3T30 系列柴油机说明书

DIESEL ENGINE MODEL 3T30 SERIES

OPERATION MANUAL

山东华源莱动内燃机有限公司
SHAN DONG HUA YUAN LAI DONG ENGNE CO..LTD
 PREFACE

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

PRECAUTIONS

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

CHAPTER Ⅱ engine operation and precautions…………………………….5

1. Engine operation
2. Precautions when operating
3. Assembling air filter

CHAPTER Ⅲ engine maintenance……………………………………...7

1. Daily maintenance
2. Maintenance after 100 hours
3. Maintenance after 500 hours
4. Engine preservation storage
CHAPTER IV the structure of engine…………………………………10
1. Cylinder block assembl y
2. Cylinder head assembl y
3. Crankshaft and fl ywheel assembl y
4. Piston-connecting rod assembl y
5. Driving mechanism
6. valae s ystem
7. Fuel suppl y s ystem
8. Lubrication system
9. Cooling system
10. Electric systsem

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

A. Engine can not be started
B. Engine power declines
C. Engine stops suddenly
D. Enigine running with knocking sound
E. Oil pressure too low
F. Engine over heat
G. Encine exhausts abnormal smoke
H. Troubles and remedies of the fuel injection pump
I. Starter is out of order
J. Alternator is out of order
 CHAPTER I ENGINE INTRODUCTION
1. MAIN SPECIFICATIONS
Dynamic Norm of the Engine(the power of each type is show on the nameplate)
3T30 Diesel Engine
order Rated Power/Speed(KW/rpm) Max Torque/Speed(N·m/rpm)
1 23.5/2350 110/1650
2 22.1/2350 103/1650
3 20.6/2350 96/1650
4
5

Main Paraments of the Diesel Engine

MODEL 3T30
SPECIFICATION
Type In---Line,water—cooling,direct injector
No.of Cylinder 3
Cylinder bore(mm) 85
Piston stroke(mm) 95
Compression ratio 18
Displacement(L) 1.617
Cylinder working sequence 1—3—2
Lowest steady speed without load(rpm) ≤850
Lowest fuel consumption at full load(g/KW.h) ≤238
Oil consumption at full load(g/kw.h) ≤0.5%
Oil pressure At idle speed(kpa) ≥50
At rated speed(kpa) 300~450
Crankshaft rotating direction counterclockwise
Injection advance angle(T.D.C) 14±1
Fuel injection pressure(kpa) 19000~20000
Valve timing Intake valve open 14.5°before T.D.C
phase Intake valve close 37.5°after B.D.C
Exhaust valve open 56°before B.D.C
Exhaust valve close 12°after T.D.C
Valve Intake valve(mm) 0.20~0.30
clearance Exhaust valve(mm) 0.25~0.35
Valve sinkage Intake valve(mm) 0.7~0.9
Exhaust valve(mm) 0.7~0.9
Steady speed adjusting ratio at rated conditon ≤10%
Oil sump capacity(L) 6
Temperature(℃) Water outlet 75~85
Oil 85~95
Exhaust pipe ≤650
Starting method Electric starting
Lubricating method Pressure & splash
Cooling method Water cooling
Overall dimension (L×W×H) (mm) 567×584×625
Net weight (kg) 200
Tractor, engineering
Applications
machine
Assembling two
hydraulic pumps
Characteristics
and one air pump
at one time

2. MAIN ACCESSORIES SPECIFICATIONS

Model 3T30

Model IW or BQ
Injection
Type Plunger
pump
Plunger diameter (mm) Ф9
Nozzle tip model LT-Z2066
Starter QD1315A (12V, 2.5Kw)
JF11 (14V, 350W) or JFWB13A1
Alternator
(14V, 350W)
Water pump Centrifugal, ≥112L/min
Oil pump Rotary, ≥38L/min
Model CX0706
Fuel filter
Type ——
Model WB447
Oil filter
Type Rotary
 3. FITTING CLEARANCES AND WEAR LIMITS OF THE MAIN MOVING PARTS
单位：
单位：mm
STANDARD NEW ENGINE L1MIT
No. NAME FITTING
SIZE FITTING CLEARANCE ALLOWANCE
0
Main journal and Shaftφ65(–0.019 ) Clearance
1 0.064~0. 128 0.25
main bearing hole +0.109 fit
Holeφ65+0.064
-0.075
Axial clearance of 28-0.165 Clearance
2 0.075~0. 215 0.50
crankshaft +0.05 fit
280

Crankshaft journal 0
shaft φ53(–0.019 ) Clearance
3 and connecting rod 0.04~0.094 0. 20
+0.075 fit
bearing hole holeφ53+0.04

Connecting rod big -0.14

30-0.22 Clearance
4 end facing 0.14~0.32
+0.10 fit
clearance 300

Piston pin & 0

Shaftφ29(–0.006)
connecting rod Clearance
5 0.025~0.044 0.10
small end bushing +0.038 fit
Holeφ29+0.025
hole
0
Piston pin & piston Shaftφ29(–0.004)
6 Interim fit -0 0045~+0. 0105
pin seat hole Holeφ29±0.0045

-0.105
Piston skirt & Skirt 85-0.12 Clearance
7 0.105~0. 135
cylinder liner +0.015 fit
φ85( 0 )

Piston ring opening First ring 0.30-0.50

8 2.2
clearance Third ring & oil ring 0.25-0.45

First ring and its Clearance

9 0.095~0.145 0.20
slot fit

Second & third ring Clearance

10 0.04-0. 072 0.18
and its slot fit

Oil scraper ring and Clearance

11 0.03~0.062 0.18
its slot fits

No NAME STANDARD FITTING NEW ENGINE LIMIT

SIZE FITTING CLEARANCE ALLOWANCE
12 Camshaft journal -0.050 Clearance 0.05~0.1 0.20
Shaftφ44c7(–0.075 )
and its bushing fit
+0.025
Holeφ440
13 Camshaft axial -0.09 Clearance 0.09~0.245 0.60
5-0.145
clearance fit
+0.10
50

14 Valve tappet -0.016 Clearance 0.016~0.045 0.25

Shaftφ13f6(–0.027 )
and its hole [it
+0.018
Holeφ13H70

15 Rocker arm shaft -0.016 Clearance 0.016~0.045 0.20

Shaftφ16f6(–0.027 )
and shaft hole fit
+0.018
Holeφ16H70

16 Intake valve and -0.025 Clearance 0.025~0.069 0.15

Shaftφ8e8(–0.047 )
valve guide hole fit
+0.022
Holeφ8H80

17 Exhaust valve and -0.040 Clearance 0.040~0.077 0.15

Shaftφ8d7(–0.055 )
valve guide hole fit
+0.022
Holeφ8H80

18 Idle gear shaft -0.025 Clearance 0.025~0.089 0.20

Shaftφ44f7(–0.050 )
journal and fit
+0.039
bushing hole Holeφ44H70

19 Idle gear end facing Clearance 0.15~0.32

clearance fit

20 Gears engaging Clearance 0.11~0.18 0.30

side clearance fit

4. MAIN BOLT TIGHTENING TORQUE

Cylinder head bolt 135~150 N.m
Main bearing cover bolt 115-130 N.m
Connecting rod bolt 80~90 N.m
Fly wheel bolt 50~60 N.m
Idle gear shaft bolt (for 4L22T. 4L22BT) 50~60 N.m
 CHAPTER Ⅱ
ENGINE OPERATION AND PRECAUTIONS
1. ENGINE OPERATION

Fuel, oil and cooling water

1) Fuel and oil:

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

Inspection and preparation before starting:

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

Engine starting

1) Set speed adjusting level at middle position.

2) Loosen the air exhaust screw on fuel filter, continuously press the hand – operated fuel delivery
pump to discharge the air inside fuel system, especially for new engine or engines stocked for long
time.
3) To start the engine first turn the switch to “pre-heat” position to heat the engine for 25-30
seconds.. Then turn to “pre-heat” p osition to start th e en gin e. Rep eat as abo ve p rocedu res in 2
min utes, if you failed to start th e en gin e.
4 ) After startin g， immed iately adju st fu el supply to make th e en gin e runn in g at idle sp eed．
Care shou ld b e taken to ensu re th at th e oil p ressure is up to50 kP a， th en gradu ally in crease
sp eed to warm up th e en gine with out 1o ad．
Engine running

1 ) En gin e is on ly a1 1o wed wo rkin g with 1o ad wh en the coo1in g water temp eratu re is up to

50 ºC. Runn in g at rated po wer wh en th e coo1 in g water temp eratu re is abo ut 80 ºC.
2 ) In creasin g or d ecreasing th e 1o ad and sp eed should b e smo oth ly and gradu ally carried
ou t． No rmally is n ot a11owed to in crease o r d ecrease th e 1o ad su dd enly.
3 )Durin g en gin e op eration， care mu st b e taken to see wh eth er th e meter is normal， the
co1o ur o f exh aust air and the sound o f runn in g. Sh ould an y abno rmal app ears， stop th e en gine
and ch eck.

Eng ine stopping

1 )Befo re stopp in g th e en gine， 1 o wer th e sp eed to th e id le con dition and grad u ally disch arge
th e 1o ad un til th e water temp eratu re co mes do wn b elow 70 ℃， th en th e en gin e can b e stopped
b y stop — 1 ever．
2 )After the en gin e stopp ed， tu rn th e switch to mid dle po sition．
3 )After the en gin e stopp ed， drainin g th e coo lin g water b y op en in g th e water co ck on b oth
cylind er b lo ck an d water tan k wh ile th e co olin g water temp erature co mes do wn b elo w 60 ℃.
Wh en amb ient temp erature b elo w 5 ℃． Drain in g is n ot n ecessary wh en an ti-fro zen 1iqu id is
fi11 ed．

2 . PRECAUTIONS WHEN OPERATION

En gine shou ld be maintain ed and adju sted acco rdin g to th e stipulatio n in th e op eration
man u al．
Fu ll sp eed and full 1 oad op eration is not a11o wed for th e n ew or repaired en gine. First
wearin g-in shou ld b e carried o ut fo r 45 ho urs in 1ow speed and 1o ad． Th en th e en gin e cou ld b e
pu t in normal 1 o ad op eration．
En gin e fuel sh ould b e precipitated and filtered clean．
Keep n ormal water temp erature at 75℃ -85 ℃ ， no rmal o il Pressu re at 3 00-450 kPa．

3 . ASSEMBLING AIR FILTER ．

Air filter sh ould b e correctly， reason ab ly and tightly assemb led at a suitab le place on b ack
o r fron t o f th e ch assis o f cab in， and conn ected to intake p ip e b y rubb er wave pipe which both
end s should b e tighten ed with clips． Th e dirt d isch arge p ort shou ld b e do wn ward s．
 CHAPTER Ⅲ ENGINE MAINTENANCE

To en su re a lon ger service life, th e en gin e shou ld b e main tain ed acco rd in g to th e

fo llo win g p ro cedu re.

1. DAILY MAINTENANCE

Ch eck th e oil level in oil su mp, to en su re th e oil level b e b etween th e two marks o n th e
o il dip stick.
Ch eck water qu antity in water tan k.
Ch eck th e oil level in injection pu mp and sp eed adju sto r, refill to sp ecified po sition wh en
in su fficien t.
Ch eck and remo ve any o il, fu el, water and gas leakage.
Ch eck for th e tigh tn ess o f each attach ed p arts.
Ch eck for th e tigh tn ess o f en gin e b racket.
Keep th e en gin e clean,and remo ve dirt and mud . Sp ecial care mu st b e taken to en su re th e
electrical eq uip men ts dry and clean. After 45 hou rs wearin g - in o f n ew en gin e with ligh t lo ad,
o il should b e rep laced an d th e oil filter cartrid ge sho uld b e clean ed in time.
Remo ve oth er troubles and abno rmals.

2. MAINTENANCE AFTER 100 HOURS

Rep lace o il in o il su mp
Clean o r rep lace o il filter cartrid ge.
Clean o r rep lace fu el filter cartrid ge (or after 20 0 ho urs)
Ch eck for tigh tn ess o f cylind er h ead b olts.
Ch eck valve clearan ce and adjust wh en n ecessary.
Ch eck fan b elt tigh tn ess an d adju st wh en n ecessary.
Remo ve d irt in intake pip e and air filter.
Ch eck injection and injection p ressu re after 200 hou rs. Clean an d adju st when n ecessary.
Ch eck tile accu mu lato r vo ltage. Th e sp ecific gravity o f electrolyte shou ld b e 1.28 - l.
29 , wh en air temp eratu re at 15 °C. It is n ormally not lower than 1 .27.
Ch eck wh eth er th e electro lyte level is 10 to l5 mm h igh er th an polar p lates. Oth erwise fill
in vap orized water.
Rep lace coo lin g water wh en not clean .
Take ou t th ermo stat, assemb le water ou tlet pip e, start th e en gin e and ch an ge th e en gin e
sp eed altern atively so as to ch an ge th e coo lin g water flo w sp eed to wash o ut sed imen t. Th en
stop th e en gin e and op en the water co ck both on cylinder b lo ck and water tan k to d rain water.
Wh ile fill clean water into the water tank, restart the engine and run in idle to make water flow.
Close the water cocks as soon as the drained water is clean. Stop the engine and reassemble the
thermostat.
To ensure the parts disassembled for maintenance are reassembled correctly.

3. MAINTENANCE AFTER 500 HOURS

Carry out the follow procedure besides item 2.

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

Fig.1 cylinder head bolts tighten sequence

Besides the above mentioned procedures, you may carry out more detail maintenance
according to your, own condition.

4. ENGINE PRESERVATION AND STORAGE.

To store the engine for long time, immediately drain out oil, cooling water and fuel
after engine stops. Clean oil sump and oil filter cartridge.
Carry out maintenance procedure accordingly.
Disassemb le intake and exh au st p ip es. Fill 50 g dewatered clean o il in to air po rt and turn
cran ksh aft to make th e o il smo o th ly co ver th e valves, cylin der h ead, cylind er lin er, piston and
piston rings etc.
Remove all dirt from engine surface; brush the unpainted parts with butter except
rubber and plastic parts.
Cover the mouths of air filter and silencer, wrapped in plastic paper.
 Engine should be stored in place of dry, clean and good ventilation.
Chemical medicine is strictly prohibited nearby.
The above preservation method could store the engine for 3 months, if the preservation is
overdue, the engine should be preserved as above again.
 CHAPTER IV THE STRUCTURE OF ENGINE
1. CYLINDER BLOCK ASSEMBLY.

Th e cylin d er b lo ck is plan er-typ e with th e fu ll suppo rtin g b earin g and d ry cylind er lin er,
wh ich th e shou ld er is 0.0 2 - 0 .10 mm h igh er th an th e cylin der blo ck upp er su rface. Th e h eight
d ifferen ce o f adjacent lin er is no t mo re th an 0.03 mm.
D i s mo u n t i n g c y l i n d e r l i n e r s m u s t u s e t h e s p e c i a l t o o l s a n d s h o u l d k e e p t h e c y l i n d e r
bore inner surface and the cylinder liner outer surface dry and clean, coating grease is
prohibited.
Th e water cavity o f cylind er b lo ck is tested b y 400 kpa water p ressu re for 2 min utes. The
o il ch ann el shou ld b e tested b y 6 00 kp a oil p ressure for 1 minu te, and leakage is not allo wed.
Cylinder block have valve tappet cavity opener, a connecting pipe on the cover plate
c o n n e c t s wi t h b r e a t h e r . T h e o i l fi l t e r a n d w a t e r d r a i n c o c k i s a s s e m b l e d o n t h e c y l i n d e r
b l o c k b y t h e s i d e o f i n j e c t i o n p u mp .

2. CYLINDER HEAD ASSEMBLY

C y l i n d e r h e a d i s a u n i t a r y o n e , a n d i s m a d e o f H T2 0 0 c a s t i r o n p l u s t o c u p r u m
c h r o mi u m o r H T2 5 0 c a s t i r o n .
C y l i n d e r h e a d w a t e r c a v i t y i s t e s t e d b y 4 0 0 k p a w a t e r p r e s s u r e fo r 3 m i n u t e s . N o
leakage is allowed. Valve guide is pressed into cylinder head leaving a protruding of
1 0 m m , s h o wn a s F i g . 2 . T h e c o n e a n g l e s o f i n t a k e a n d e x h a u s t v a l v e a r e r e s p e c t i v e l y
9 0 ° a n d 1 2 0 ℃ . Th e w i d t h o f c o n t a c t i n g s u r f a c e i s 1 . 2 - - 1 . 7 m m . Th e s i n k a g e o f i n t a k e a n d
e x h a u s t v a l v e i s 0 . 7 - 0 . 9 m m s h o wn a s F i g . 2 . 3 .

Fig.2 V a l v e g u i d e mo u n t i n g d i m e n s i o n Fig.3 Valve sinkage diagram

Th ere is an oil hole on th e cylind er h ead co ver, which is d esign ed fo r fillin g in o il. While
mo u ntin g cylind er h ead gasket, p ay atten tio n to th e position o f o il hole, water h ole and screw
ho le. In co rrectly mo untin g is no t allo wed. Before mou ntin g cylind er h ead, pou r 20 g lubrication
into each cylind er lin er su rface.
Cylind er h ead is po sition ed on blo ck b y po sitionin g b ushin g and tigh ten ed b y cylind er
h ead bo lts. Tigh tenin g torqu e is 135~15 0N.m wh ich shou ld b e effected twice.

CRANKSHAFT AND FLYWHEEL ASSEMBLY

C r a n k s h a f t i s m a d e o f Q T9 0 0 - 3 n o d u l a r c a s t i r o n . M a i n b e a r i n g i s m a d e o f s t e e l b a c k
2 0 % a l l o y w i t h h i g h t i n a n d a l u m i n u m w h i c h c a n ' t a d h e r e o i l w h i l e mo u n t i n g t o a v o i d
a f f e c t i n g i t s r a d i a t i n g e f f i c i e n c y a n d d a m a g i n g b e ar i n g s . Th e t h r u s t p l a t e i s o f t h e s a m e
m a t e r i a l a s m a i n b e a r i n g . Th e y a r e mo u n t i n g o n t wo s i d e s o f t h e l a s t m a i n b e a r i n g a n d
p o s i t i o n e d b y t h e c o n v e x t a i l o f t h e l o w e r t h r u s t p l a t e . Wh e n mo u n t i n g , t h e o i l c h a n n e l o f
t h r u s t p l a t e s h o u l d f a c e t o c r a n k s h a f t t h r u s t s u r f a c e . R e v e r s e m o u n t i n g i s n o t a l l o we d .
Main bearing cover is machined in couple with cylinder block. Cylinder block No. and
s e q u e n c e N o . a r e e n g r a v e d o n m a i n b e a r i n g c o v e r . Th e f o r t h - m a i n b e a r i n g c o v e r i s
p o s i t i o n e d b y p o s i t i o n i n g b u s h i n g . Wh e n m o u n t i n g , t h e t o p a r r o w o n m a i n b e a r i n g s h o u l d
b a c k - f a c e t o t h e s i d e o f c a m s h a f t a n d c o mp i l e t h e n u mb e r f r o m fr o n t e n d .
R e v e r s e mo u n t i n g i s n o t a l l o we d . Ti g h t e n i n g t o r q u e o f m a i n b e a r i n g b o l t s i s 1 1 5 ~ 1 3 0 N . m.
wh e n t i g h t e n i n g , fi r s t l y t i g h t e n t h e c e n t r a l o n e , t h e n t h e t wo s i d e s a l t e r n a t i v e l y . A ft e r
t i g h t e n e d , t h e c r a n k s h a f t s h o u l d r u n fr e e l y .
Flywheel is positioned by pin and tightened by bolts on the crankshaft rear end. Bolts
a r e t i g h t e n e d a t a t o r q u e o f 5 0 - 6 0 N . m a l t e r n a t i v e l y o n d i a g o n a l l i n e . Th e b e l t p u l l e y i s
p o s i t i o n e d b y s t a r t i n g p a w , t i g h t e n e d a t a t o r q u e o f 1 6 0 - 1 7 0 N . m o n t h e c r a n k s h a ft f r o n t
end. Pounding or beating is strictly prohibited when mounting or dismounting.
Cran ksh aft, flywh eel and b elt pu lley, h ave b een balan ced. Care mu st b e taken o f en surin g
its b alan ce wh en replacin g p arts. Both flywh eel housing and gear case co ver are mou nted with
o il seal. Do no t d amage th em wh en mou ntin g o r dismoun tin g.

4. PISTON AND CONNECTING ROD ASSEMBLY

Th e p i s t o n i s m a d e o f a l u m i n u m a l l o y Z L1 0 9 , wh i c h h a s t o w a i r - - c o m p r e s s i o n r i n g s
and one oil scraper ring.
Th e fi r s t c o mp r e s s i o n r i n g i s o f c h r o m e - p l a t e d b a r r e l s h a p e ; t h e s e c o n d o n e i s o f t a p e r
s h a p e s . Th e o i l s c r a p e r r i n g i s s p i r a l s p r i n g e xp a n d i n g r i n g w i t h t h e i n n e r c y l i n d e r fa c e ,
i n n e r r o u n d f a c e a n d o u t e r c y l i n d e r e d g e fa c e p l a t ed b y c h r o m e , p a y a t t e n t i o n t h a t t h e
spring connecting point should space out 180° apart from the oil scraper ring gap.
I t i s a d v i s e d t o i n s t a l l t h e p i s t o n r i n g w i t h s p e c i a l e xp a n d e r ; e x c e s s i v e e xp a n d i n g i s
n o t a l l o w e d t o a v o i d b r e a k i n g . Th e r i n g s h o u l d t u r n e a s i l y i n t h e s l o t a n d c a n f a l l i n t o t h e
s l o t s u p p o r t i n g f a c e b y i t s e l f. Th e p i s t o n c o n c a v e s h o u l d b e p o u r e d l u b . o i l .
Th e p i s t o n r i n g s h a p e a n d i t s o p e n i n g d i r e c t i o n , p l e a s e r e f e r t o F i g . 4 a n d F i g . 5
Fig.4 Piston ring shape Fig.5 Piston ring opening direction
Th e c o n n e c t i n g r o d i s m a d e o f 3 5 C r M o A. Th e r e i s c o u p l i n g m a r k o n t h e b o d y a n d c a p .
Y o u mu s t i n s t a l l a c c o r d i n g t o t h e m a r k ; w r o n g i n s t a l l i n g s h o u l d b e a v o i d e d . Th e
t i g h t e n i n g t o r q u e o f t h e c o n n e c t i n g r o d b o l t s i s 8 0 – 9 0 N . m.
Th e c o n n e c t i n g r o d b e a r i n g i s m a d e o f s t e e l b a c k a l l o y w i t h a l u mi n u m , t i n , s i l i c o n a n d
c u p r u m.
Wh i l e m o u n t i n g t h e p i s t o n p i n , t h e p i s t o n s h o u l d b e h e a t e d t o 1 0 0 °C , wh i l e mo u n t i n g
t h e c o n n e c t i n g r o d , t h e p i s t o n t o p fa c e t o t h e i n s t a l l e r , t h e t u b c o n c a v e i s o n t h e u p p e r s i d e ,
and the bearing positioning slot in the connecting rod big end hole should also be on the
l o we r s i d e .
Th e w e i g h t o f c o n n e c t i n g r o d b i g e n d & s m a l l e n d h a s a s t r i c t d i s t r i b u t i o n p o r t i o n ; t h e
weight difference of piston and connecting rod assembly of each engine should be limited
to below 20g.

5. DRIVING MECHANISM

Th e g e a r d r i v i n g s y s t e m o f t h e e n g i n e , p l e a s e r e f e r t o F i g . 6 .

Wh e n i n s t a l l i n g t h e g e a r s , p a y a t t e n t i o n t o t h e t i m i n g m a r k o n t h e g e a r f a c e s t o e n s u r e
g o o d p h a s i n g a n d fu e l d e l i v e r y .
A ft e r i n s t a l l i n g t h e i d l e g e a r , c h e c k a x i a l c l e ar a n c e . E a c h g e a r s h o u l d t u r n e a s i l y
without clicking.

6 . VA L V E S Y S T E M

V a l v e me c h a n i s m:
Th e m e c h a n i s m i s t o p - m o u n t e d v a l v e t yp e . Th e c a m s h a ft i s m a d e o f N o . 4 5 s t e e l
c h o i c e l y . Th e s u r f a c e s o f c a m s h a ft a n d g e a r a r e h i gh fr e q u e n c y q u e n c h e d . Th e r e i s a t h r u s t
p l a t e i n fr o n t o f f i r s t s h a ft j o u r n a l . A x i a l c l e a r a n c e o f c a m s h a f t i s 0 . 0 9 - 0 . 2 4 5 m m .
V alve tapp et is mad e o f chilled castin g iro n. There is a po sition d eviation b etween tap p ets
cen ter and cam center, so th at th e tapp et cou ld continuo usly tu rn fo r smo oth wearin g du ring
op eration to p reven t seizin g. Pu sh rod is mad e o f steel; on e end is b ail stru ctu re, th e oth er end
is o f bo wl stru cture. Ro cker arm sh aft is fully suppo rted fo r h igh rigidity. Ro cker arm an d sh aft
are lubricated b y p ressed oil fro m cylind er h ead.
V a l v e a n d v a l v e s e a t a r e m a d e o f a l l o y s t e e l a n d a l l o y c a s t i r o n a n d l a p p e d t o fi t . To
c h e c k i t s f i t t i n g , p o u r k e r o s e n e i n t o a i r p o r t a n d w a i t fo r 2 mi n u t e s , n o l e a k a g e i s a l l o w e d .
A i r l e a k a g e o f t h e v a l v e m a y a f f e c t e n g i n e t e c h n i c al p e r fo r m a n c e o r e v e n b u r n t o d a m a g e
valve and seat. So leakage check should be carried out according to technical requirement
wh e n i n o p e r a t i o n . La p i t wh e n n e c e s s a r y .
A c h a m f e r i s d e s i g n e d o n v a l v e g u i d e t o p r e v e n t o i l fl o w i n g b a c k i n t o c y l i n d e r l i n e r
and burning.
V a l v e c l e a r a n c e a dj u s t me n t :
V a l v e c l e a r a n c e s h a l l a f f e c t e n g i n e p e r fo r m a n c e . I t s h o u l d b e c h e c k e d a n d a d j u s t e d
a c c o r d i n g t o t e c h n i c a l m a i n t a i n i n g s t i p u l a t i o n . Th e i n t a k e v a l v e c o o l i n g c l e a r a n c e i s o f
0 . 2 0 - 0 . 3 0 m m , t h e e x h a u s t v a l v e c o o l i n g c l e a r a n c e i s o f 0 . 2 5 - 0 . 3 5 m m . Th e a d j u s t i n g
p r o c e d u r e a s fo l l o wi n g :
Make th e first cylind er piston stop at T.D.C. position wh en th e "0 " mark o n cran ksh aft
pu lley is align ed with th e arro w mark o n gear case co ver, th en ch eck and adju st valve clearan ce
o f th e first valve (co unt from th e en gin e fro nt end) b y in sertin g a valve clearan ce gau ge. Turn
th e cran ksh aft 1 80 ° sub ject to th e cylind er wo rkin g o rd er 1 – 3 - 2 to adju st every valve
clearan ce.

7. FUEL SUPPLY SYSTEM

Th e fu e l s u p p l y s y s t e m c o n s i s t s o f d e l i v e r y p u m p , i n j e c t i o n p u mp , s p e e d a d j u s t o r , fu e l
fi l t e r , i n j e c t o r , d e l i v e r y p i p e a n d i n j e c t i o n p i p e e t c . F u e l i s d e l i v e r e d t o fu e l fi l t e r f r o m
fu e l t a n k b y d e l i v e r y p u m p wh e r e t h e f u e l i s fi l t e r e d a n d t r a n s f e r r e d t o i n j e c t i o n p u mp b y a
h i g h p r e s s u r e a n d a t o mi z e d , t h e n i n j e c t e d i n t o c h a m b e r t h r o u g h i n j e c t i o n p i p e .
1 ) Th e fu e l d e l i v e r y p u mp i s o f p i s t o n t yp e a n d a s s e m b l e d o n t h e s i d e o f i n j e c t i o n
p u mp . Wh e n i n n o r m a l o p e r a t i o n i t i s d r i v e n b y t h e e c c e n t r i c c a m s h a ft g e a r o f ' i n j e c t i o n
p u mp . Ai r i n s i d e t h e s y s t e m c a n b e d i s c h a r g e d b y m a n u a l p u m p wh e n n e c e s s a r y a ft e r t h e
engine stopped.
2 ) F u e l f i l t e r c a r t r i d g e i s m a d e o f p a p e r , wh i c h s h o u l d b e mo u n t e d c o r r e c t l y t o e n s u r e
c o mp l e t e l y s e a l i n g . To k e e p fu e l c l e a n , r e p l a c e a n d c l e a n t h e c a r t r i d g e a s i n s t r u c t i o n ,
o t h e r wi s e s o m e e l e m e n t s m i g h t b e c h o k e d o r wo r n o u t t o c a u s e t r o u b l e o r s h o r t e n s e r v i c e
l i fe .
3 ) Th e i n j e c t i o n p u mp i s B Q p u mp o r I W p u mp , a n d t h e p l u n g e r d i a m e t e r o f i n j e c t i o n
p u mp i s 7 m m fo r s wi r l t y p e e n g i n e a n d 7 . 5 m m fo r d i r e c t t yp e e n g i n e . Lu b r i c a t i o n o i l i s
fi l l e d i n t o i n j e c t i o n p u m p f r o m r i g h t u p p e r s i d e u n t i l o i l d r o p o u t f r o m s i d e p i p e fo r
c o mp l e t e l u b r i c a t i o n . O i l r e fi l l i n g s h o u l d b e c a r r i e d o u t p e r i o d i c a l l y .
I n j e c t i o n p u mp d i s a s s e mb l i ng :
Tr y n o t t o t u r n t h e c r a n k s h a ft a ft e r t h e p u mp i s d i s a s s e m b l e d s o t h a t t o e n s u r e t h e fu e l
s u p p l i e s t i mi n g . O t h e r w i s e t h e m a r k s o n i d l e g e a r a n d p u mp g e a r s h o u l d b e a l i g n e d a g a i n
by turning tile crankshaft.
A dj u s t f ue l s u p pl y t i mi n g :
To a d j u s t t h e a n g l e , f i r s t l y d i s c h a r g e a i r i n fu e l s y s t e m , c r a n k t h e c r a n k s h a ft t o l e t
i n j e c t i o n p u mp fi l l fu e l . D i s m o u n t i n g i n j e c t i o n p i p e o n f i r s t c y l i n d e r . B l o w o f f t h e a i r i n
t h e h o l e o f d e l i v e r y v a l v e s e a t c o n n e c t o r , t h e n c r an k t h e c r a n k s h a ft s l o w l y a n d i n s p e c t t h e
fu e l l e v e l i n d e l i v e r y v a l v e s e a t c o n n e c t o r , s t o p c r a n k i n g i m m e d i a t e l y wh e n fu e l l e v e l
w a v e s . C h e c k t h e m a r k o n c r a n k s h a ft b e l t p u l l e y t o s e e wh e t h e r t h e a d v a n c e a n g l e i s i n
c o mp l y w i t h t h e a b o v e m e n t i o n e d s p e c i f i c a t i o n . L a r g e r o r s m a l l e r a d v a n c e a n g l e c a n b e
adjusted by loosening three bolts on pump connecting plate. If the angle is larger, turn the
g e a r s e a t c o u n t e r c l o c k wi s e a p r o p e r a n g l e , I f t i l e a n g l e i s s m a l l e r , t u r n i t c l o c k w i s e fo r a
proper angle, then tighten three bolts and check the angle again.
A dj u s t i nj e c t i o n p u m p:
I n j e c t i o n p u mp w a s a l r e a d y a d j u s t e d , c h e c k e d a n d l e a d s e a l e d b e fo r e e x - - wo r k s . I f
readjustment is necessary, it should be made on special testing machine at repairing
wo r k s h o p .
I nj e c t i o n pi p e : i n n e r d i a m e t e r x o u t s i d e d i a m e t e r x l e n g t h = φ l . 6 × φ 6 × 3 4 0 m m
I nj e c t o r :
Open pressure of injector and injector nozzle of every model engine refers to operation
manual page 4 and page 2.
H i g h e r o r l o w e r i n j e c t i o n p r e s s u r e s h a l l a f f e c t n o r m a l i n j e c t i o n . Wh e n t h e p a r t i s
d a m a g e d , t h e e n g i n e s h a l l e x h a u s t b l a c k s mo k e , l o w e r p o w e r a n d s p e e d , r a i s e e x h a u s t
t e mp e r a t u r e o r k n o c k t h e c y l i n d e r . To c h e c k t h e t r o u b l e i n j e c t o r , l o o s e n i n j e c t i o n p i p e s o n e
b y o n e , s t o p i n j e c t i o n , a n d i n s p e c t t h e c o l o r o f e xh a u s t s m o k e . O n l y t h e t r o u b l e i n j e c t o r
s t o p i n j e c t i o n c a n m a k e t h e e n g i n e n o s m o k e , c r a n k t h e c r a n k s h a ft s l o wl y t o c h e c k
i n j e c t i o n s o u n d o f e a c h i n j e c t o r , t h e t r o u b l e i n j e ct o r s h a l l b e n o s o u n d i n j e c t i o n .
I nj e c t o r a d j us t me n t :
S e t i n j e c t o r o n t e s t i n g m a c h i n e ; s l o wl y i n c r e a s e p r e s s u r e t o p r e s s u r e r e q u i r e d i n m a i n
t e c h n i c a l s p e c i fi c a t i o n t a b l e . C h e c k t o e n s u r e n o fu e l d r o p s o r l e a k a g e , o t h e r w i s e c l e a n o r
lap the nozzle and try again.
Th e n c h e c k a t o m i z a t i o n a t a s p e e d o f o n e i n j e c t i o n p e r s e c o n d . A t o mi z e d i n j e c t i o n
s h o u l d b e s mo o t h a n d fo g s h a p e w i t h o u t s p l i t , d r o p s , u n e v e n o r p a r t i a l i n j e c t i o n b u t wi t h
o b v i o u s a n d m e l o d i o u s s o u n d wh e n fu e l s u p p l y i s c u t o f f . G e n e r a l l y s p e a k i n g , a n a b n o r m a l
i n j e c t i o n i s c a u s e d b y u n s mo o t h mo v e m e n t o f p l u n g e r a n d b a r r e l . Wh i l e f u e l d r o p s i n
injection hole is caused by damaged sealing surface, and uneven injection is caused by heat
d e fl e c t i o n d u e t o c a r b o n d e p o s i t o n h e a d .
I nj e c t o r di s mo u n t i ng :
Wh e n d i s m o u n t i n g i n j e c t o r , fi r s t l y c l e a n o u t s i d e s u r fa c e . C l a mp i t o n b e n c h v i c e wi t h
n o z z l e t o w a r d u p s i d e . N o t e t h a t t h e v i c e m o u t h s h o u l d b e c o v e r e d wi t h c o p p e r p l a t e s .
S c r e w o u t t h e t i g h t e n i n g n u t , p u l l o u t p l u n g e r a n d b a r r e l a n d p u t i n c l e a n d i e s e l . Tu r n t h e
i n j e c t o r u p s i d e d o wn a n d c l a m p a g a i n . S c r e w o u t p r e s s u r e a d j u s t i n g s c r e w a n d n u t , t h e n
take out pressure adjusting spring and push rod. Clean the plunger and barrel when they are
s e i z e d o r e f f e c t p o o r a t o m i z a t i o n . S i n k i t i n d i e s el f o r a wh i l e wh e n s e i z e d , c l a mp i t w i t h
c l o t h c o v e r e d c l i p p e r a n d l i g h t l y t u r n o u t t h e p l u n g e r . To c l e a n p l u n g e r a n d b a r r e l , s c r a p
w i t h wo o d e n s h e e t d i p i n g a s o l i n e o r d i e s e l , m e t a l s h e e t i s s t r i c t l y p r o h i b i t e d . I f p l u n g e r
c a n 't m o v e s m o o t h l y i n b a r r e l , l a p i t wi t h c l e a n d i e s e l , t h e n c l e a n t o r e mo v e a l l d i r t y a n d
metal chips.
Speed adjustor:
S p e e d a d j u s t o r i s w e l l a d j u s t e d a n d l e a d s e a l e d wh e n e x - wo r k s . D o n 't a d j u s t i t u n l e s s
necessary.
Ad j u s t s p e e d c o n t r o l l e r o n l y o n p u mp t e s t i n g b e n c h t o p r e v e n t d a m a g i n g .

8. LUBRICATION SYSTEM

Lu b r i c a t i o n s y s t e m wh i c h e f f e c t p r e s s u r e a n d s p l a s h l u b r i c a t i o n c o n s i s t s o f o i l p u mp , o i l
fi l t e r a n d o i l c h a n n e l .
O i l p u mp i s o f r o t o r t yp e a n d i s d r i v e n b y ca mshaft gear. The g e a r s h a ft a n d
c a m s h a ft g e a r a r e l u b r i c a t e d b y s p l a s h e d o i l . O i l f i l t e r i s o f p a p e r c a r t r i d g e t yp e , wh i c h
s h o u l d h a v e a g o o d s e a l i n g . Wh i l e i n s t a l l i n g t h e c a r t r i d g e , c a r e m u s t b e t a k e n t o p r e v e n t
l e a k a g e o r s h o r t - w a y . Th e s y s t e m w o r k i n g p r e s s u r e i s 3 0 0 - 4 5 0 kp a .
To e n s u r e a l o n g e r s e r v i c e l i fe , m a i n t a i n t h e l u b r i c a t i o n s y s t e m c o mp l e t e l y a n d i n t i m e .

9. COOLING SYSTEM

C o o l i n g s y s t e m i s o f c l o s e d , fo r c e d w a t e r - c o o l e d , wh i c h c o n s i s t s o f w a t e r p u mp ,
t h e r mo s t a t , f a n , c o n n e c t i n g p i p e a n d r a d i a t o r e t c .
Th e c o o l i n g w a t e r i n r a d i a t o r i s p u m p e d i n t o c y l i n d e r b l o c k w a t e r c a v i t y, t h e n t o
cylinder head. Some water directly flows up to cylinder head and accumulated near
t h e r mo s t a t . S o m e w a t e r h o l e s i n c y l i n d e r b l o c k a n d h e a d a r e v e r y s m a l l , s o c a r e mu s t b e
taken not to block them especially those holes between cylinder bores and the triangle area
wh e r e i n j e c t i o n n o z z l e l o c a t e d t o p r e v e n t t r o u b l e c a u s e d b y o v e r h e a t i n g . Wa t e r p u m p i s
c e n t r i fu g a l t yp e . I f t h e r e i s t r o u b l e i n w a t e r s e a l , w a t e r m a y l e a k o u t fr o m o v e r f l o wi n g h o l e ,
repair it in time. Alter long time operation, some deposit shall be left in cooling system
wh i c h c a n b e r e mo v e d b y t h e fo l l o w i n g p r o c e d u r e :
P o u r t h e mi x t u r e o f 7 0 0 - 8 0 0 g N a O H a n d 1 5 0 g k e r o s e n e i n t o w a t e r c o o l i n g s y s t e m . R u n
t h e e n g i n e fo r 5 - 1 0 mi n u t e s , t h e n s t o p fo r 1 0 - 1 2 h o u r s . R e s t a r t t h e e n g i n e fo r 1 0 – 1 5
m i n u t e s , d r a i n o u t t h e mi x t u r e a n d c l e a n c o o l i n g s ys t e m wi t h c l e a r w a t e r .

10. ELECTRIC SYSTEM

E l e c t r i c s y s t e m c o n s i s t s o f g e n e r a t o r , s t a r t i n g mo t o r , r e g u l a t o r , a c c u m u l a t o r , o i l
pressure sensor, glow plug and connecting wire etc. Engine normal voltage is 12v.
Th e n e g a t i v e p o l e o f a c c u mu l a t o r a n d g e n e r a t o r s h o u l d b e e a r t h e d ; p o s i t i v e a n d
n e g a t i v e p o l e c a n 't b e s h o r t c i r c u i t t o p r e v e n t d a ma g e .
 CHAPTER V ENGINE TROUBLES AND REMEDY

A: ENGINE CAN NOT BE STARTED

Trouble Cause Remedy

1. Fuel System

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

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

Check each connection for leakage.

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

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

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

to force the lever to max. fuel supply position.

2. Electrical System

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

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

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

speed. handle, or fill in preheated oil.

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

5. Lower Compression Pressure in cylinder.

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

2) Valve and valve seat fitting not good.

3) No valve clearance. 2) Lap valves.

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

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

5) Check cylinder head nuts torque. check whether the

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

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

7) Check and adjust.

6. Fuel supply advance angle not correct. 6. Check and adjust it.
 B: ENGINE POWER DECLINE.

Trouble Cause, Remedy

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

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

C: ENGINE STOP SUDDENLY

Trouble Cause Remedy

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

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

D: ENGINE RUNNING WITH KNOCKING SOUND.

Trouble Cause Remedy

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

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

E: OIL PRESSURE TOO LOW.

Trouble Cause Remedy

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

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

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

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

F: ENGINE OVER HEAT

Trouble Cause Remedy

1. Cooling system out of order

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

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

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

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

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

G: ENGINE EXHAUST ABNORMAL SMOKE.

Trouble Cause Remedy

1. Exhaust blue smoke (oil in cylinder)
1) Piston rings, cylinder liner worn out or piston rings jammed. 1) Repair or replace it.
2) Intake or exhaust valve guide hole worn out. 2) Replace it.
3) Too much oil in oil sump. 3) Drain out some oil.
2. Exhaust white smoke (Engine in cold condition with bad fuel
atomization in low load condition. ) 1) Adjust fuel delivery.
1) Fuel injection pump delivery too much fuel. 2) Inspect injection pressure or replace fuel
2) With bad fuel atomization, fuel pressure is too low injector when necessary.
3) Fuel delivery too late 3) Adjust fuel advance angle
4) Cylinder compressing pressure is low. 4) Refer to a-5
5) Fuel with water 5) Replace fuel.
3. Exhaust black smoke (bad combustion) 1) Reduce the load.
1) Engine overloaded 2) Adjust or replace the nozzle.
2) Nozzle with bad atomization or leak fuel 3) Adjust the fuel delivery advance angle.
3) Fuel delivery too late 4) Clean air filters and air intake pipe or
4) Air filter blocked replace filter cartridge.
5) Too much fuel delivery 5) Adjust the fuel delivery.

H: FUEL INJECTION PUMP OUT OF ORDER

Trouble Cause Remedy

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

4. Unsteady fuel delivery.

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

5. Unsteady operating of the engine

1) Governor internal friction too high. 1) Inspect and solve it.
2) Camshaft axial clearance too big 2) Adjust the clearance.
3) Governing spring deformed or rigidity too small 3) Replace it.
4) Fly weight loose 4) Tighten it.
5) Too much lub.oil 5) Add lub.oil as requirement
6. Insufficient fuel supply,
1) Pump element or delivery valve worn out. 1) Replace it.
2) Calibrator out of order. 2) Adjust it.
3) High speed limit abnormal 3) Adjust it.

7. Uneven fuel delivery of each cylinder

1) Adjusting arm loosen. l) Tighten it.
2) Plunger spring broken, 2) Replace it,
3) Delivery valve or nozzle with dirt. 3) Clean it.

8. Engine unsteady in low speed.

1) Idle speed screw not correct. 1) Adjust it.
2) Uneven fuel supply in low speed. 2) Adjust it,
 I. STARTER IS OUT OF ORDER

Trouble cause Remedy

I. The starter can't work.

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

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

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

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

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

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

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

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

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

magnetic pole.

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

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

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

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

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

causes a bad connection. polish it.

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

in conformity with the requirement.

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

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

together.

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

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

Trouble cause Remedy

1. The alternator can not generating power.

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

2. The charged power is insufficient.

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

3. The charged current is unstable.

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

4. There are abnormal sounds in the alternator.

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

5. The charged power it excessive

1). The regulator's regulating voltage is higher or it is out of order. 1). Repair or replace the regulator.
6. The alternator is burnt out and damaged.
1). The alternator's silicon elements is short circuit or its stator knocks 1). Repair it.
the rotor.
2). The regulator's coil is burnt out and damaged or the connecting spot 2). Repair or replace it.
is burnt out and melted Together cause it is out of order.
3). The regulator's voltage coil or resistance wire is broken. 3). Repair it.