines in the block 14.
Crankshaft and bearing

34

K ~ K ~ ~K
 g ~ pfa m j~ d lK

5.9 Cooling system

The cooling system is a forced circular water cooled type, as shown in Fig.10.
The system consists of a radiator, water pump, cooling fan, thermostat and diversion
hood, etc.
The cooling water, pumped from the radiator into the cylinder block water gallery,
flows tangentially and round to the cylinder liner, then up to the cylinder head. The
hot water from the front end of the cylinder head flows back into the radiator through
the thermostat and outlet water pipe. When the temperature of cooling water is below
70℃, the thermostat closes, and the cooling water will be short-cut for circulation
from the branch water pipe on the front end of the cylinder head to the water pump
inlet pipe and the water pump; when the temperature of the cooling water is above
70~80℃, the thermostat opens, and the cooling water flows into the upper part of the
radiator through the thermostat and flows downward the thermostat and flows
R
E
downward along the flat-tube into the lower part of the radiator, during which the
cooling water is cooled by the fan and completes the regular circulation. The cooling
fan can be of either suction or blast type according to its application.

W
The centrifugal water pump is driven by the fan belt on the crankshaft pulley. In

O
case of severe water dropping out from the weep hole at the lower part of the pump
housing due to the damage of water seal during operation, it is necessary to replace

P
the water seat but blocking the weep hole at the time of leakage is not permitted, or
the water will enter the bearings, which causes their quick wear. Replacement must be
considered while regularly with ZC-4 calcium based grease which amounts to about

A
1/2~1/3 of the capacity of bearing cavity according to the maintenance. The bearing
will be overheated with excessive grease. The single valve type thermostat with

D
corrugated pipe is filled with temperature-sensitive fluid which can automatically

I
control the valve opening and closing.
The fan belt must be checked and adjusted regularly for its tension according to

S
the procedures for the maintenance. The slack is 10~20mm when pressing the belt
between the fan and the dynamo pulleys.

Fig.10 cooling system

1. Radiator 2. Thermostat 3. Cooling fan 4. Water pump 5. Inlet water pump

35

K ~ K ~ ~K
 g ~ pfa m j~ d lK

5.10 Electric system

The electric system is composed of the battery, starting motor, dynamo, electro
thermal plug, starting button and instrument, etc., as shown in Fig.11.
The parallel excited silicon rectifying dynamo comprises the three —phrase
alternator and silicon diode rectifier. Be careful that the armature must be negative
pole grounded, or the dynamo will be damaged. Refer to operation and maintenance
manual for dynamo for the operation and maintenance of the dynamo.
After turning on the start switch, the flywheel gear is engaged with the motor
pinion by the solenoid; meanwhile the flywheel is driven by closing the current circuit
of starting motor.
As soon as the engine is started, the starting switch must be turned off
immediately. Then the core along with the pinion returns to the original place under
the actuation of spring. The continuous working time for the starting motor should not
R
E
exceed 15 seconds. The interval between two starting operations is 2~3 minutes. It is
necessary to check and eliminate the faults in case of starting failure for three attempts.
The electrifying time of the air heater each time during operation is not permitted to
be over 30 seconds.
W
O
P
A
ID
S Fig.11 electric systems
1. Battery 2. Starting motor 3. Wire 4. air heater 5.Preheating and starting
switch 6. Galvanometers 7. Ignition switch 8. Regulator 9. Dynamo

5.11 Pressurization、turbocharged system

Pressu rization system main consists of turbocharger、oil pipe in and out.
Turbocharaed system mainly by the supercharger empty the supercharqer oil pipe and
cold composition, turbocharger consists of turbine and supercharqing compressor.It
works as follows:turbine inlet casing Connected with Diesel exhaust manifold, Have
certain high temperature of the energy of the waste gas High speed into the turbine
cavity push in the same shaft turbine and high speed rotary compressor impellers,

36

K ~ K ~ ~K
 g ~ pfa m j~ d lK

High speed rotary compressor impeller into the cylinder of fresh air flow and pressure
be increased, To ireprove the power of diesel engine create conditions. Turbostructure
see the Fig.12

R
E
W
O
Fig.12
1-rurbine shroud 2-components of turbocharger 3-Turbine sealing ring

P
4-floating bearing 5-middle case 6-thrust bearing 7-compressor casing
8-compressor sealing ring 9-blower impeller 10-air evacuation valve

A
Dectorate in front of the cold water tank empty fuction is use of diesel engine
colling fan and vehicle head-on the sway of the wind colling when to reduce diesel

D
engine temperature increase air density, To increase the diesel engine power to

I
improve performance.
Because the supercharger turbo compressor rotor shaft speed work every minute

S
as high as 200000turn around,Therefore guarantee the supercharger rotor floating
bearing lubrication and cleaning lubricating oil is very important, Also note the
supercharger tubing installation in importance.

37

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Chapter 6 Faults and Remedies for Diesel Engine

6.1 Hard or refuse to start

Causes Remedies
1. Fuel filters and fuel pipelines 1. Clean.
blocked. 2. Exhaust air and tighten all fuel pipeline
2. Air trapped in fuel system. connector.
3. Advanced fuel injection angle 3. Readjust it according to specifications.
incorrect. 4. Readjust fuel injection pressure according to
4. Fuel spray abnormal. specifications and clean or replace injector

R
needle valve sets.
5. Compression pressure low. 5. Check or replace piston rings & cylinder

E
liners. Grind valves. Cylinder head nuts
should be tightened in case of leakage on

W
cylinder head gaskets.
6. Valve lash incorrect. 6. Adjust it according to specifications and align

O
gear marks.
7. Battery charge insufficient. 7. Charge it.
8. Wire connection loosened.
9. Ambient temperature too low, and
oil too viscous.
P
8. Check and tighten wire connections. Clean up
contact points.
9. Preheat cooling water & lube oil.

A
D
6.2 Insufficient

I Causes Remedies

S
1. Compression pressure inside
cylinders too low.
2. Advanced fuel injection angle
1. Refer to item 5 in Paragraph 1 and replace
components exceeding wear limits.
2. Adjust it according to specifications.
incorrect.
3. Valve lash incorrect. 3. Adjust it according to specifications.
4. Fuel supply for each cylinder 4. Adjust fuel injection pumps to proper supply.
unbalanced. 5. Clean.
5. Air filter clogged. 6. Replace them with new sets, adjust fuel injection
6. Fuel injection pumps, fuel pressure and check fuel spray.
injector sets worn off or fuel 7. Adjust it with governing handle in order to reach
injection pressure incorrect. specified speed.
7. Rotation speed incorrect.

38

K ~ K ~ ~K
 g ~ pfa m j~ d lK

6. 3 Smoking exhaust

Causes Remedies
1. Reduce the load properly and in case of unsuited matching
adjustment should be made.
1. Engines overloaded.
2. Check the injection pressure and fuel spray. Replace then
2. Fuel injection not
in case of damage.
well atomized.
3. Use qualified fuel.
3. Fuel unqualified.
4. Mainly caused by unqualified fuel injectors, incorrect
4. Combustion
advanced fuel injection angle, leakage at cylinder head
incomplete.
gaskets and low compression pressure. Remedy in
accordance with specified problems.

R
6.4 Knocking noise in engine
E
W
Causes Remedies
1. Advanced fuel injection angle incorrect. 1. Readjust it according to

O
specifications.
2. Air trapped in fuel systems. 2. Exhaust it.

P
3. Fuel supply for each cylinder unbalanced. 3. Readjust fuel supply.
4. Fuel unqualified. 4. Use qualified supply.
5. Wear of certain components exceeds limits. 5. Replace them.

A
6.5

ID
Oil insufficient or no pressure
Causes Remedies

S
1. Oil level in oil sumps too low.

2. Serious leakage from oil pipelines.

1.

2.
Add oil up to mark line on dip
sticks.
Eliminate leakage.
3. Oil strainers, oil filters and pipelines clogged. 3. Clean and replace elements if
necessary.
4. Oil gauges damaged or gauge line clogged. 4. Check and replace elements if
5. Oil too thin. necessary.
6. Oil pump gears seriously worn off, with 5. Use qualified oil.
excessive clearance. 6. Adjust the clearance or replace
7. Pressure relief valves of oil filter cease to them.
function. 7. Check and repair or readjust
8. Main bearings, connecting-rod bearings and them.
camshaft bushings seriously worn off with 8. Check and repair or replace
excessive clearance. them.

39

K ~ K ~ ~K
 g ~ pfa m j~ d lK

6.6 Overheating of engine

Causes Remedies
1. Temperature of cooling water too high: 1. (1) Fill the rank to make cooling water
(1) Insufficient cooling water or vapor level higher than the center line of
lock in water pipes. water pump.
(2) Bad working state of water pump. (2)Check water pump clearance and
(3) Water scale in cooling systems too tightness of belts. Eliminate leakage.
thick. (3) Remove it.
2. Oil temperature too high: 2. (1) check whether the oil level is
(1) Insufficient or excessive oil. between the dip stick scale lines.
(2) Oil pressure too low with insufficient (2) Refer to section 5.
flow.

R
3. Engines overloaded. 3. Relieve load.

6.7 Engine running-away

E
W
Causes Remedies
1. Malfunction of governors. 1. Stop engines immediately, check and repair.

O
2. Control rod fuel injection pump 2. Stop engines immediately, check and repair.
gets stuck. 3. Stop the engine and readjust injection pump

P
3. Injection pump delivery too much delivery.
4. Excessive oil burnt. 4. Stop engines immediately, check and repair.

A
ID
S

40

K ~ K ~ ~K
 g ~ pfa m j~ d lK

Appendix:

Wearing parts of diesel engine

No. Name No. Name

1 Cylinder liner 10 Water sealed ring
2 Piston ring 11 Fan belt
3 Piston 12 Bearing, bushing
4 Oil seal 13 Injector coupler
5 Generator 14 Injection pump plunger coupler
6 Starting motor 15 Injection pump valve coupler

R
7 Valve 16 Various gaskets
8 Valve seat ring 17 Filters filter
9 Valve guide pipe
E
W
Service life of diesel engine wearing parts is closely related to users’ operation
and maintenance. Operating and making maintenance strictly according to product

O
manual can extend the engine’s service life; if not, its service life may be shortened

P
seriously. Users should pay close attention to proper operation and maintenance of
diesel engine.

A
ID
S

41

K ~ K ~ ~K