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1. emission of engines is improved please use Class CC and CD lube oil dedicated to Brand Xichai diesel engines This lube oil meets GB11122 1997 National Standard for Diesel Engine Oil and its performance conforms to Class CC and CD of American Petroleum Institute APD and conforms to Viscosity Class SAE30 40 15W40 and 20W50 of standard of the Society of Automotive Engineers SAE USA 1 Engine oil quality and class should be selected according to engine model type and automobile model type 2 Viscosity class should be selected according to ambient temperature 3 Higher class one class higher than normal required class oil should be used when load is heavy or travel distance is long or where road condition is bad or in dusty regions 4 Recommended are CD15W40 and CD20W50 engine oil with several viscosities which not only have low temperature dynamic viscosity and low temperature boundary pumping performance but also have such high temperature characteristics as high temperature shear stability high temperature viscosity and evaporation loss etc ensuring engines to be reliable Specification amp applicable scope of lube oil dedicated to Brand Xichai diesel engines Oil spec CD30 CD40 CD15W20 CD20W50 Application scope Service ambient k 0 C 30 C 5 C 40 10 C 40 C 0 50 temperature Suggested oil change 6000 8000 km 10000km interval Natural aspiration
2. H P d 75 Reamer 6 A 8 o T m 5 SE E Fig 3 Trimming of valve seat Fig 4 Deflection of valve The valve guide when assembled should be 12 5 13mm higher than the plane of cylinder cover It is necessary to often inspect the valve lash or clearance For its adjusting method please see Section I Chapter X Incorrect clearance will influence the accuracy of valve timing and tightness of valve Additionally too big clearance will lead to more noise of valve driving device and too small clearance will lead to an un tight closing and burn out of the valve 2 Cylinder cover gasket The gasket should be flat and smooth Gaskets with defects such as warp and burn should be replaced When the piston is at top dead center there should be a clearance between the top of piston and bottom plane of cylinder cover to prevent the compression ratio from being influenced or the valve from being collided by the top of piston 19 H Engine body 1 Engine body The engine body is of gantry design On the top surface there are cylinder jacket opening and bolt holes and additionally there are water hole through to cylinder cover Near the back end there is lube oil hole by which the cylinder cover is lubricated At the upper part of the front end face of engine body is cast with the water in chamber of water pump Flywheel casing and rear oil seal cover ar
3. gt Z gt 05 SREZGWDER Operation amp Maintenance Manual For 485 490 Serres Diesel Engines FAW JIEFANG AUTOMOTIVE COMPANY LTD WUXI DIESLE ENGINE WORKS FOREWORD 4DW series diesel engines code 800 have two options of cylinder bores 1 85 and 90 and strokes i e 95 and 100 Aspiration modes of 4DW series are natural aspiration supercharge and supercharge inter cooled etc 4DW series have two options of speed 1 3000 r min and 3200 r min Power of 4DW series diesel engines ranges 34KW 62kW maximum torque ranges 124 3N m 230N m and speed at max torque ranges 1800 r min 2200r min In this Manual only natural aspiration type diesel engines of which power ranges 34kW 46kW are described 4DW series diesel engines with a natural aspiration mode are suitable for use as power completed for light duty automobiles 0 75 2t agriculture use transport vehicles small size construction machinery tractors combines electric generator sets etc This Manual describes main specification adjusting methods operation and maintenance requirements etc of 4DW series diesel engines Correctly using and maintaining the diesel engines are extremely important to both travel safety and their longer service life Users are kindly requested to read carefully this Manual and operate and maintain the diesel engines complying with its requirement As this series engine is in the process of ceaseless improvement and
4. M 45 Eneine overheat 2 eee x ee P E SAAR AA 46 Too much engine oil consumption 2 2 46 IX Speed increased greatly oeste ee De ipt NES 46 X Enginestops byitself usis REENEN ENNEN ENNEN NEEN EN ANEN EE NEEN 46 Rougkidle een NE ea qe eege 47 XII Engine oil raised e e abe e AA PASARAN ANE 47 Annex Fit Clearance Table ee 202 1 1 2 629 Secor 0Z09 Suueog D Right view of 4DW81 46 diesel engine INY ond 9565 S 8 l ID Left view of 4DW81 46 diesel engine N veo xc eqo uonoenq 49 5 S LcT 9215 osu H A Z 7 S q c mm K y di 170 17 e 492 Front view of 4DW81 46 diesel engine P 269 JEM eye eon Jo aus yo ootj puo Sess D 2 9 d RSS Cc HEN We CH Z 3 yoo q Jo puo xoeg Usus IV Vertical view of 4DW81 46 diesel engine 4 701 Direction P View 180 12 x 10 6 depth 19 156 98 90 0 0 5 50 50 90 Two hol
5. 0 065 gt Interference fit 0 040 0 090 Cylinder cover Hole 33 0 025 0 0 025 Intake valve Shaft 8 0 040 8 Clearance 0 025 0 062 Valve guide Hole 8 0 022 0 0 040 Exhaust valve Shaft 8 0 055 Clearance 0 04 0 077 Valve guide Hole 8 0 Rocker arm shaft Shaft 18 0 018 Clearance 0 016 0 052 Valve rocker arm bush Hole 18 EC TU 0 080 External rotor of engine oil pump Shaft 50 0 119 Clearance 0 080 0 144 Engine oil pump body Hole 50 5027 0 056 Rocker arm bush Shaft 21 0 035 Interference fit 0 014 0 056 Valve rocker arm Hole 21 001 49 2 Fit clearance for Allowable Names Standard size Fit category assembly of new engine clearance limit D as 0 Conn Rod journal Shaft P 54 0 019 Clearance 0 050 0 108 Conn Rod bush Hole 54 0 089 0 050 0 Shaft 65 0 019 Clearance 0 060 0 108 Hole 65 0 089 0 060 0 100 Divided into 2 Shaft 85 0 120 Clearance groups Hole 85 0 035 0 0 11 0 145 Clearance 0 Shaft 14 0 018 Hole 14 0 043 0 016 Engine oil pump shaft 0 15 Engine oil pump body 0 025 Shaft P 68 0 Hole 68 0 030 0 Injection pump pad Timing gear chamber Crankshaft main journal Main bearing bush Piston skirt section Cylinder jacket Valve concaving into cylinder cov
6. 050 0 030 Piston ring groove 0 5 0 012 Oil ring End face clearance 0 03 0 062 Open clearance 0 25 0 40 5 0 050 0 030 0 185 31 0 325 Axial clearance 0 185 0 335 31 0 050 0 Interference fit 0 045 0 086 Piston ring groove 2nd piston ring Crankshaft thrust face width Crankshaft thrust journal distance 0 Shaft 50 0 070 Hole 32 Camshaft bush front rear Hole on engine body 0 050 Shaft 46 0 075 Hole 46 we Camshaft journal Camshaft bush front rear 0 016 Shaft b 14 0 034 Hole 14 aes Valve tappet Tappet hole 48 Fit clearance Allowable Names Standard size Fit category assembly of new engine clearance limit 4 Camshaft pressure plate Camshaft thrust journal distance 4 ees 0 T 40 046 Valve guide pipe Shaft 13 40 028 Interf fi 010 0 04 Cylinder cover Hole 13 0 018 0 0 025 Timing gear shaft Shaft 45 0 050 1 025 0 Bush Hole 45 0 025 E UE 0 0 Idle gear shaft Shaft 14 0 011 Idle gear shaft hole on engine body Hole 14 0 018 Ge Ge 0 Meshing side clearance of each timing gear 1 Gem 0 13 0 17 0 090 Intake valve seat Shaft 41 0 066 2 Interference fit 0 041 0 090 Cylinder cover Hole 41 0 025 0 0 090 Exhaust valve seat Shaft 33
7. engine for their correctness and firmness 6 Check if the support connected to engine is secured and other driven equipment if connected properly 7 Keep the engine clean Use dry cloth or cloth with dipped gasoline to clean away oil stain and dust pay special attention to the dry and clean condition of electrical equipment 8 For a new engine after running for 50h at light load it is necessary to change the engine oil including the oil in speed regulator of fuel injection pump and the element of engine oil filter and to clean the crankcase sump and engine oil filter 9 Eliminate the faults and abnormal phenomena if found any Il Maintenance after running for every 100h In addition to the instructions in Daily care followings should also be performed 1 Change the engine oil in the crankcase sump 2 Clean or replace the element of engine oil filter 3 Replace the element of diesel oil filter it can also replaced after 200h Check the bolts on the cylinder cover if secured Check if valve lash or clearance conform to requirement and adjust it if necessary Check the tension of fan belt and adjust it if necessary Inject some lube grease into the parts with a grease cup OQ tA Clean away the carbon soot deposited in air intake and gas exhaust pipes and muffler 9 It is necessary after running every 200h to check fuel injector for its pressure and atomization conditions and clean or adjust it if necessa
8. low Mid supercharging 4DW Suitable engine model supercharging 4DW agriculture passenger buses light weight Type of vehicle I vehicles light weight trucks vehicles 3 Cooling water rainwater tap water or clean river water is preferred as the cooling water However tap water with well water as its source or well water which both contain more minerals should not be used otherwise inside the engine cooling system more water scale will be produced thus cooling effectiveness will be affected and engine be troubled In winter when the temperature is very low it is possible to add some anti freeze liquid to prevent freezing Most commonly used anti freeze liquid is ethylene glycol glycol water solution or alcohol When 12 ambient temperature is below 0 C and the engine has difficulty in starting cooling water can be heated to higher than 80 C so that it can be used normally Selection of cooling water For engines with advanced water cooling its cooling system have a very high requirement for cooling medium used Please use the coolant dedicated to Brand Xichai diesel engines This coolant conforming to National Standard 5 0521 92 not only has an anti freezing capability and has a freezing point of 3 5 C 4 C but also has a boiling point as high as 107 108 C effectively preventing the evaporation of water Also it can prevent water scale and prevent the cooling water from forming
9. may perform more detailed maintenance depending on actual conditions IV Storage 1 Before out of service for a long time the engine after shutdown should as in warm state be drain completely away the engine oil cooling water and fuel oil Crankcase sump and engine oil filter should be cleaned 2 Corresponding maintenance should be made 3 Remove the intake exhaust pipes 200g clean and dehydrated engine oil via gas way into each cylinder i e heat the engine oil to 110 120 C until bubbles completely disappear and turn the crankshaft so that the oil will be uniformly and evenly applied on surfaces of valve cylinder jacket and piston etc Fit back the intake and exhaust pipes 4 Oil stain water trace and dust on outer surface of the engine should be wiped and cleaned Unpainted parts except for those made from rubber or plastic should be applied with anti rust oil 5 The outlet inlet of intake and exhaust pipes muffler should be blocked with a wooden plug or covered well with plastic cloth to keep foreign bodies dust away 6 The engine should be stored in ventilated dry and clean places and in its surrounding areas chemicals are forbidden to be stacked The engine can be stored for 3 months if above mentioned oil seal procedures are followed In case this period is exceeded then oil seal once more is necessary 17 Chapter IV Structure L Cylinder head On the cylinder head are fitted intake an
10. of piston piston ring piston pin retaining ring connecting rod connecting rod bolts connecting rod bush and connecting rod sleeve etc Weight difference between assemblies of piston and connecting rod for same diesel engine should be no more than 25g and weight difference between assemblies of connecting rod should be no more than 15g 1 Piston Combustion chamber at the top of piston should be o shape Skirt section is processed to be drum shape along height direction and ellipse shape along circumference direction On the piston there are 2 gas ring grooves and 1 oil ring groove 2 Piston ring Ex circle of first gas ring is plated with porosity chromium which can help reduce wear off between cylinder jacket and piston ring Second gas ring is a conical face ring When fitted its side marked with Up should face towards the top face of piston and do not reverse it Oil ring is inside swell ring Such ring still can remain certain radial elastic force when its elasticity is reduced due to wear off Therefore the service life of the oil ring can be prolonged 21 Inspect the open gap before the piston ring is fitted Lie the piston ring flat to the place which is 15 20mm away from the top face of cylinder The open gap should measured with feeler gage be 0 25 0 4 mm See Fig 6 Trimming with a file is possible if the gap is too small and match it again if the gap is too big Additionally it is necessary to use the
11. pin is too big This sound is low but sharp and 10 If crankshaft thrust piece is worn off gap is too big the collision sound of crankshaft playing back and forth can be heard 1 Adjust the advance angle 2 Clean repair or replace the needle valve couple 3 Adjust valve clearance 4 Increase the valve clearance a little bigger correct the gap of connecting rod s bearing or replace the rod s bush 5 Replace cylinder cover gasket 6 Replace the spring push rod or tappet etc and adjust valve clearance 7 Depending wearing conditions determine if cylinder jacket and piston are to be replaced 8 Replace connecting rod s bush 9 Replace connecting rod s bush 10 Replace the thrust piece of crankshaft VI Severe vibration 1 Oil supply for each cylinder is not uniform oil nozzle of one or two cylinders has poor atomization one or two cylinders severely leak compression ratio difference is big etc 2 Water or air enters into diesel oil 3 Poor alignment when the engine is installed support s bolts are loosened 4 Cylinder s is heavily knocked Engine works roughly 1 Inspect and adjust oil supply rate of fuel injection pump repair the oil nozzle eliminate the leakage problem inspect and adjust compression pressure of each cylinder 2 discharge the air make the diesel oil to be deposited 3 Correct the alignment tighten them 4 Inspect the fuel supply advance an
12. pits or wear off causing leakage it is necessary to grind them Apply some grinding paste fine valve sand on the conic sealing surface of valve then pair grind the valve and valve seat until a uniform continuous and gloss less sealing surface is obtained Grinding paste is strictly forbidden to enter the valve guide After the grinding valve valve seat and valve guide should all be carefully cleaned 18 because valve guide wear off lead partial grinding of the sealing surface causing poor sealing After grinding is done pour some kerosene or diesel oil into the air way to see if the valve leaks and check for its tightness Normal width of the sealing surface between valve and valve seat is 1 2 1 7mm After it has been used for long time and ground for more times the sealing surface can become wider causing poor sealing Therefore it is necessary to use 15 and 75 reamer separately to scrape and trim it as per the positioning of inner hole of valve guide as shown in Fig 3 After the scraping pair grinding with valve is again necessary The deflected distance between intake exhaust valve plane and cylinder cover plane is 0 55 0 85mm for a new engine as shown in Fig 4 After scraping and trimming for several times the distance will increased and thus will influence the compression ratio Therefore the valve seat may necessarily be replaced if the deflected distance is increased to be 2mm or more
13. water scale and bubbles by which the cooling effectiveness is improved In addition it has long term effective anti rust and corrosion characteristics This coolant is suitable for the cooling systems of all types of diesel engine and can be used throughout the year and has a preservation period as long as 1 5 2 years The coolant dedicated to Brand Xichai diesel engines which contains water distilled water or ion water additives and ethylene glycol can directly be add into the cooling system Its specific parameters and quality indexes as follows Item Coolant Brand 35 45 Color Blue Odor No peculiar Odor Freezing point 35 45 Boiling point 107 108 Influence on organic coatings No influence PH Value 7 5 1 Corrosion test Varied value on test strip mg strip Copper 10 Brass 10 Steel 10 Cast iron 10 Soldering tin 30 2 Inspection amp preparation before starting the engine 1 Check each connection on the diesel engine if reliable and handles e g handle for throttle and stopping etc if go smoothly and freely 2 Turn the crankshaft for several turns and check all moving parts if move smoothly and freely 3 Check the oil level in crankcase sump and fuel injection pump if at the scale position specified 4 Check the water tank if filled full with the cooling water and check water pipe joint s if any leaks 5 Check the fuel tan
14. 1 Fuel injection pump 2 Fuel injection pump s flanged packing 3 Fuel injection pump s pad 4 Fuel injection pump s coupling disc gasket 5 Gear chamber 6 Advancer Fig 10 Turning of fuel injection pump VIL Fuel amp speed governing system As the main operating part of the diesel engine fuel and speed governing system consists of fuel transfer pump diesel oil filter fuel injection pump speed regulator advancer H P and L P oil pipes and fuel injector etc See Fig 11 The fuel transfer pump will pump the fuel oil in the fuel tank to the diesel oil filter After 26 filtered the fuel oil will enter the fuel injection pump Inside the pump high pressure is produced by which the fuel will via high pressure fuel pipe be atomized and injected into the combustion chamber where the fuel is combusted 1 Fuel transfer pump With a single function roller design the fuel transfer pump consists of hand pressed fuel transfer pump roller piston piston spring pump body fuel in out check valve and fuel in out pipe fittings etc The fuel transfer pump is driven by eccentric gear on fuel injection pump camshaft The eccentric gear pushes the rod and the rod then pushes the piston pressing and transferring the fuel into the fuel chamber of fuel injection pump Inside the pipe fitting of fuel in pipe of fuel transfer pump is fitted a filter gauze used to filter the fuel During overhaul maintenance the filter gauze should be cleaned if
15. Conic surface gas ring is mistaken for its upper and lower direction 2 Increase the temperature of cooling water 3 Inspect the gasket of cylinder cover 1 Clean or replace the piston ring 2 Discharge excessive oil 3 The side marked with a Up should face up IV Insufficient power 1 Filter gauze in oil in pipe joint of diesel oil filter or oil transfer pump is clogged 2 Oil injector has an incorrect pressure or poor atomization 3 Precise pair part of fuel injection pump is severely worn off 4 Speed governor spring is deformed and loosened thus rated speed cannot be reached 5 Air enters into fuel system 6 Fuel supply advance angle is not correct 7 Oil supply rate for each cylinder is not uniform or even 8 Air filter not fluent or be clogged 9 Valve leaks gas 10 Compression pressure is not enough 11 Valve timing is not correct 12 Hole injector leaks 13 Bolts on cylinder cover loosened 1 Clean or replace it 2 Inspect repair the injector or replace the oil nozzle couple 3 Adjust oil supply work detection plunger couple and oil delivery valve couple 4 Adjust high speed limiting screw and replace speed governing spring 5 Remove the air in fuel oil system 6 Adjust it as per requirement 7 Adjust the oil supply rate for each cylinder 8 Clean or replace filter element 9 Inspect valve clearance spring force and inspect va
16. It consists of 3 phase a c generator and silicon diode rectifier Negative pole is grounded i e connected to iron Do not mistake the polarity or the generator will be damaged For use and maintenance of the generator refer to Operation and Service Manual for JF Series Silicon Rectified Excited Generator 3 Regulator JF11A generator is matched with FT111 voltage regulator When the speed of generator changes a regulator can automatically stabilize the output voltage of generator within specified range automatically limit load current and automatically switch on off the electric circuit of battery and generator When installing the regulator it should be vertically placed with its two terminal posts downward and with its wiring being correct and reliable As regulator is a precise device its working clearance should not be arbitrarily adjusted For its inspection and adjustment it is possible to refer to Operation Manual for FT111 Regulator 4 Starting motor It is series excited d c motor engagement between the starting motor and engine flywheel gear ring is controlled electro magnetically When the starting switch is turned on electromagnetic switch makes gearwheel to be engaged with gear ring and at the same time the circuit of starting motor is switched on thus driving the flywheel After the engine is started immediately turn off the starting switch The iron core under the action of spring will drive the gear
17. Oil leaks on crankshaft front rear oil seal crankcase sump joint plane and side cover etc 5 Engine oil temperature or pressure is too high or evaporated and splashed 1 The oil the brand of which is specified in this Manual should be used 2 Replace clean the oil return hole 3 Clean or replace it 4 Inspect or replace them if necessary 5 Reduce the temperature see previous section inspect adjust the pressure limit valve of engine oil pump IX Speed increased greatly 1 Speed governor is failure and pull rod is jammed at large oil flow rate position 2 Speed governor s sliding disc shaft sleeve is jammed 3 Adjust arm is released from shifting fork 1 Inspect and repair the speed governor and its pull rod 2 Inspect and repair it 3 Inspect and repair it X Engine stops by itself 1 Air in oil passage oil transfer pump does not supply oil diesel oil filter is clogged 2 Piston is jammed in cylinder journal is jammed by bush 3 Fuel injection oil delivery valve is jammed plunger spring is broken speed governor sliding disc sleeve is jammed 1 Discharge the air inspect and repair oil transfer pump clean diesel oil filter 2 Fit clearance is not correct repair and replace it 3 Inspect repair or replace it 46 Trouble causes Remedial methods XI Rough idle 1 Un uniform oil flow rate in each cylinder oil i
18. ase is possible after the engine is warmed up 1 Clean and make it unclogged III Smoke emitted in exhaust gas 1 Black smoke emitted in exhaust gas 1 Oil injector is clogged with accumulated soot and needle valve is clogged 2 Load is too much 3 Fuel injecting is too late and partial fuel is burned during the course of exhaustion 4 Incorrect valve clearance valve sealed poorly 5 For each fuel supply by fuel injection pump is not uniform and even cylinder 6 Intake pipe air filter clogged and air intake is not smooth 2 White smoke emitted in exhaust gas 1 atomization is poor fuel dripping Fuel injecting pressure is too low 1 Inspect repair or replace it 2 Adjust the load to the range specified 3 Adjust the fuel supply advance angle of fuel injection pump 4 Inspect the valve clearance and sealing surface and spring force etc and eliminate the problems 5 Adjust fuel supply amount for each cylinder 6 Dismantle and clean the filter 1 Inspect adjust repair or replace the fuel nozzle couple 43 Trouble causes Remedial methods 2 Cooling water temperature 15 too low 3 Moisture enters cylinder 3 Blue smoke emitted in exhaust gas 1 Piston ring severely worn off or elasticity not enough due to accumulation of soot causing engine oil enter the combustion chamber of the cylinder 2 Engine oil level too high 3
19. ate of 1 time sec Atomized fuel should be thin uniform and mist like without abnormal phenomena such as visible splashed tiny foam local un uniform density and one side fuel injection When the fuel oil is cut off an obvious and clear sound should be heard Abnormal fuel injection is usually caused by free less and smooth less nozzle needle valve motion Fuel dripping at fuel injecting hole is caused by a damaged sealing surface Branched fuel beam is caused by a head which is accumulated with soot or deformed due to heat 2 Dismantle and repair of fuel injector 1 When dismantle the oil injector at first clean the outer part With the nozzle facing upwards clamp tightly the injector onto a bench clamp padded with copper Unscrew the screw cap and take out the needle valve couple and pull out the needle valve and immerse it in clean kerosene Turn the fuel injector by 180 and then clamp tightly it Unscrew the pressure adjusting screw cap and pressure adjusting screw then the pressure adjusting spring and push rod can be taken out 40 2 When the needle valve couple is jammed atomization is poor it is necessary to clean it The Jammed needle valve couple should at first be immersed in kerosene for some time then the needle valve should be clamped by a pair of wire pliers lined with cloth and turned gently and pulled out Care should be given to prevent it from being napped Wooden pieces with gasoline or kerosene can be used to
20. ated by its manufacturer When disassembling assembling repairing or adjusting is really need it is necessary to keep clean Plunger couples and oil out valve couples etc are not allowed to be interchanged 4 Speed governor Speed governor is of whole course mechanical centrifugal type It consists of driving parts sliding disc sliding bush speed governing spring speed governing handling shaft etc See Fig 12 Speed sensitive element for Model T7B is steel ball and for Model T 110 is fly ball Operating the speed handle can change the speed of the engine Changing the position of speed governing handle means changing the acting force of spring and the balancing position of speed governing pull rod will accordingly be changed When the speed governing handle is moved towards the direction on which the speed governing spring is twisted tight fuel supply flow rate will increase and engine speed will increase accordingly When the handle is moved towards the direction on which the spring is twisted loose fuel supply flow rate will decrease and engine speed will decrease accordingly Therefore to restrict maximum idle speed and minimum steady speed it is only necessary to restrict the limit positions on the handle which can be realized by using the two screws on the speed governor This adjustment work has already been done before delivery and should not be arbitrarily performed during operation 28 the speed governor is also fitt
21. ck side is a plane When installing it it is necessary to put the working surface towards the thrust surface of crank arm and inverse direction is not allowed Tighten it and then tap it ensuring that the upper and lower thrust pieces are kept on the same plane Then tighten them one by one as per specified tightening torque Upon assembling of crankshaft if turn the crankshaft by hand at the flywheel end it should rotate smoothly and freely 3 Cylinder cover The cylinder jacket is of wet type At the lower part of the cylinder jacket there are two ring shape grooves into each of which a rubber water seal ring is to be fitted The water seal ring should not twist or awry when fitted into the groove Then press the cylinder jacket into the 20 jacket opening The flange plane on cylinder jacket should be 0 04 0 12 mm higher than engine body top face so that the cylinder cover gasket can press closely on it ensuring the tightness between the cylinder jacket and cylinder cover See Fig 5 Engine body 2 Cylinder liner Fig 5 Distance between cylinder jacket flange plane and engine body top face The crankcase sump is made from cast aluminum or by drawing from steel plate When cleaning the inside of crankcase sump do not leave yarn waste on its wall otherwise the copper wire gauze of filter and element of lube oil filter will be clogged III Piston amp connecting rod The assembly of piston and connecting rod consists
22. currence of black smoke decrease of power and speed increase of exhaust temperature or knock of cylinder etc For fuel injector judged to be faulted in turn cylinder stoppage method can be used That is loosen the oil injector and high pressure oil pipe one by one and stop injecting oil At the same time watch the color of exhaust gas If faulted injector stops injecting oil exhaust gas will stop producing black smoke Now speed of engine has little or no change It is also possible to turn the flywheel by hands to listen to fuel injection sound of each cylinder If the sound is not clear and melodious the oil injector is this cylinder may have a fault 1 Adjusting procedure 1 Use hand pump to pump to a gauge pressure of 12 7MPa Continue to slowly press the hand pump to raise the gauge pressure to 13 7MPa at which the fuel is injected Watch if fuel dripping or leakage at fuel injection hole at fuel nozzle If fuel dripping is found in tests by several times it is necessary to remove the fuel nozzle couple for a cleaning After inspection or grind perform test again 2 Adjust the pressure of fuel injection Remove the pressure adjusting screw cap s on the fuel injector and loosen or tighten the pressure adjusting screw s make the pressure of fuel injection to be 13 7MPa Then tighten the pressure adjusting screw cap s and perform re test 3 Watch the quality of atomization Perform atomization test with a fuel injecting r
23. d exhaust valve valve seat valve guide pipe valve spring valve rocker and support The cylinder head is secured onto the engine body by bolts When securing the bolts it is necessary to use a torque wrench to tighten them one by one by several times as per the sequence shown Fig 2 At first pre tighten them then tighten them as per specified tightening torque values In case of assembly disassembly of the cylinder head after the engine runs heat at first time stop and cool the engine and re tighten the bolts as per specified tightening torque values and re adjust valve lash or clearance o 0 0 Fig 2 Tightening sequence of bolts cylinder head On the upper part of the cylinder head is placed the fuel injector forming an inclination angle with the centerline of the cylinder head In the mounting hole of the injector there is a copper shim used for adjustment of the height from the protruding injector to the base plane of cylinder head and used for sealing When installing the fuel injector please evenly and tightly press the pressboard without any leakage It is important that when installing the pressboard the side with an inclination should face downwards 1 Intake and exhaust valve valve seat and valve guide Both intake and exhaust valve and valve seat should all be paired ground to avoid leakage When on the sealing surface between valve and valve seat there is burning
24. dt 18 I ae rtt ue oro e e e ee ae x e oen ore Ue 20 Piston amp connecting rod 21 IV Crankshaft amp flywheel exert e e Soa ENEE dd RE RR ERAT u as 23 Camshaft Pr da 24 VL Geat SYStOM EEN 25 VIL Fuel amp speed governing system 0000 26 AE Lubricating System wayaqa atap ish Nee 31 IX Coolingssystemy EE E PADA BA Ae 33 X Electrical Systems ua atre LR Cuy EN EE A aq dea 36 Oil pressure sensor amp water temperature sensitive plug 38 Chapter Adj stment c per p so e he e e e Er EE DRE iqu E Ne qe 39 I Adjustmentot valve 39 IL Adjustment of fuel supply advance angle sese 39 Adjustment of fuel injector 0 40 IV Fueldnjection pump n tree emet EEN e 41 Chapter VI Troubles amp Troubleshooting esses 42 T Engine does not start a n Leer NEEN 42 IL Abnormalengine oil pressure 43 III Smoke emitted in exhaust gas 2 43 IV Insufficient pOWeEr 2 sor una eo See AE e aa Pee Tee pide e digo Melek EE e 44 V Abnormal sound aqa uapa eee ere bem der ride Napu k 45 WI Severe vibratiot 25 dE EE ee EN e
25. e Works August 2006 CONTENTS D Right view of 4DW81 46 diesel engine 0 000 1 ID Left view of 4DW81 46 diesel engine 0 112 2 III Front view of 4DW81 46 diesel engine 222 3 IV Vertical view of 4DW81 46 diesel engine 00012 4 V Power output end of 4DW81 46 diesel engine 5 Chapter I Technical Characteristics 2 6 I Technical parameters for 4DW B00 diesel engine amp its variants 6 H Maii technical oett reete ee eere dee ted op nits sedes vedete tas 7 External characteristic curve of 4DW engines 02 9 Chapter I Operation et oot degen 11 PERONDA de 11 Wes Operation den AA A ser ae 11 Chapter IH Maintenance Ss is aa SEENEN NEEN ENEE EE pe Ty e ge gea artes 15 slo ph Geo E een e ir e Eee dah AA AN 15 Maintenance after running every 100h aneka kasa 15 Maintenance after running every 500h sss 16 Storage nescis EEEE noe ke VR Ve TEE RR ER TRIN 17 Chapterdv Structure itecto Rr e tr ENEE S OA IB PAIRE MR VUE 18 The Cylinder head se cebat re putent nietos eb his olen et cavas dui
26. e cam profile is symmetrical Profile of intake cam is different from that of exhaust cam When the cam rotates it will push the valve tappet push rod valve rocker and valve controlling the intake and exhaust respectively At the front end of cam there is thrust flange At the front end of engine body is fitted camshaft thrust flange Length of the thrust flange is 0 08 0 25mm longer than the thrust plate controlling the axial playing of the shaft See Fig 8 0 08 0 25 1 Timing gear on camshaft 2 Thrust plate 3 Camshaft Fig 8 Camshaft timing gear amp thrust plate Each bearing on the camshaft is lubricated by main oil passage When fitting the camshaft sleeve it is necessary to check if the oil hole on sleeve is connected with the oil hole on engine body 2 Valve tappet The axis of valve tappet is 2mm offset the symmetrical centerline of cam width While working the tappet rotates making the bottom face and cylinder face wear uniformly 24 Gear system 1 Timing gear Gearing system consists of timing gear and timing idle gear on crankshaft timing gear on camshaft and timing gear and timing gear seat etc on fuel injection pump Each timing gear is marked with timing mark When fitting the gear marks should correctly be followed where is engaged so as to ensure correct moving relationship between moving parts See Fig 9 Timing gear fuel injection pump ST ff gear S T
27. e fitted at the rear end On the bottom surface of engine body there are bolt holes for bolts of main bearing lube oil inlet engine oil pump opening and bolt holes on crankcase sump On the right side of engine when viewing from front end there are engine oil filter diesel oil filter and water discharge valve In the engine body main oil passage and branch oil passages are all horizontal arranged When disassembling the engine for repair it is necessary to clean each oil passage ensuring cleanness and smoothness Screw plug for each oil passage should be tight and reliable without oil leakage 2 Main bearing The main bearing is of full support suspension design Main bearing cap and engine body adopt paired boreholes with paired marks on the engine body bearing cap When assembling disassembling it the marks should be followed and incorrect direction is not allowed When assembling front main bearing cover it is important that it should be flushed with front end face of engine body and should not protrude otherwise the pressing of timing gear chamber will be influenced When removing the main bearing bushes for cleaning do not mistake the upper bush and lower bush bush with oil groove is upper bush Crankshaft thrust pieces are installed at the last main bearing each piece at upper and lower at front and rear The thrust piece is subject to axial thrust force of crankshaft Its working surface has oil groove on it and its ba
28. e valve body are couples having been pair ground During disassembling assembling process do not interchange them and keep them clean 29 a 222227222021 lt WEN S NN PANNE ASI Z Es Sal 1 Respirator and fuel filling port 2 High speed limiting screw 3 Idle speed limiting screw 4 Max fuel flow rate limiting screw 5 Sliding sleeve Fig 12 T7B Speed governor 30 y FI 1 Screw 2 Washer 3 Pressure adjusting spring 4 Push rod 5 Injection nozzle cap 6 Washer 7 Needle valve couple Fig 13 Fuelinjector Lubricating system Lubricating system consists of engine oil collector engine oil pump engine oil filter and pipes as shown in Fig 14 The diesel engine adopts pressure lubrication and splash lubrication Pressure lubrication is used for crankshaft main bearing connecting rod bearing camshaft bush fuel injection pump seat bearing and rocker shaft bush etc while splash lubrication is used for cylinder jacket piston pin connecting rod bush cam and tappet and valve and valve guide etc Additionally rolling bearings used for water pump and generator etc will periodically be added grease for lubrication Oil stored in the crankcase sump will via engine oil collector pass through oil in pipe and then sucked into engine oil pump where the oil is pressurized and sent to engine oil filter Filtered oil enters the main oil passage of engine and then divided into t
29. e worked for a wear in period of 50 100h during which they run at a low speed no more than 2200 r min or less load no more than 70 of full load 5 Fuel oil for the engines must be clean Before use the fuel oil must at least be precipitated for more than 4 days or filtered with silk cloth 6 Normal water temperature 75 90 C should be kept Normal engine oil pressure when the engine is running at a medium speed should be 196 392 kPa Operation 1 Fuel oil engine oil and cooling water 1 Diesel oil specification The diesel oil should have a sulfur content of less than 0 5 Diesel oil with low freezing point should be used in winter Diesel oil brands should be selected basically as per ambient temperature conditions see Table 2 1 For example 35 diesel oil should be used for ambient temperature of 29 C Table 2 1 Relations between diesel oil brands and suitable lowest temperature Diesel oil brand 10 0 10 20 35 Sulfur content 0 2 0 2 0 2 0 2 0 2 Cetane value 45 45 45 45 45 Freezing point 10 0 10 20 35 Suitable lowest temperature engine s 18 4 5 14 29 operating ambient temp Diesel oil must be kept highly clean free of pollution by dust or impurities Before being injected into the fuel tank the diesel oil should be kept still for more than 27h Then upper part layer of diesel oil should be taken for use This is extremely important f
30. ed maximum fuel flow position limit screw which is connected with speed governing spring thrust plate This screw is used to limit maximum fuel supply flow rate and prevent the engine from overloading at each gear of speed For the maximum fuel flow position limit screw the adjustment work has already been done before delivery and should not be performed during operation On the casing of speed governor a stoppage handle is fitted When the engine needs to be stopped move this handle then the engine will be stopped Above the cover of speed governor is fitted a respirator part below which there is a oil drain screw plug As the speed governor seat is connected with oil pump body when oil level appears in oil indication window of fuel injection pump oil level in the speed governor can also meet requirement for lubrication 5 Fuel injector Fuel injector is 5 series Fuel injector consists of injector body nozzle cap needle valve couple push rod pressure adjusting spring and pressure adjusting screw etc See Fig 13 The high pressure fuel oil pumped by fuel injection pump enters the chamber of fuel injector needle valve couples via high pressure fuel pipe Oil pressure acts on the conic surface of needle valve When fuel pressure overcomes the resistance of pressure adjust spring the needle valve is raised and fuel oil is injected via fuel injecting hole into the combustion chamber Fuel injection nozzle s needle valve and needl
31. er Bottom plane depth Extruded part of nozzle above 31 cylinder cover Bottom plane height Fuel supply advance angle Intake valve clearance At cold state 0 28 0 33 0 28 0 33 Exhaust valve clearance 34 At cold state 50
32. es marked 90 are match reamed with clutch housing 2 x 10 5 depth 19 Counter bore 14p7 depth 8 Direction K View 90 4 x M12 x 6H 120 120 NOTE In Direction K View values in parentheses are suitable for NJ130 and values without parentheses are suitable for BJ130 V Power output end of 4DW81 46 diesel engine Chapter I Technical Characteristics L Technical parameters for 4DW B00 diesel engine amp its variants 1 Model designation 4DW81 46 B01 4DW81 50B05 4DWS1 40B71 DW91 63B41 4DWOIAGIB 2 Type 4 cylinder in line 4 stroke water cooled direct injection 3 Aspiration mode Natural air suction 4 Ignition sequence 1 3 4 2 Cylinder diameter mm X piston stroke 5 85x95 85x100 90x 100 mm 6 Piston total displacement L 2 16 2 27 2 54 7 Rated power kW 34 37 36 46 8 Rated speed r min 3000 3200 3000 3200 9 Max torque N m 124 3 131 155 10 Speed at max torque r min 2200 1900 2100 Minimum steady idling speed r min 800 50 12 Steady regulation rate 10 Minimum fuel consumption at full load 13 lt 235 g kW h Consumption ratio of engine oil to fuel oil 14 0 8 96 15 Maximum smoke at full load Bosch lt 3 5 16 Free acceleration smoke Bosch lt 3 0 Crankshaft rotation direction viewing 17 Anticlockwise towards flywheel 18 Lubrication mode Pressure lubrica
33. feeler gage to measure the end face gap between piston ring and piston ring groove The end face gap for first gas ring should be 0 05 0 082 mm for second gas ring should be 0 03 0 062 mm and for oil ring should be 0 03 0 062 mm See Fig 7 1 Feeler gage 2 Piston ring 3 Cylinder liner Fig 6 Measuring the end face gap of piston ring Fig 7 Measuring the end face gap of piston ring The piston rings should be removed and fitted back by special tools When fitting the rings opening of each ring should be staggered each other for 120 and should not be at the direction of piston pin During maintenance repair if the piston ring is found seized dead and cannot move it is possible to immerse the ring in diesel oil kerosene or gasoline for 24h or longer then tap gently the ring to make it to be loosened After that the ring should be taken out and then cleaned with diesel oil or carbon tetrachloride Check each position of the piston for crack and scar If defect s is found renew it and replace the piston ring 3 Piston pin Before removing or fitting back the pin fit a retaining ring at one end or remove retaining rings at two ends Place the piston in engine oil or boiled water where the piston is heated to 22 100 120 C With a appropriate forcer being padded gently tap the piston pin or push the pin in Clean engine oil should be applied into the pinhole and connecting rod sleeve After the piston pin i
34. found clogged and should be replaced if found broken or damaged Otherwise the friction couple 1 friction paired part of fuel transfer pump will be severely worn off and fuel in out check valve will have a poorer sealing causing insufficient fuel supply 27 1 Diesel oil filter 2 Speed regulator 3 Fuel transfer pump 4 Fuel injection pump 5 High pressure fuel pipe 6 Fuel injector 7 Fuel return pipe 8 Advancer Fig 11 Fuel amp speed regulating system 2 Diesel oil filter Diesel oil filter is used to remove the impurities in diesel oil It consists of casing filter seat and filter element etc 3 Fuel injection pump Fuel injection pump is No 1 series pump or BQ pump type with right integration plunger design This pump consists of pump body camshaft plunger couple oil out valve couple and control mechanism etc The fuel injection pump is driven by its timing gear Through transmission effect of fuel injection pump s camshaft roller and tappet the piston of the pump is moved back and forth The control mechanism for changing fuel supply flow rate consists of speed governing pull rod shifting fork and adjusting arm fitted onto plunger of fuel injection pump The position of pull rod is controlled by speed governor Moving the pull rod forward will increase fuel supply flow rate and moving back will decrease it Do not arbitrarily disassemble assemble the fuel injection pump which has been calibr
35. front end face of engine body The water pump is supported by two E60202 bearings Water seal is of ceramics graphite design Driven by crankshaft pulley fan belt the water pump consists of pump body impeller shaft bearing and water seal etc See Fig 16 During its use in case the water seal is damaged and the drain hole below pump body has serious dripping the water seal should be replaced and it is not permitted that the leakage drain hole is clogged otherwise water will enter the bearing causing it soon to be worn off The bearing if giving abnormal noise while running should be preferred to be replaced The grease cup of water pump should periodically be added 4 calcium based lube grease according to requirement in Maintenance The lube grease should not be too much otherwise overheating on bearing can be caused It is suggested that the amount of lube grease be approx 1 2 1 3 of cavity of bearing 34 1 Water pump housing 2 Pump belt pulley 3 Pump shaft 4 Grease cup M8 X 1 5 Water seal II F 12 6 Pump impeller 7 Connecting plate 8 Connecting plate gasket 9 Pump gasket Fig 16 Water pump 3 Thermostat The thermostat is tubular and wax type is fitted in a casing at water out at the front end of cylinder cover It automatically controls the on off of valve It both indicates a fault at thermostat that after engine is cold started and before water temperature reaches 70 C there is water flowing out of water out pipe or
36. gged 4 Fuel transfer pump does not supply fuel 5 Fuel injector injects no or little fuel too low pressure and poor atomization fuel injector spring injection hole is clogged pressure adjusting 18 broken 6 Fuel injection pump fuel discharge valve leaks fuel spring is broken plunger couple is worn off 3 Insufficient compression pressure 1 Valve clearance too big 2 Valve leaks 3 Cylinder cover gasket leaks 4 Piston ring worn off stuck opening overlapped 4 Other causes 1 Air temperature too low oil viscosity too big 2 Water in combustion chamber or cylinder 1 Recharge it tighten the terminals repair wire post if necessary 2 Repair or replace the carbon brush 3 Turn the flywheel to another position If necessary inspect the installation of starting motor and eliminate the non parallelism between the axes of starting motor and gear ring 1 Fill it or open the valve 2 Remove the air change the oil tighten the joints 3 Clean the passage replace element of diesel oil filter and clean fuel in pipe of fuel transfer pump 4 Inspect if any air leakage on fuel in pipe Inspect and repair fuel transfer pump 5 Dismantle the fuel injector and adjust it on its tester and inspect if fuel injection pump starting has more concentricity 6 Grinding it repair or replace parts 1 Adjust it as per requirement 2 Grind the valve 3 Replace the cylinde
37. gle apply load after engine is warmed up 45 Trouble causes Remedial methods VII Engine overheat 1 Fuel enters into crankcase or engine oil is mixed by water it becomes thinner too much or less engine oil low flow rate and pressure of engine oil fit clearance of bearing is too small 2 Water pump impeller is damaged and broken and fan belt slips positions of heat radiator and fan are improper thermostat is failure cooling system piping is clogged too thick water scale in water Jacket water pump displacement is not enough cylinder cover gasket is broken and fuel gas enters water passage 1 Inspect and replace piston ring change engine oil inspect oil level inspect wearing conditions of inner outer rotor inspect and adjust the fit clearance of each bearing 2 Inspect and replace the impeller inspect the belt s tightness or replace the belt inspect the position of heat radiator inspect the working condition of thermostat clean the cooling system and water jacket inspect the clearance of impeller fill fully water replace the cylinder cover gasket VIII Too much engine oil consumption 1 The viscosity of the oil used is too low or the brand is not correct 2 Piston and cylinder jacket is severely worn oil return hole on piston ring groove is clogged 3 Piston ring is stuck by glue gas ring if fitted with upper and lower faces being reversed too much wearing 4
38. he resistance is measured to be infinity it means that the sensor is disconnected and indicating needle of oil pressure gauge water temperature gauge will not move 38 Chapter V Adjustment I Adjustment of valve lash When the engine is overhauled or maintained it is necessary to check and adjust valve lash or clearance Adjusting procedure of valve lash and valve timing mechanism is as follows 1 Dismantle the hood of cylinder cover and check and tighten press the nuts on valve rocker arm seat 2 Turn the crankshaft to the position of top dead center at first cylinder piston between the end of compression stroke and beginning of expansion stroke Now the mark at sight window on flywheel is just aligned with the 0 scale line on flywheel or the 0 scale line on crankshaft pulley is just aligned with the indicator on the cover of timing gear chamber 3 Insert feeler gage into intake valve and exhaust valve of first cylinder into intake valve of second cylinder and into exhaust valve of third cylinder and rocker arm respectively and inspect and adjust intake valve lash and exhaust valve lash Cold state clearance should be kept as 0 28 0 33 mm Turn the crankshaft by 360 and adjust the valve clearance of the rest cylinders as foregoing procedure II Adjustment of fuel supply advance angle To ensure that the engine has most economical fuel consumption rate and good running performance fue
39. heck fuel supply advance angle and if necessary adjust it 3 Check gas valve for its tightness and if found not complying with requirement grind and correct it 4 Check the tightening condition for bolts on connecting rod main bearings and flywheel 5 Re tight the bolts on cylinder cover and adjust the valve clearance or lash as per requirement 6 Clean or replace the element of air filter This can depending on the dusty degree working environment be performed as in Maintenance after running every 100h or be performed in shorter interval 7 Change the engine oil in the speed regulator of fuel injection pump 8 Clean the cooling system Clean liquid is a mixture of NaOH and water every 150g NaOH is mixed with 1L water Before the cleaning drain away all the water in cooling system and then fill fully clean liquid and remain 8 12h Then run the engine and stop it after water temperature reaches working temperature Upon stoppage immediately discharge the clean liquid to prevent the deposit of water scale in the liquid Finally clean the cooling system with clean water 16 9 Check the working status of thermostat 10 Check each part of starting electric equipment Check fasteners if secured and check wire ends if closely contacted and it should be replaced if scorch trace found on it 11 Check each part of engine and repair and adjust them if necessary In addition to above information on maintenance users
40. hree branches One branch leads to main bearing passes crankshaft oil hole and reach connecting rod bearing one 31 branch leads to camshaft bearing then to cylinder cover to lubricate rocker arm bearing other branch leads to idle gear bearing passes to timing gear chamber branch oil passage and then to the timing gear seat bearing of fuel injection pump 4 Emn i in N r LU Wi BSS 1 Crankcase sump 2 Engine oil collector 3 Assembly of piston and connecting rod and cylinder jacket 4 Engine oil pump 5 Driving gear of engine oil pump 6 Engine oil filter 7 Gearing system 8 Engine oil pressure gauge 9 Valve rocker arm 10 Valve push rod valve tappet and valve tappet hole of engine body 11 Valve rocker shaft 12 Valve and valve guide 13 Camshaft and bush 14 Oil passages in engine body 15 Crankshaft and bearing Fig 14 Lubricating system schematic diagram 1 Engine oil pump The engine oil pump is of rotor type The rotor inside the pump is fixed on shaft with pin s The gear of the engine oil pump is driven by the driving gear of engine oil pump on the crankshaft On the engine oil pump body is fitted pressure limiting valve which can regulate the flow rate and oil pressure On the cover of engine oil pump is cast oil in out hole which connects to cylinder body The pump body and cover are fixed by bolts to the cylinder body During operation when engine oil temperature is 80 C engine oil
41. in until the fault has been eliminated 4 After the engine is started immediately release the pushbutton and then turn the ignition switch to another position to switch on the charging circuit of the generator to make charging In addition immediately adjust the throttle and observe tachometer and make the engine to be idling and check if it is running normally and if any abnormal sound with special attention being given to whether the engine oil pressure is normal Then pull the speed governing handle little by little so that the engine speed reaches 1800 2000 r min thus the engine is warmed up with no load 5 When the ambient temperature is lower than 0 C and it is difficult to start the engine perform air intake pre heating for 20s Once the engine is started successfully the pre heating should immediately be stopped 4 Running of engine 1 The engine can work with load only when the temperature of cooling water reaches 50 C and temperature of engine oil reaches 40 C However when running with the declared power the water out temperature should reaches approx 80 C 2 Increase decrease of loads or speed should be gradual and little by little and usually an abrupt increase decrease of loads or speed is not permitted 3 When the engine is running it is necessary to give attention to whether or not the indications of gauges on gauge board are normal Attention should be given to exhaust color and running sound and sto
42. inder jacket to the cylinder cover Worked cooling water all flows from the front end of cylinder cover via thermostat and water out pipe then back to heat radiator When water out temperature is lower than 70 C the thermostat will 33 off the cooling water flows through small circulation pipe without through heat radiator and directly enters into water pump Thus the small circulation in body is realized When water out temperature is higher than 70 80 C thermostat will be full on and at this moment cooling water flows via the thermostat to the upper water chamber of heat radiator and flows along flat copper pipe to the lower water chamber of heat radiator During this course cooling water is cooled by the fan Thus the big circulation is realized Heat radiator is preferred to be Model BJ130 with a heat dissipation area of 10 62 m2 Depending on use the air fan can be of air suction or exhaust type Distance between end face of fan and heat radiator is preferred to be 45mm When water temperature is too low in winter it is possible to be able to invert the arrangement of blades converting air suction to exhaust type facilitate heat preservation for engine Where it is very hot or when water temperature is too high in summer the thermostat can be removed to increase the flow rate of cooling water and raise heat dissipation efficiency 2 Water pump The water pump is of centrifugal type Its water in chamber is at
43. k if filled full with diesel oil and check fuel pipelines if fluently and unclogged and each fuel pipeline Joint if any leaks and open the valve s of fuel tank 13 6 Check the storage battery if full Check each terminal electrical system if wired correctly and reliably 7 Check each accessory of engine if connected reliably fuel injection pump fuel transfer pump diesel oil filter water pump fan charging generator and its support fan belt starting motor engine oil filter and heat radiator etc 3 Starting of engine 1 Set the speed governing handle at mid speed position 2 Loosen the air discharging screw of engine filter and push the hand pressured fuel transfer pump to remove the air in fuel system In case the engine is new or has not been used for long time which means substantial amount of air exists in the fuel oil system loosen the air discharging screw of fuel injection pump and continually push the hand pressured fuel transfer pump to remove the air in the system For engines often being used this procedure is not necessary 3 Turn the ignition switch to start position and push the starting pushbutton to start the engine If the engine does not start release the pushbutton and re start it 2 3 minutes later If such operation bas been performed consecutively for three times and the engine still does not start then it is necessary to check if any fault and if so the engine should not be re started aga
44. l supply advance angle must be adjusted appropriately Correct fuel supply advance angle should be 16 1 before top dead center Adjusting procedure of fuel supply advance angle is as follows 1 Remove the air in fuel oil system Turn the crankshaft repeatedly to make fuel injection pump to be filled fully with fuel oil Remove high pressure oil pipe in first cylinder and blow off the leftover fuel oil inside the joint hole on fuel discharge valve seat Turn the crankshaft slowly on positive direction paying attention to the fuel level inside joint hole As soon as the fuel level begins fluctuating immediately stop turning the crankshaft 2 Check if the top dead center mark on sight window of flywheel casing 18 aligned with the scale on flywheel or the scale on crankshaft pulley and if conforms to best angle degree specified above 3 If the advance angle is too small loosen the nuts on the three kidney shape openings in fuel injection pump seat and turn the fuel injection pump inwards the engine body Contrarily if the advance angle is too big it can be turned outwards 39 Adjustment of fuel injector Testing and adjustment for fuel injector should be performed on a tester The purpose is to adjust the fuel injecting pressure and eliminate faults If fuel injecting pressure inside the oil injector is too high or too low fuel injection is abnormal and part s is damaged when the engine runs faults will occur such as the oc
45. lve guide for wear off conditions and inspect valve if stuck and inspect valve sealing surface If necessary replace part s and grind the valve 10 See III of this chapter 11 Camshaft is camshaft can possibly replaced severely worn The 12 Replace the copper washer and clean seat hole surface and tighten uniformly the nuts on pressure plate of oil injector 13 Tighten tightening torque them as per specified 44 Trouble causes Remedial methods V Abnormal sound 1 Fuel supply advance angle is too big and metal knock rhythmic sound can be heard from inside of cylinder 2 Oil nozzle drips oil and needle valve is jammed causing the sound like ta ta ta 3 Valve clearance too big and clear and rhythmic knocking sound 4 Piston collides with valve causing heavy and rhythmic knocking sound if put a hand at nut on cylinder cover vibration can be felt 5 Piston collides with the bottom of cylinder cover causing heavy and strong knocking sound 6 Valve spring is broken valve push rod is bent valve tappet is worn off causing valve mechanism to produce slight knocking sound 7 Sound due to too much gap between piston and cylinder jacket This sort of sound will be reduced with the engine being warmed up 8 If connecting rod bearing gap is too big when speed is abruptly reduced heavy and strong knocking sound can be heard 9 Gap between connecting rod bush and piston
46. modification the diesel engine you purchase in the future may somewhat deviate from this Manual When ordering engine accessories please tell us the Model declared power and speed order No month and year of manufacture and serial No of the diesel engine s you purchased so that our company can provide you with correct accessories FAW Jiefang Automotive Company Ltd Wuxi Diesel Engine Works August 2006 Written by Zhai Yonghui Huang Qiwei Yang Xueming Reviewed by Wang Xinze Li Peiran Yao Zugen Users Dear Users When new diesel engines or engines just subjected to an overhaul e g main parts such as piston crankshaft or connecting rod etc are replaced are used on automobiles the automobile must not run at normal or heavy load condition until it has run for a wear in distance of 2000 km in which engine speed should be no more than 2200 r min and power should be 70 of full load This is very important to the reliability and after overhaul service life of the engine 4DW engines will bring you more economic effectiveness if you timely maintain them as per this Manual Contact phone numbers of our Works are as follows Sales Company 0510 85013436 fax Main engine dept 0510 85014990 8362 8363 Accessories dept 0510 85014990 8370 85010814 Service dept 0510 85014990 8372 8373 FAWDE 24h hotline 0510 85017315 Production License No 06 002 00014 FAW Jiefang Automotive Company Ltd Wuxi Diesel Engin
47. n oil duct engine oil pressure at declared working condition 196 441 2 4 5 kPa Engine oil pressure when idling kPa no less than 98 4 Tightening torque for important bolts N m or kgf m 1 Bolts connecting rod 60 70 6 7 2 Bolts cylinder head 118 137 12 14 3 Bolts on main bearings 120 140 12 14 4 Bolts on flywheel 110 130 10 12 5 Starting bolts 110 130 10 12 5 Lube oil capacity L 7 kw Pe C Tr glkW h ge 518 452 386 320 262 254 246 238 LA E S III j m Meraba External characteristic curve of 4DW engines 1 External characteristic curve of 4DW81 46 B01 a Nm Me RB Bosch kg h Gt 2 External characteristic curve of 4DW81 50 B05 37kW 3200 r min _ Lp r min uu MER LEN AN Chapter II Operation IL Precautions 1 When using the diesel engine it is necessary to make adjustment and maintenance as per this Manual 2 When the engine is cold started pre heating is necessary Pre heating time should be 20s 30s and no more than 40s 3 The starting motor should be used at one time no more than a duration of 5s Interval between every two starting operations should be more than 2min 4 New diesel engines or engines just subjected to an overhaul must not work at high speed or at full load until they hav
48. njector drips oil pull rods shifting fork screw is loosened 2 Gap between shifting fork and adjusting arm 18 too big steel ball sliding disc is worn and dent s occurs 3 Too much axial moving clearance of fuel injection pump camshaft 4 Sleeve of sliding disc is jammed 1 Make the flow rate uniform repair or replace oil nozzle needle valve couple secure shifting fork screw 2 Replace them 3 Adjust it with copper shim 4 Clean repair or replace it XII Engine oil raised high 1 Cylinder jacket water seal ring is damaged 2 Cylinder jacket gasket leaks water 3 Cylinder cover or engine body leaks water 1 Replace the ring 2 Replace the gasket 3 Inspect and replace it 47 Annex Fit Clearance Table 4 Fit clearance for Allowable i Names Standard size Fit category assembly of new engine clearance limit 0 090 Conn Rod bush Shaft 32 0 050 Conn Rod small end hole Hole 32 40 025 0 Interference 0 025 0 090 0 05 0 082 0 Shaft 28 0 009 Hole 28 40 033 0 020 Piston pin Conn Rod bush 0 Shaft 28 0 009 Hole 28 40 009 0 Piston pin Piston pin s hole 0 Ist piston ring 2 5 0 012 End face clearance 0 21 Piston ring groove 2 5 0 070 30 050 0 2 5 0 012 2nd piston ring End face clearance 0 03 0 062 0 18 2 5 0
49. or preventing the fuel injection pump and plunger from being earlier worn off 2 Engine oil specification Correct selection of engine oil directly helps ensure reliable working and prevention of parts from being abnormally worn off A natural air intake type engine should use oil of Class CC or Class CD while a supercharge type engine should use oil of Class CD In addition selection of engine oil brands also bases on engine s operating ambient temperature see Table 2 2 For example 15W 40 oil should be selected for Class CC or CD when ambient air temp is 15 C 11 If ambient temperature occasionally exceeds its limit only starting performance will affected and the engine itself will not be damaged Engine oil should be kept clean free of pollution by dust or impurities After the engine oil is added it is necessary to inspect the oil level inside the crankcase sump as follows pull out the oil dipstick and clean it with gauze then insert it back pull it out again and inspect if the oil level indication is between the upper limit and lower limit The oil level should at any time be no lower than the lower limit on oil dipstick Table 2 2 Relations between engine oil brands and suitable lowest temperature Oil brand 5W 30 10W 30 15W 40 20W 40 30 40 Engine s operating ambient temp 25 20 15 10 5 gt 25 For ensuring that the diesel engines properly operate and have a longer service life as well as
50. ot have a storage battery it When the engine is running it is necessary to give attention to the value of charging current If it is near O it indicates that the battery has fully been charged and the charging circuit can be turned off When measuring the electrolyte of battery metal rod is prohibited to be used to prevent it from reacting chemically with the electrolyte Only when distilled water is not available can the boiled water rainwater and snow water after precipitated to remove impurities be added Use of well water and river water is strictly prohibited In winter it is necessary to add water when the engine is running and the battery is being charged to avoid freezing caused by uneven and un uniform mixture of water and electrolyte When in daily use the plug cover of battery should be screwed and tightened venting hole 36 the cover should be kept un clogged battery outer surface should be clean After discharging the battery must be re charged within 24h to avoid sulfuration on plate electrode and long time delay is prohibited If the battery needs be stored for long time then it should firstly be fully charged 1 Battery should be so charged that inside it air bubbles occur Later the battery should be re charged once a month When the battery is being stored never pour out the electrolyte 2 Charging generator It is a silicon rectified shunt excitation generator
51. p the engine for inspection if abnormal conditions are found 5 Stoppage of engine 1 Before stoppage load on the engine should be gradually reduced and speed should be reduced to approx 800 r min so that the engine idles Only until discharging water temperature decreases to below 70 C can the engine be stopped by using the stoppage handle 2 When the ambient temperature is lower than 5 C in winter if the water temperature is lower than 60 C after stoppage open the water discharge valves on engine body and heat radiator to drain away the cooling water and prevent a frost crack The discharge of water is unnecessary if anti freeze has been added into the water 14 Chapter III Maintenance To prolong the service life of the diesel engine following maintenance procedures should be followed I Daily care 1 Check the engine oil level in the crankcase sump if it is between the two scale marks and close to the upper scale mark For an engine that is new or has not been used for long time after the engine oil is filled to the upper scale mark run the engine at a low speed for 5 10 min then stop it and measure the oil level with the oil dipstick 2 Check the water amount in the heat radiator 3 Check the engine oil level in the speed regulator of fuel injection pump and add oil to specified position if found insufficient 4 All oil water and gas leakage in the engine should be eliminated 5 Check each part device on the
52. pressure is 200 400 kPa 2 4 kgf cm2 Lowest pressure at idle should be no lower than 98 kPa 1 kgf cm2 2 Engine oil filter 32 filter periodically be replaced filter is equipped with safety valve case of clogging open the safety valve to let oil enter into main oil passage but this will make it lose filtering effect Therefore it is necessary to periodically clean and replace the filter element as requirement in Maintenance 3 Oil drain screw plug This screw plug is located at lower right bottom in crankcase sump Each time engine oil is changed remove the screw plug drain completely the oil then clear up the iron filings impurities Before adding engine oil it is necessary to check the oil drain screw plug if oil leakage IX Cooling system Cooling system is of forced circulation loop water cooling type Cooling system includes heat radiator water pump air fan thermostat and wind guide hood etc 1 Cooling water passage See Fig 15 1 Heat radiator 2 Thermostat 3 Air fan 4 Water pump 5 Water in pipe Fig 15 Cooling system Cooling water in heat radiator is pumped by the water pump into main water passage and directly enter into the cylinder cover Then via water in guide one branch of it firstly cools the triangular area of valve and combustion chamber while the other branch enters tangentially the outer area of cylinder jacket and then enters around cyl
53. r cover gasket and tighten the bolts on cylinder cover 4 Replace it clean it adjust it 1 Put some water into the cooling system Start after pre heating Use engine oil with brand specified 2 Inspect repair or replace it 42 Trouble causes Remedial methods II Abnormal engi ne oil pressure 1 No or little pressure for engine oil 1 Engine oil level too low oil deteriorates or is thinned 2 Oil pipe is broken pipe joint not tight enough causing oil leakage engine oil pressure gauge is damaged 3 Engine oil pump pressure adjusting spring is deformed or broken 4 Engine oil pump has too much clearance 5 Engine oil pump gasket is broken 6 fit clearance between bearings is too much 7 Oil passage screw plug is loosened and leaks 2 Engine oil pressure too high 1 Engine oil pump s pressure limiting valve does work abnormally oil returning does not go smoothly 2 Air viscosity too higher temperature too low engine oil 3 Rocker arm cannot be added engine oil 1 Upper oil hole at support bottom of rocker arm shaft cylinder head oil passage are clogged 1 Add the oil change the oil 2 Weld tighten or replace it 3 Replace it 4 Return it to factory for repair replace it 5 Replace it 6 Inspect adjust or replace it 7 Inspect it block it 1 Inspect and adjust it 2 Use engine oil with brand specified decre
54. ry 15 10 Check the battery for its voltage Specific gravity of electrolyte should be 1 28 1 29 atmospheric temperature is 15 C and should normally be no less than 1 27 Additionally check if the electrolyte level is 10 15mm higher than plate electrode and if sufficient distilled water should be supplemented 11 After running every 200h or according to water muddiness turbid ness change the cooling water Take out the thermostat and fit the lid of thermostat water out pipe and start the engine and change ceaselessly the speed so that the cooling water flow fluctuates flushing the deposit in cooling system Then open the water discharge valves on heat radiator and engine body to discharge the water and stop the engine Inject continually clean water via radiator inlet and start the engine and have the engine idle so that the water flows Timely inspect the quality of the water discharged through the discharge valve and after found clean close all discharge valves and stop the engine and fit back the thermostat 12 When parts that have been removed for maintenance are fit back it is necessary to ensure their correct position and reliability Maintenance after running for every 500h In addition to the instructions in Maintenance after running for every 100h followings should also be performed 1 Check injection pressure of fuel injector and observe atomization quality and if necessary clean and adjust it 2 C
55. s fitted other retaining ring should be fitted 4 Connecting rod and its bush The body of connecting rod has a cross section of I shape The connecting rod and connecting rod cap are pair bored Therefore they should be fitted as per pair marks and do not make mistake In the hole of small end of connecting rod bronze bush is press fitted Oil hole on the bush must be aligned with the oil hole above the small end to ensure splash and lubrication onto the piston pin and bush When clearance due to wear off of the bush exceeds limit value or when serious stripping or burning occurs on the surface replacement with a new pair should be made When the engine is overhauled or when the connecting rod is replaced with a new one it is necessary to check the parallelism of axes of small end hole to big end hole The parallelism should be no more than 0 03mm for 100mm at vertical direction and be no more than 0 06mm for 100mm at horizontal direction Correct it if above mentioned values are exceeded Before the assembly of piston and connecting rod is fitted into or removed from cylinder jacket it is necessary to scrape completely the soot and oil dirt at upper part of the jacket Before it is fitted it is necessary to apply some clean use engine oil on cylinder jacket opening outer surface of the piston and the surfaces of piston ring rod bush and crankshaft rod journal etc Then place the guide sleeve onto the cylinder jacket Turn the crank
56. scrub the needle valve couple and metal pieces are prohibited for this purpose If the needle valve and valve body are not smooth or active enough it is possible to adjust it by grinding it with clean kerosene When pair grinding them the needle valve should not collide with the valve body seat surface After the grinding carefully clean them with no dirt leftover 3 Protruding distance The distance between injector head end and the bottom plane of cylinder cover should be 3 0 25 mm Adjustment if necessary be made with 0 2 mm copper shim IV Fuel injection pump The fuel injection pump has been adjusted and inspected before delivery Re adjustment if necessary should be made on a test stand specially for fuel injection pump with standard fuel injector and standard length high pressure fuel pipes on it For specific parameters for adjustment please refer to relevant instructions for fuel injection pump Chapter VI Troubles amp Troubleshooting Trouble causes Remedial methods I Engine does not start 1 Low starting speed 1 Battery runs low or connecting terminals are loosened 2 Starting motor s carbon brush contacts poorly with commutator 3 Starting motor s gearwheel cannot nest the gear ring of flywheel 2 Abnormal fuel system 1 No fuel oil in the fuel tank or valve of the tank not open 2 Air in fuel system water in diesel oil oil leaks at joints 3 Fuel passage clo
57. shaft and carefully put the assembly of piston and connecting rod into the cylinder jacket Tighten the bolts on the rod one by one in several times as per specified tightening torque value After tightening the bolts the crankshaft should be able to rotate freely and smoothly if turned by hands IV Crankshaft amp flywheel 1 Crankshaft At the front end of crankshaft is fitted crankshaft timing gear engine oil pump drive gear crankshaft pulley At the rear end of crankshaft is fitted with the bearing and flywheel positioned by positioning pin s and secured by 6 bolts on flywheel tightened as per specified tightening torque The bolts on flywheel are prevented from being loosened by 3 locking pieces At the center of flange is fitted a E60203 bearing for supporting the drive shaft of gearbox On the crankshaft pulley is marked scale line used to watch the fuel supply advance angle On the cover of timing gear chamber is fitted an indicator used to indicate the degree of fuel supply advance angle 23 2 Flywheel Outer ring nests gear ring Scale line used to watch the fuel supply advance angle is marked on the flywheel On the flywheel it is prohibited to directly install a machine which is towed transversely by pulley otherwise the main bearing can be damaged Bearing seats should be added and fitted onto the two ends of the pulley if user needs to use the transversely towed machine V Camshaft 1 Camshaft Th
58. tion amp splash lubrication 19 Starting mode By electricity Overall dimensions excluding clutch 20 696 X 492 X 650 housing L x W x H mm 21 Net weight kg 205 Note Declared power denotes the power under atmospheric pressure of 100kPa 750 mmHg ambient temperature of 25 C and relative humidity of 30 and without air filter and When atmosphere condition is different from standard atmosphere check calculation should be made per GB T6072 1 2001 Performance of Reciprocating Internal Combustion Engine Part 1 Declaration and Testing Methods of Standard Basic Information Power Fuel and Engine Oil Consumption Main technical data 1 Valve timing Intake valve opens 12 2 before T D C Intake valve closes 38 2 behind B D C Exhaust valve opens 50 2 before B D C Exhaust valve closes 12 2 behind T D C Valve lash at cold state Intake valve 0 28 0 33 mm Exhaust valve 0 28 0 33 mm T D C Intake valve opens Exhaust valve closes 244 Exhaust valve opens Intake valve closes B D C Fig 1 Valve timing diagram 2 Fuel supply advance angle 16 1 before T D C 3 Temperature and pressure values of the engine 1 Exhaust temperature At 15 minute rated power 620 At one hour rated power 550 At 12 hour rated power 500 2 Engine oil temperature lt 95 3 Water out temperature 70 90 maximum lt 95 4 Mai
59. to go back to original place Each continuous duration period for the use of starting motor must not exceed 5s Interval between every two starts should be more than 2 min If three successive starts all fail then it is necessary to inspect and eliminate faults 5 Ignition switch Ignition switch has 3 positions Middle position means the circuit s is completed cut off When turn the key clockwise turn on the starting switch and regulator now the engine can be started After the engine is started turn the key anticlockwise to the end At this moment only 37 regulator is the generator charge battery but the starting motor cannot start to avoid accidents XI Oil pressure sensor amp water temperature sensitive plug With double metal piece design internally the oil pressure sensor and water temperature sensitive plug are matched for electro thermal type meters Inside there is silver contact for conduction Gently installing the sensor is necessary because accidental vibration can cause the contact relocate resulting in failure It is preferable that the resistance be measured when installing the sensor Resistance is 8 11Q for Model 303 oil pressure sensor and 8Qfor Model 306 water temperature sensitive plug If the resistance value is measured to be 0 it means that the sensor is directly connected and indicating needle of oil pressure gauge will go to the end and the gauge can possibly be damaged If t
60. ul E d 2 gt Drive gear of engine oil pum Fig 9 Timing gear system assembly 2 Mounting dismounting of the gears Mounting dismounting of the timing gear on crankshaft needs special tools Timing gear on camshaft can be pulled out by a gearwheel puller or be pushed up by a pressing machine Clearance fit is adopted between the timing idle gear and engine body be secured with bolts Mounting of gear of fuel injection pump Gear of fuel injection pump is fitted on the coupling disc of the advancer Before dismounting the timing gear of fuel injection pump the cover of advancer should be removed then the nut s on shaft of fuel injection pump should be loosened 25 by socket wrench Take together the timing gear and the advancer and then take the timing gear from them See Fig 10 Loosen the three fixing nuts on the pad of fuel injection pump then the pump can be pulled out When mounting the timing gear of fuel injection pump be ensure that the 67 hole R34 5 aligns with the M6 hole R34 5 on the coupling disc of the advancer and joined by M6 bolt The three kidney shape openings on fuel injection pump seat are used for adjusting fuel supply advance angle When adjusting fuel supply advance angle loosen the three nuts for the three openings Then if turn the fuel injection pump towards outside of engine body the fuel supply advance angle will decrease and vice versa R34 5 R33 6 5 4 3 2 1
61. when the water temperature is 70 C or higher there is no water flowing out of water out pipe The faulted thermostat should be removed for inspection Heat the thermostat slowly in the water When water temperature reaches 70 C valve on thermostat should open and when water temperature reaches 85 C the valve should fully open If this requirement cannot be met then the thermostat should be replaced The thermostat should preferably not be removed Cooling water with a over low temperature has a negative effect on normal operation of the engine 4 Air fan It is required to inspect periodically the belt of fan as per Maintenance for its tightness or tension and adjust it if necessary 35 Tightness of the belt judeed appropriate if the belt between fan generator pulley is pressed down by hand a distance of 10 20 mm It is possible to make adjustment after loosening the bolts on generator bracket and support X Electrical system Electrical system consists of starting motor charging generator starting pushbutton and meters etc Wiring of electrical system is shown as Fig 17 1 Storage battery 2 Starting motor 3 Electric wire part 4 Ammeter 5 Ignition switch 6 Regulator 7 Charging generator Fig 17 Electrical system schematic diagram 1 Storage battery Model 6 Q 150 battery can be used new battery without being re charged needs to be charged This diesel engine when delivered does n

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