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WHAM, A ZARRD PATH MATH OTe RE BeYZ485D $e WH BU EFA BE 3 OO Htae— YZ48SD 2d 8 dh BL Js HAE 4S BS ® = se em * & 1 | -yzassqp-o1121 aan 2 | yzsasqn-o1122 ATT 3. | vaasso1-4 Brg 4 | yz4eso1-3 aN 5 | yzsasqn-o1123 reise 6 | yzsssqp-1a erat 7 | yz485.03-6 LEK 8 | yz485.03-7 Fea 9 | yz4s5.03-1 rs 10 | YZ485QB.05-3 BAK 11 | vzass.os—4 RIA 12 | yza8s.05.2 sew 13. | yz48s.0s-s NE 14 | yz485qB.05-1 Be 15. | Gp9877.1-88 Ber RRS AIM FRS070128N | araahat 16 | cB9877.1-88 eRe MLGESIEM FBBOLODIZSN | as asy 17 | @B13352-1996 Fuser AVET«o40 18. | cxo708B-c200B Sen 19 | sxov0sB-317008 sma 20 | DSLA 153 P 027 St ~29 -24850 $M HEARSE Vitae YZ485D 58 hPL Sb Dove Be — WERE Fe] ee th 1 |BHEQTSRS AE | eae OA LA 2 ER (Pee RROARAR 3 [SER ARRAS IRE + [Ree LUMEN ERE AAD 5 [Race ARP AAA 6 [at CRE RTRA RL 7 [ewe LEGER RROARAS 3 [Ra TARR ARAT HE RARORA A 9 [an eATROA RAR AeA! 10 [ATE | eRES I RRR ut [Are RAAT ere, Came 12 |e eabRaae encaoneRoA se caraesaie 5 Sune: [RC Soe 14 [era aaa Ee ee ae 16 [Rts NRE EAC 17 [aR KATA AL SCA TRA AL TPR ET i SRA [BATSON AS RT RRA v9 [atresieney | GREG TOAST SRREH CARA IR 20 a BAVA WEA UR ANET 21 [eRe er ee ee al 2 ERAT 23 [Bete | sae cman mare 2a [RB USAT ES RRR 25 [AHO TRA ATR ROR PAT 30 -Y2485D 5 34 BI A FOR 3 HDB BERR = YZ48SD 258 nee Ai iA RS Ai Bet iE 1 | seat 18 2 | YZA8SD AURAL ST Biz 3 [aoe 1 4 RY 1k RAIL AA PAL asiY24850 $2 1 OLR HB CONTENTS Section I Main Specifications and Engine Dat L.1 Specifications of the Engine... 1.2 Specifications of Main Components. 1.3 Main Operation Parameters. 1.4 Fits and Wear Limits of Main Parts of Diesel Engine Section I Operation of the Engine .. 2.1 Fuel, Lubricating Oil and Cooling Watei 2.2 Rumning-in of the Engine 2.3 Preparations for Starting 2.4 Starting the Engine. Section II Engine Assembly and Disassembly . 3.1 Cylinder Head 3.2 Cylinder Block 3.3 Valve System 3.4 Crank—connecting Rod Mechanism 3.5 Fuel Supply Syste 3.6 Lubricating System. 3.7 Cooling System. 3.8 Electrical System Section IV Adjustment of the Engine 4.1 Adjustment of Valve Clearances... 4.2 Adjustment of Fuel Delivery Advance Angle. 4.3 Adjustment of Fuel Injector Opening Pressure 4.4 Adjustment of Lubricating Oil Pressure. 4,5 Adjustment of V-Belt Tension .. Section V Technical Maintenane 5.1 Shift Maintenance sn. -2-BS 24850 58 A I Hm 5.2 Maintenance at the Completion of Every 125 Working How 5.3 Maintenance at the Completion of Every 500 Working Hours. 5.4 Maintenance at the Completion of Every 1000 Working Hours. 6.2 Lack of Power 63 Insufficient Compression Pressure in Cylinder 6.4 Engine Stops Completely. 6.5 Engine Racing... 6.6 Abnormal Noise .. 6.7 Black Exhaust 6.8 Coolant Temperature Too High .. 6.9 Low lubricating Oil Pressure .. 6.10 Excessive Oil Consumption .. 6.11 Degradation of Lubricating Oil =33-YZA85D $2 WH BEA HE EBB Section I Main Specifications and Engine Data 1.1 Specifications Of Main Components Model ¥z485D Type ‘Water-cooled, vertical, in-line, four-stroke, direct injection ‘Type of aspiration Naturally aspirated ‘No of eylinder-BorexStroke 4-85%92, Total displacement L 2.088 Compression ratio 18: 1 BMEP MPa 0.67 Mean speed of piston m/s 4.60 552 Rated output kW 175 2 Rated speed sain 1500 1800 BSFC at rated power _g/(kW~ h) <235 Specific tub.oil consumption in g/(KW-h) Speed droop % <5 Idle speed min 800-850 Firing order 1-3-4-2 Lubricating method ‘Combination of pressure and splash . Cooling method Pressurized water-cooling Starting method Electric Volume of lubricating oil 8.0 Dry weight kg 195 Lomm m Overall dimensions | W mm 602 Hmm 822 — 34, Ey Y2485D 9 3 LR A BR 38 EB 1.2Specifications of Main Components . Engine Order No. C51-001 €52-001 Type In-line, plunger type 1 : Model BHAQTESR Isision ovr Taiaes TT Phinger dia 8s Govemor Centrifugal, ype TOA Feed pump Single-acting, piston ype Model KBAL-PO28 Injector Nozzle DSLA 153 PO27 i Hole dia 5x60 injector opening presre 2324 : Modei Rotor type 7 Luboil pump | Rated speed an t (cimin) i Flow rate, 1 (Limin) a ' Model Centrifugal type | cooling water Tared poed ed spe ' pump ann 1500 Flow rate | (min) i Type Spinon I pees Model CX0708 5 Type paper aaa Model K2007 ‘fitter [EYRE Spin-on | boil filter fodel 7X0708 | Type ‘Waxelement eee Model 155B. Model Qois8y ‘Starting motor | Voltage (V) 12 Power supply 25 «W) a Model TEWZI3 ener Voltage _(V) 4 Power (kW) 0.35, ieactator (Gptionaly _[ Voltage _(V) 2 —35— , ' : i , Bleetromagnet | Model 37AXBI2-220YZAR5D 9 WH DL OR FR HF 1,3 Main Operation Parameters Engine Order No, Lub oil pressure in main oil gallery atrated speed i) 02~05 at low idle speed MPa) 3005 ‘Temperature of lub.ol in oil sump (°C) <95 Cooling water temperature ¢c) 75~95 Exhaust temperature at rated conditions co) = Tightening torques wm 1) Cylinder head bolts 95~105 2) Main bearing cover bolts 130~150 3) Connecting rod cap bolts 60~70 4) Flywheel bolts 60~70 5) Crankshaft pulley clamping bolt 140~160 Valve timing (deg. crank angle) Tatake valves open (Before T.D.C.) a Intake valves close (After BDC) 42 “Exhaust valves open (Before BD.C.) 42 Exhaust valves close a {After TDC.) ‘Valve clearances (on cold engines) (mm) Intake valves 0.2.0.2 Exhaust valves 025-030 ‘uel delivery advance DE Fuel delivery advance angle before T.D.C. 4su05 pa (deg, crank angle) Protrusion of the nozzle tip (cam) 3340.1 a' ' { | | } Y2485D 5 ih Bl RH A 38 HB 1.4 Fits and Wear Limits of Main Parts of Diesel Engine ‘Assembly | Wear Limit Standard . No Item pinndanl | ‘ype of Fit | Clearance | (for reference) (mam) (mm) [Crankshaft main journal | 64.019 1 " Clearance | 0.05~0.114 020 fand main bearing bore | 964303 ‘Asal clearance between ae 2. |erankshal and cylinder 0.075-0.285 block Crankpin O.D. and ° 3 Jeonnecting rod hissed Clearance | 0.040-0.101 920 cexankpin bore 950885 ° Piston pin and connecting |28.o!ns ance rod small end bushing LD. | gog038 — ee 0103 5 ee eb ae Clearance | 0.103-0.155 6 |First compression ring and|2.605-303 eee anata) 02 ing groove width 2.720.015 ‘Second compression ring|2.5-abis 0.18, 7 \eed'ag gov wilts | ah Clearance | 0.05~0.085 ; sne|5-03 ® lorore sian ne 4 Se sane Clearance | 004-0075 | 18 9 peaketicnss 0.25-0.45 cd 10 en ce in eee 020-040 ce Intake valve seat O.D. and | @390054 12 | jnuake Interference | 0.069-0.119 bore in cylinder head | p39 -37-24950 8 LR BB 3 an ‘Assembly | Wear Limit No Item painted | Type of Fit | Clearance | (lor reference) (am) (nm) Exhaust valve seat OD. | 3572932 13] borin epider bead [eae Interference | 0.069-0.119 Rocker arm shaft OD. | 16 9 4 7 rocker arm bushing cream Clearance | 0.016~0.045 0.20 . a [Camshaft journal O.D. and |@45-2103 15 Clearance | 0089-0139 | 0.20 bearing bushing LD 45:0 Height of eylinder liner | gvar Height of 8331 collar top face 16 Jcollar and depth of | |p als to fee | 0.04-0.12 ecess in cylinder block [8-005 a Idle gear shaft O.D. and | 9407080 at Ey Clearance | 0025-0075 | 0.15 ile gear shaft bushing LD. | g4g"92S Intake valve stem O.D. — | p8-2583 so nate ie seg [eee Clearaace | 0025-0067 | 01s Exhaust valve stem 0.D. | 8-2055 19| Ovals guide LD. eens Clearance | 0.040-0.077 015 — 38 =| } i 3 Y2485D 5 Hh OE FS 9 iB Section Il Operation of the Engine 2.1 Fuel, Lubricating Oil and Cooling Water Fuel The fuel for the engine is the light diesel oil (grades10, 0, -10, -20 and -35) specified in the China National Standard GB 252. The fuel oil for the engine should be chosen according to the fuel specifications below: Fuel Specifications Grade of fuel 10 0 10 20 -35 Cetane value 50 50. 50. 48, B Pouring point(*C) 10 0 =10 -20 35 Lowest ambient temperature(‘C) +18) 8 2 -12 23 Before using, diesel oil should be stored for at least 48 hours to settle down impurities and then filtered with a sik cloth. Luboil The lubricating oil for the engine should be chosen from the products specified in the China National Standard GB11122 according to ambient temperatures. Proper grades of lubricating oil for different ambient temperatures are shown in the table below. Lub.oil Specifications CDgrade tow | sw/30 | 10/30] 1w/30]1sw/40|20W/40|20w/20| 30 | 40 Ambient temperatures |-20~5|-25~25 |-20-20| -10-25 | -10~35 | -10-30 | -10~10|~30| >25 Check the oil level with the dipstick at least 5 mins after refilling or stopping the engine, Cooling water Cooling water for diesel engines should be clean soft water, such as water from rain, snow or clean rivers. In ease of hard water, such as water from wells and fountains, it should be softened beforehand. There are two methods of doing it. (1)To boil up the hard water. (2)To add caustic soda into hard water (20 grams of caustic soda for 30 liters of hard water). a39-Y24050 9 MH ARPA IPH 33 2.2 Running-in of the Engine ‘Anew engine or an overhauled one should not be run before it has gone running in, ‘Through the running in period, the contact surface of motion parts can he coordinated with each other well, which can avoid abnormal abrasion and damages. Only 1 to 2 hours of running-in of the new or overhauled engine is carried out on the test bench. They should be run 40 to 50 hours at less than 70 percent of rated speed and under about half the full load before normal service at rated conditions. Operating an engine under heavy load without going through the running—in period may cause excessive wear, resulting in a reduction of service life or even damages to the cylinder, piston and bearings. After the replacement of any of the important parts such as the piston, piston ring, cylinder liner, crankshaft, main bearing and connecting rod bearing, the engine should be run at low speed and under light load for 10 to 15 hours before normal service. If anything abnormal occurs during the running-in period, stop the engine to check for the cause and make corrections. After running in, there are lots of metal particulates mixed into the lubrication oil, so it all should be changed and cleaned. Otherwise, the parts will be abraded. + After stopping the engine, drain the oil from oil sump completely when the engine is still hot, so that the impurity can be leaked ont with the slop oil. Then use the diesel to clean the sump and oil strainer. + Clean or replace element of lub.ol filter. + Check and adjust valve clearance. + Check and tighten all outer screws and nuts. Check the abrasion of the main bearing and con-rod bearing; the tightness and work conditions of all parts. Retighten the bolts of eylinder head, main bearing bolts and con-rod bolts. + Check and make corrections if other abnormal occurs. + Take maintenance of the interrelated lubrication joints. 2.3 Preparations for Starting 23.1 Check the tightness and security of the mounting of engine parts and accessories, including the injection pump, fuel filter, lubricating oil filter, generator, clectrie starter, water pump, fan, pulleys, etc. Check the freedom of movement of the fuel injection pump control levers. -49-{ f ' gS YZ485D 5 Mi BL RH AR 38 HB 2.3.2 Fill the engine with clean fuel oil, ubricating oil and cooling water as specified above. Check the oil levels in the ofl sump. Oil level in the oil sump should be near to the upper mark on the dipstick but not above it. 2.3.3 Check for the leakage of oi] and water. 2.3.4 Tum the crankshaft for several revolutions to check whether the movable parts move smoothly without interference, 2.3.5 Check the battery and wiring in the electric system. 2.3.6 Bleed the fuel supply system in the following procedure: (2) Slacken the venting serew on the fuel filter. Actuate the handle of the prime pump to bleed the fuel filter and pipes. And then retighten the venting screw. 2) Slacken the venting screw on the injection pump. Bleed the fuel injection pump by actuating the handle of prime pump until no air bubbles can be found in the outflowing fuel. Retighten the ven @) Slacken the union nuts connecting the injectors and high pressure fuel pipes. ig screw. ‘Tum the speed control lever of the govemnor to its halfway position. Crank the engine by means of the starting motor until fuel flows out from the joints. Then retighten the union nuts. 2.4 Starting the Engine Before starting check to see that the prime pump handle resists hand operation and that a puffing sound of injector can be heard when engine is cranked. If not, bleed the fuel system again. ‘Turn the speed control lever halfway and set the starting switch to the “start” position to start the engine. In cold weather, pour hot water into cooling water tank with the drain cock open until drain water temperature is over 30°C. Then start the engine in the procedure described above. It is not allowed to run the starting motor continuously for more than ten seconds. If the engine fails to start up, wait for two minutes before making another attempt. It is necessary to check over the engine if it fails to start up for three times in succession. After starting up, let the engine run at about 800r/min for several minutes. Do not load the engine until the lubricating oil pressure is in the normal range. Running at rated speed and full load is not allowed until the outlet cooling water temperature reaches 60°C. te24050 9 i HHA BL SS During operation, pay close attention to the indications of meters especially that for ubricating oil pressure, Before stopping the engine, reduce the load and speed gradually. Stop the engine by pulling the engine stop lever after the engine has been run at idle speed for several minutes. In case of engine running away choke the intake pipe to stop the engine. ‘After stopping the engine, switch off the battery supply to prevent the reverse current from battery to the excitation coil of the generator. If the ambient temperature falls below 0°C and the engine is not to be run for a long time, drain the cooling water from the engine and radiator to prevent frost fracture of the engine. -2-= YZ485D 32 OLD IE BB Section I Engine Assembly and Disassembly 3.1 Cylinder Head ‘The monolithic cylinder head is made of high strength cast iron. The fuel injectors, glow plugs and valve train parts are mounted on the cylinder head, j €P | Eph ety fit 2 ‘The inlet and exhaust valve guides are of the same design. ‘The valve guide and valve seat insert are press fitted into the cylinder head. The valves are not interchangeable because they and their seats have been lapped in pairs to form continuous, regular and bright seating lines. No leakage is allowed in the seat line of the valve. The normal valve seating line width is 1.0~1.4mm, If it gets too wide to ensure tight sealing, reshape it by means of a special reamer. Each valve is marked with a cylinder number, because they are not interchangeable in assembly. The standard valve recession, i.e. the specified distance from the valve head to the cylinder head surface is 0.4#0.1mm (see Fig.l). If the valve recession is too small, ream the valve insert to enlarge it; if it is too large, replace the valve and valve seat. B-Y2485D $M AL AEF RIF BB The cylinder head is mounted on the cylinder block with 18 bolts. They should be cevenly tightened in 2~3 steps . The tightening of the bolts in each step should be done in the order as shown in Fig.2. When dismounting the cylinder head, slacken the bolts in the reverse order. The operation procedure should be followed to prevent leakage and cylinder head deformation. 3.2 Cylinder Block On the front, there are the oil pump, driving gear, water pump and fan assembly. On the right side of the cylinder block mounted the injection pump, fuel filter and lubricating oil filter. On the left side are mounted the generator and starting motor. The flywheel housing is attached to the rear face of the cylinder block. Both flywheel and fly wheel housing have the SAE standard dimensions. The main bearing covers and the eylinder block are machined in couple. The main bearing covers are marked with sequence numbers and orientational arrow marks. They are not interchangeable and should be installed with the arrow marks pointing to the front side (fan and gear side) of the engine. When tightening the main bearing cover bolts, tighten the middle ones first and then the ones on both sides symmetrically to complete one operation cycle. The specified torque should be reached gradually in 2~3 steps. The two halves of main bearings are different. The upper one has an oil groove and an oil hole. It should be placed in the bearing saddle of the cylinder block. On both sides of the fifth main bearing cover are installed two thrust washers to control the endwise ‘movement of the crankshaft. The thrust washers should be placed with the grooved face outward. The cylinder liner is of the dry type. After the liners are pressed into the eylinder. block, the top surface of each cylinder liner TEN collar should be 0.04~ 0.12 mm higher above the surface of the cylinder block (see Fig3). For the same cylinder block, the difference in the height between one cylinder liner and another should be less than 0.05 mm. If this dimensional tolerance is exceeded, replace the wrong eylinder liners with selected ones. ft - 4Beso catenne nn ‘When pressing-in a liner, be sure to apply the force evenly and perpendicularly on its top. There is a graphite coated gasket between the cylinder block and cylinder head. Check to see that the holes in the gasket line up respectively with the holes for the locating, sleeves and the holes for the circulation of water and oil in the cylinder block. Place an O- ring seal (6.3x18) in the oil hole of the gasket. 3.3 Valve System The valve system consists of the camshaft gear, camshaft, valve tappets, push rods and valve mechanism. It is of the valve-in-head type with the camshaft located below in the cylinder block. Both camshaft gear (part 1 in Fig.4) and injection pump gear (part 3 in Fig.4) are driven by the crankshaft gear (part 6 in Fig.4) via an idle gear (part 2 in Fig.4). The gears have dot marks on them . In assembly, all the marks should be correctly placed to ensure correct valve timing and injection timing (see Fig.4) ‘The valves are opened and closed in certain timing events. They are driven by the camshaft through tappets, push rods and rocker arms. i 1.Camshaft timing gear 3 2.1dle gear \ B.Dnjection pump gear 4.0 pump gear Z \ 5.0il pump driving gear 6.Crankshaft timing gear fit 4 34 Crank-conneeting Rod Mechanism ‘The crank -connecting rod mechanism is composed of the piston ~connecting rod assembly and crankshaft—flywheel assembly. ‘The piston connecting rod assembly consists of the piston, compression rings, oil scraper ring, piston pin, connecting rod, connecting rod bearings and connecting rod bolts. ‘The crankshaft-flywheel assembly consists of the crankshaft, flywheel, crankshaft 45 ~Y24850 $e i OH HE ses timing gear and crankshaft pulley. ‘Two compression rings and one oil scraper ring are fitted into the piston. The first compression ring is a keystone ring, When the rings are fitted into their grooves, their gaps should be apart from each other around the circumference of the piston. Furthermore the oil scraper ring should be so placed that its gap is 90 degrees apart from the pinhole centre around the circumference. The second compression ring should have its top surface (marked with STD in the area near the gap) upward in assembly. When checking the ring gap, place the ring into a cylinder liner and measure it with a feeler gauge. If the gap is too small, correct it by fine filing; if too large, replace the ring with a new one. When assembling the piston and connecting rod, heat the piston in hot oil to the temperature of 100 to 120 degrees centigrade and then push the piston pin through them. ‘The connecting rod and cap are machined and marked in couples. They are not in- terchangeable. Two connecting rod bolts should be tightened step by step in turn to reach the specified torque, Before placing the piston and connecting rod assembly into the liner smear them with a little clean oil. Make sure the intake valve pocket (the larger one of the two pockets on the piston) is on the left side of the exhaust valve pocket viewed from the injection pump side of the engine after assembling. When moving the piston and connecting rod through the cylinder liner, be careful not to bruise the liner surface. ‘The difference in weight between the piston—connecting assemblies for the same en- gine should be less than 10 grammes. This requirement can be met through selection, ‘The crankshaft is made of ductile nodular cast iron. There are five main journals and four crankpins on the crankshaft. An oil hole in each journal leading to the neighboring crankpin is employed to supply lubricating oil to the crankpin bearing. The crankshaft is statically bal- anced to the allowance of an unbalanced moment of 30g.cm. On the front end of the crankshaft, there are the timing gear and oil pump driving gear, both driv- enwith a flat key. On the front and rear of the crankshaft, there are oil seals to prevent oil leakage When installing the flywheel, tighten the flywheel bolts evenly in the order shown in Fig.5 to reach the — 46 -| : BB so nen specified torque in 2~3 steps. The crankshaft and flywheel are dynamically balanced as an assembly. The unbalancedness should not exceed 30g.em. The same figure is marked side by side on the crankshaft flange end and the flywheel as an indication of the pairing rela- tion and mounting position. Be sure to assemble the flywheel with the crankshaft in the correct position as indicated with the figure mark. 3.5 Fuel Supply System The fuel supply system consists of the fuel tank, rough filter, feed pump, fine filter, injection pump, governor, injectors and fuel pipelines. Fuel from the fuel tank flows through the rough filter into the feed pump and then pass through the fine filter to the injection pump. The fuel at high pressure from the injec- tion pump is delivered to the fuel injector and sprayed into the combustion chamber. The superfluous fuel from the injection pump and injectors flows back to the fuel tank. ‘The fuel feed pump is of single~acting and plunger type. It is mounted on one side of the injection pump and driven by a cam on the camshaft of the pump. A primer pump is attached on the feed pump to bleed air from the fuel pipeline before starting the engine. When it is not in use, lock the primer pump handle by pressing and turning the nut on the top of it to prevent leakage of fuel. Fuel should be kept absolutely clean to ensure a long service life of the parts in the fuel supply system. Clean the filter cartridge at regular maintenance intervals and check to see if the paper element is broken or clogged. Replace the cartridge with new one if nee- essary. 1 2 1, Fuel-retur pipe 2. Fuel injection pipe 3. Fuel fine filter 4, Fuel tank 5. Fuel rough filter 6. Injection pump fit 6 -47-24950 $8 ARTO The fuel injection pump is of the type 4QF150G, an updated version of the series BQ injection pumps. The injection pump has been adjusted and sealed in the factory. It should not be readjusted by customers except when absolutely necessary. All the service opera- tions should be carried out by qualified servicemen on an injection pump tester according to the instructions in the service manual of the injection pump. The type TQA governor is a centrifugal and variable-speed governor. The maximum speed setting screw is used to set the maximum speed of the engine and the idle speed set- Ling screw is for setting the idle speed, The speed setting screws have been properly ad- justed in the factory and are not allowed to be readjusted by customers. is of the P type, with 5 holes of dia.0.22mm. It is mounted with one clamping plate and one tightening bolt. ‘The injector nozzle tip protrusion is 3.340.1mm. The fuel injector ‘The nozzle needle and valve seat are finely matched to each other and should not be inter- changed. Keep the injector parts absolutely clean during maintenance operation. 3.6 Lubricating System ‘The lubricating system consists of the oil pump, oil pump strainer, oil filter and oil pipeline. ‘The lubrication of the engine is of the splash-and-pressure combined type. Some bearings such as the main bearing, connecting rod bearing, camshaft bearing and rocker arm bearing are pressure—lubricated, while other friction surface such as the cylinder lin- ex, piston, piston pin, valves and gears are lubricated by splashed oil. ‘The lubricating oil drawn by the oil pump flows into the oil filter. Filtered oil ows through the main oil gallery in the eylinder block to lubricate the crankshaft main bear- ings, camshaft bushings and rocker arm bushings, and oil through the oil hole from the crankshaft journal to the crank pin to lubricate the connecting rod bearing. ‘The lubricating oil filter cartridge is a spin-on canister. In case the cartridge is seri- ously clogged, the bypass valve will open, allowing unfiltered oil to flow directly to the main oil gallery in the cylinder block. Be sure to follow the instructions described in Chapter V during maintenance operation of the oil filter. Replace the filter cartridge if necessary. The pressure adjusting valve serves to adjust the oil pressure in the main oil gallery and keep it within the range from 200kPa to 500kPa. 3.7 Cooling System The engine has a pressure type cooling system. It consists of the radiator, fan, water — 48 -Y2485D 5 3H OL AR Be HH NB pump and thermostat, When the engine is cold and the cooling water temperature is below 73°C, the thermo- stat is closed and the cooling water is stopped from going to the radiator. It goes from the thermostat housing back to the water pump. So the engine will be warmed up in a short while. As the water temperature gets higher above 80°C ,the thermostat opens gradually and lets the cooling water into the radiator. The cooling water from the radiator goes through the tube and back into the water pump. ‘The water pump is of the centrifugal type. In the water pump are mounted mainte- nance free hearings. The bearings need no greasing. When water continuously leaks out from the weep hole in the bottom of the pump housing due to excessive wear of the water seal, dismount the impeller from the shaft and replace the water seal. 1. Radiator 2. Thermostat 3. Fan 4, Water pump 3.8 Electrical System ‘The electric system is composed of the starting motor, battery and generator. Be sure to have the negative pole of the generator connected to the ground. -49-Y24850 5 OL AR BE IE LB ates Section I! Operation of the Engine 4.1 Adjustment of Valve Clearances It is essential to adjust the valve clearances in operating an engine. The valve clearances on cold engines are 0.20 ~0.25mm for inlet valves and 0.25 ~0.30mm for exhaust valves, Apart from the adjustment of valve clearances after the engine being reassembled, it is necessary to check and adjust the valve clearances periodically because of the possible loosening of adjusting screws and wear of parts in the valve system. The inspection interval is recommended to be 250 running hours. ‘The adjustment should be carried out on a cold engine. The procedure is as follows: Remove the cylinder head cover. Turn the crankshaft until the mark of the top dead center of the first cylinder on the crankshaft pulley aligns with the pointer of the timing indicator. When the piston of the first cylinder is at its top dead center on the compression stroke, both intake and exhaust valves of the first cylinder are closed. In this position, check the clearances of intake valve and exhaust valve of the first eylinder, the intake valve of the second cylinder and the exhaust valve of the third cylinder (i.e. the clearances of the first, second, third and sixth valves counted from the front) with a feeler gauge. To adjust the valve clearances, slacken the lock mut with a wrench and hold it, screw in or out the adjusting screw with a screwdriver until the feeler gauge inserted between the rocker head and the top surface of the valve stem feels neither too loose nor too tight. Then tighten ‘the lock nut and check the clearance again. Readjust if necessary till it is properly set. ‘After the adjustment of the clearances of the above-mentioned four valves, rotate the crankshaft a complete turn to place the piston of the forth cylinder at its top dead center on the compression stroke. In this position, check the clearances of intake valve and exhaust valve of the fourth cylinder, the intake valve of the third cylinder and the exhaust valve of the second eylinder (ie. the clearances of the fourth, fifth, seventh and eighth valves counted from the front). Adjust the clearances of these valves in the same way as described above. 4.2 Adjustment of Fuel Delivery Advance Angle In order to maintain fuel economy and power characteristics of the engine, it is necessary to check and adjust the fuel delivery advance angle after the engine being reassembled or running for 500 hours. ~ 50 -Y2495D 9 Wi HL Ok FA Be 3 ik BB ‘The procedure for checking and adjusting is as follo Remove the high-pressure fuel pipe of the first cylindér; connect a pipe joined to a thin glass tube with the first cylinder delivery valve holder of the injection pump. Set the speed control lever to the maximum delivery position and bleed off air in the fuel system. (Turn the crankshaft till there are no air bubbles in the fuel flowing out of the glass tube). Then turn the crankshaft slowly and watch attentively for the rise of the fuel level in the glass tube. Stop turning the crankshaft at the beginning of the rise of fuel level, which implies the beginning of the fuel delivery to the first cylinder. Check to see if the line for the correct fuel delivery advance angle on the rim of the flywheel aligns with the timing pointer inside the flywheel housing. If not, readjust in the following procedures. Slacken the bolts, which fasten the injection pump onto the connecting flange. Tuming the injection pump with its top towards the cylinder block results in the increase in the fuel delivery advance angle, and vice versa. 4.3 Adjustment of Fuel Injector Opening Pressure Dismount the fuel injector from the cylinder head and mount it on the injector tester for checking and adjusting. Actuate the pump handle and watch the indication of pressure. ‘At the time of injection starting, the pressure should be 23-24Mpa. The fuel spray should be uniform and the puffing sound of injection should be short and clear. If not qualified, adjust in the following processes. Dismount the nut from the injector holder; screw in or out the adjusting screw with a screwdriver. Serewing—in results in the increase in fuel injector opening pressure, and vice versa. After the adjustment, tighten the nut and check for the pressure again. 4.4 Adjustment of Lubricating Oil Pressure Pay frequent attention to the lubricating oil pressure. ‘The normal oil pressure ranges from 200 kPa to 500 kPa. The adjustment of lubricating oil pressure should be carried out after the engine gets warm (when the lubricating oil temperature is around 80%). Dismount the sealing nut from the adjusting screw on the oil filter. Turn the adjusting screw to adjust oil pressure. Serew in or out the adjusting serew to increase or decrease the oil pressure. After adjustment, put on the sealing washer and then tighten the sealing nut. 4.5 Adjustment of V-belt Tension ‘Though very easy to adjust, the tension of V-belt has great influence on the rotational speed of the generator and water pump and hence the operation of the engine. It is -51-24850 Je HF BB recommended to adjust it periodically. When engine is not running, press on the middle of a straight section of the belt with a force of 30~40 N. The sag of V-belt should be within the range of 10~15 mm. If not qualified, loosen the adjusting bolt on the adjusting bracket to move the generator to adjust the belt to a proper tension. Excessive tension will shorten the service life of the belt and cause the premature wear of bearings in the generator and water pump due to the heavy load resulted from excessive belt tension. Insufficient belt tension, however, will lead to the belt creep and fracture, resulting in the engine overheating. eaeY2485D $2 3H OL BRR 9 BB SectionV Technical Maintenance Regular maintenance of the engine is essential to efficient and trouble ~free ‘operation, good mileage between major repairs and long service life. General procedures of different assignments of technical maintenance stipulated below should be followed in principle. Customers can make some alterations according to particular service conditions. The maintenance work schedule is as follows: 1)Shift maintenance 2)Maintenance at the completion of 125 working hours. 3)Maintenance at the completion of 500 working hours. 4)Maintenance at the completion of 1000 working hours. 5.1 Shift Maintenance A)Check the oil level in oil sump. Refill to the specified level if necessary. B)Check the water level in the radiator. Refill if necessary. CCheck the fuel level in fuel tank. Refill if necessary. D)Check the tightness of mounting bolts of the engine and installing bolts of components. Tighten them if necessary. E)Check the leakagés of air, oil and water. Repair if necessary. F)Eliminate all faults and abnormal conditions found in operation. )Clear oil sludge and dust from the engine and accessories. H)Clean the air filter and air duct every day in dusty environment. 5.2 Maintenance at the Completion of Every 125 Working Hours A)Complete all the procedures mentioned above. B)Check the electrolyte level, which should be kept 10~15 mm high above the plates. ‘Add distilled water if necessary. The specific gravity of electrolyte should be 1.25~1.28. If it drops to 1.14, recharge the battery. C)Cheek the tension of the fan belt. Adjust it if necessary. D)Clean away dust from the paper cartridge and dust chamber of the air cleaner. E)Check the valve clearances and make adjustments if necessary F)At the completion of every 250 working hours, replace oil filter cartridge and replace the oil inthe oil sump at the same time if necessary. G)At the completion of every 250 working hours, replace fuel filter cartridge. 5.3 Maintenance at the Completion of Every 500 Working Hours =53-Ye4950 9 AE EE 8 EB] A)Complete all the procedures mentioned above. B)Check the seat lines of valves. Relap valves and readjust valve clearances if necessary. €)Check the fuel delivery advance angle. Readjust it if necessary. D)Check the nozzle opening pressure and spray pattern. Readjust the injection pressure, E)Check the leakage from the weep hole of the water pump. Replace the water seal if the leaking rate is too high. F)Clear carbon deposits from the silencer. G)Check all cable connections in the electric connections if dark bumed spots are found. 5.4 Maintenance at the completion of Every 1000 Working Hours A)Complete all the procedures mentioned above. B)Replace air filter cartridge. C)Clear scale from the cooling system. D)Clean the fuel tank and fuel pipeline. E)Check for technical conditions and performance of the engine to see if it needs stem. Clean and tighten the some repairing. Dismount and inspect relevant parts. Clear carbon deposits from eylinder head, piston, piston rings and cylinder liner. Check to see if the piston rings, cylinder liner, crank pin bearing or main journal bearing are subject to premature wearing. 5.5 Engine preservation If the engine is to be kept in store for e long period of time, it should be treated beforehand in the following procedures. A)Drain lubricating oil, cooling water and fuel oil from the engine when it is hot. B)Dismount intake and exhaust manifolds. Through the inlet and exhanst ports in the cylinder head, pour 200 grammes dehydrated lubricating oil into each eylinder. Rotate the crankshaft to apply the oil to the piston, piston rings, cylinder liner and valve seats. C)Cover the openings of intake and exhaust manifolds to prevent foreign objects and ‘moisture from entering them. D)Smear rust resisting oil on the unpainted surfaces of the engine. E)Store the engine in a clean, dry place with good ventilation. The engine should not, be stored near chemicals. F)Repeat the procedures from A to E for every six months during the engine storage. ~ 5424850 5 wh OOF FB Section VI. Trouble-shooting 6.1 Failure to Start Possible Causes ‘Suggested Remedies efile tank (1)Fuel tank empty or fuel tank cock not open. ‘Open cock. (Fuel pipeline or fuel filter clogged. [onpeiient einialaaal thin Bleed fuel system. (3)Air within fuel system, ‘Tighten all fuel pipe connections. @efective injection pump or incorrect injection timing (6)No injection or poor characteristics of spray. Check fuel feed pump and injection pamp. Adjust fuel delivery advance angle. Clean and lap nozzle needle and body in pair. Readjust injection pressure. (Ambient temperature too low and engine too cold. Heat cooling water. (insulficient compression pressure in cylinders. See item 6:3 hereafter. (Starting motor runs at low speed or will not run. See item 6.12 hereafter. 6.2 Lack of Power Possible Causes Suggested Remedies (Ulnsuficient compression pressure in cylinders. See item 6.3 below. eee Use proper ful. Clean fuel tank and refill. = Clean sir leaner cartridge. Replace carrie if (@)Clogged air cleaner. reer (@)Choked exhaust silencer. Clear carbon deposits or dit from silencer. (6)Aie within fuel system, Bleed fuel system. Tighten all fuel pipeline connections. (incorrect valve timing. Inspect camshaft and marks on gears. Check valve clearances. (Mlncorret fuel delivery advance angle ‘Check marks on gears. Readjust fuel delivery advance angle. (8)Low injection pressure or poor spray ers Readjustinjction pressure. ; ‘Readjust uniformity of fuel delivery from fuel (©)Uneven distibution of fuel among cylinders, ee linden (10Engine unable to reach the rated speed. Reset speed control lever. = 55 -Y2485D % HH HL GH 37 HEB 6.3 Insufficient Compression Pressure in Cylinder Possible Causes Suggested Remedies (Valve clearance too small or no clearance. Readjust valve clearance. {@)Catbon deposits on valve and seat. Clear away carbon deposits and relap valve and ‘Wom valve and seat, valve seat, Ream valve seat ifnecessary. @Piston ring worn or lack of tension. Replace piston ring. (Piston ring stuck due to earbon deposits. Clean piston and rings in kerosene. (Cylinder liner and piston wor. Clearance between eylinder and piston too big. _| Replace liner and piston. (Oeakayeinelinder head Retighten cylinder heed bolis or replace the gasket, (7)Gas leakage in injector mounting bore. Check copper washer. Reset injector. (Broken valve spring. Replace valve spring. (OWWalve stuck in valve guide Clean valve in kerosene. Replace if itis worn out ordeformed. 6.4 Engine Stops Suddenly Possible Causes ‘Suggested Remedies (I)No fuel in tank. Refill fuel tank. (Q)Air and water in fuel system. aioe SE ee (3)Clogged fuel filter. Clean or replace eartridge. (4)Choked air cleaner. Replace air cleaner cartridge. (S)Piston stuck in cylinder. Repair or replace piston and cylinder liner. 6.5 Engine Racing Possible Causes ‘Suggested Remedies (0) Faulty governor Stop the engine, Dismount injection pump and governor. Repair or replace governor. (2) Restricted injection pump control rod. Stop the engine. Repair injection pump. {@) Clip ring disconnected from contol rod. Stop the engine and check. Reinstall clip ring. ~ 56 —YZ485D 5 Hh BAR HH A FB 6.46 Abnormal Noise Possible Causes ‘Suggested Remedies (Possible Causes Suggested Remedies Engine detonating with clear Readjust fuel delivery advance angle, ()Delayed combustion. Backfire in exhaust pipe. | Readjust fuel delivery advance angle. (@)Clearance between piston and cylinder liner too Dig, causing thudding noise (The noise diseppears act fuel delivery being cut of for 3 t 5 seconds) ‘Check and repair. Replace piston and liner if necessary, ()Clearance between crankshaft and main bearing too big, causing low heavy pounding noise periodically. ‘Check and repair. Replace main bearing or thrust plate. (61)Clearance between erankpin and bearing too big, causing dull pounding noise Check and repair. Replace connecting rod bearing. {Clearance between piston pin and connecting +e bushing too big, eausing sharp knocking noise. Check and repair. Replace bushing. (@Valvo clearance too big, causing chattering \ Readjust valve clearance. noise. 6:7 Black Exhaust Possible Causes Suggested Remedios (DEngine overloaded. Reduce load. Q)Fuel delivery not even or too much. Adjust injection pump and governar. @linjection pressure too low, causing poor spray characteristics. Readjust injection pressure. (@)Fuel injection timing too late. Readjust fuel delivery advance angle. : (Clear away dust from cartridge or replace ()Air cleaner choked. aes (6)Wrong grade of fuel or bad fuel. Drain tank and refill with proper fuel. 6.8 Coolant Temperature Too High Possible Causes, Suggested Remedies (Cooling water low reduction due to Toose V-belt. Adjust belt tension or replace V-belt. {@)Engine overloaded for along period. Reduce oad. (@:)Cooling water insufficient, Refill radiator. eeeYZ485D 5 3 BL BEF ORF BE Pos le Causes Sugaésted Remedies (4) Cooling water flow reduction due to low water pump effcienoy. Check clearance between water pump impeller and housing, Replace impeller if necessary. (©) Cooling wate cireulation obstructed. (Clean cooling yatem. (6 Defective thermostat. Replace thenmostat (0) Defective water themmometr. Replace thermometer. 6.9 Low Lubricating Oil Pressure Possible Canses Suggested Remedies ; ; Check oll level (2) Insuficient ol nol sump. a (2) Defective low oil pressure alam. Replce slar : ‘Clean ail gallery and blow away dirt with G) Clogged oil gallery. compeaseed sit, (@) Clogged oil strainer. Dismount oil strainer. Clean it in kerosene. (6) Clogged oil filter and defective by-pass valve. Clean ol filter or replace filter eatridge. Readjust by-pass valve if necessary. (6) Excessive bearing clearances due to wear of ‘main bearing and erankpin bearing. Repair or replace bearings. (1 Engine overheated, causing high temperature and low viscosity of lubricating oi. Reduce load to lower oil temperature or refill with suitable oil. {8) Too big clearance between oil pump rotor and housing. Replace rotor or housing of oil pump. 6.10 Excessive Oil Consumption Possible Causes Suggested Remedies (1) Wom piston ring or oil scraper ring stuck in ring groove due to carbon deposits. ‘Wash oil scraper ring in kerosene or replace defective ring. @ Oil return holes plugged due to earbon deposits. lean oil return holes in piston. {G) Oil level too high. Oil into the combustion chamber. Check with dipstick and drain oil to correct level. (4) Leakage in lubricating system. ‘Tighten connectors and replace sealing washers and gaskets, aeY2485D 9 WB BBE HH 6.11 Deterioration of Lubricating Oil Possible Causes ‘Suggested Remedies (Piston ring worn or stuck in groove, eausing combustion gas or fel to leak into the oil sump, | “He” oF replace piston ring. (2)Water leaking into oil due to faulty cylinder ae Replace gasket. {@)Water leaking into oil due to crack in cylinder rea Replace cylinder head. 6.12 Trouble-shooting in Electrical System ‘Symptoms and Causes Suggested Remedies A) No recharging of battery or current too weak. (1)Loose connections on generator and battery or | Check and tighten all connections. Clean corroded contacts. contacting surfaces and improve insulation, QLoose V-belt : Reaaijust belt tension, Generator out of order. Check and repair or replace. B) Current too strong and generator overheated. (DShort-cireuit between armature and field coil. | Repair o replace C) Starting motor will not run, (1) Loose connection of cables. Clear away dirt. Tighten connections, (@)Battery not flly charged. Check and recharge. (@)Bad contact af brushes. Clean and polish with fine sandpaper. (@)Short-cireuit within starting motor. Chock and repair. ) Starting motor running idle, unable to erank the engine. | up the engin Es (1) Bad contact of brushes. ‘Clean and polish with fine sandpaper. (@) Bad contact of cable connection and switch. | Clear away dirt. Tighten all connections. (3) Weak battery. Check and recharge. = 59)a es eel ea ae) WEICHAI POWER YANGZHOU DIESEL ENGINE CO.LTD. pes Une et ee co ees a cee ou ‘Airess: 438 iangyang Dongl, Yangzhou Jiangsu P.R.China Te:0086-614-87982288 Fax:0086-514-87962266 eer eee rene