Chapter 1 General Description of Diesel Engine 1.1 Engine Model Types and Seri 1.2 Engine Performance Curves ---- 1.3 Engine Technical Performance Data. --- 1.4 Main Characteristic Data -- 1.5 Overall Dimensions of Diesel Engine -1.1 Model Types and Si N Deed Engi Niodet 4908 DrConmercial Quads Chee 7 NAME: ezhxLz67xco pane ie Fotos oteut 45.6kw — 3200Himin See moms ie a PLACEMENT. Good Engre Na a © 102006 US EPA Regula ‘ren Enghes i Rone ioe onaemen / oe HIRRE GARR A. ZHeviane The Nameplate Position: The nameplate is on the top of the cylinder head cover, Before asking for maintenance please lovk up the relative information indicated in the nameplate. or parts service, ‘The Position of Serial Number of the Block: The stamped serial number is under the left side of the exhaust pipe and by the side of the flywheel, 1.2 Engine Performance Curve 4908C490BRGC490BT C490BG1.3 Engine Technical Performance Data Forklifts soos) sone [Avon | 90506 | MRE | Jin-tine, water cooled, 4—stroke, direct injection «w_shaped Type combustion chamber (Ring -like platform combustlon chamber for A490BPG ,C490BPG) No.. of cylinders = bore = | strake (mm) lease 4-90-100 | 4-90-100 | 4-90-1085 | 4-90-105 Tutal displacement | Firing order Max. torque (N-m) Max. torque! speed (r/min) 1700-1900 Maximum mean effective pressure (k Pa) > 738.3 Min, fuel consumption at full load ( g/kW +h) Oil consumption (g/kW-h) Min, steady idle spec Direction of crank rotation viewed from flywheel end ) Noise dB(A) aidjsua] <112 |: s ait Cooling system closed cycle, forced water cooling pressured and splashed electric motor Overall dimension Length | 700 +sest | 7517565" | 751*565* width® height (mm) 1 60 =| 690 704 Nole:The rated power is the power at standard condition that means the atmospheric pressure is 1x 10° Pa (750mmIlg) ambient temperature is 25°C, relative humidity is 305 without air filter, muffler or cooling fan.a | Construe- Usage type Generators] tion nek machineries Model 4oonT | Basonr | casonr [ 4908D | C190BG in-line, water cooled, 4 stroke ,direct injection cw shaped Type combustion chamber _( Ring -like platform combustion chamber for C490BT ,C490BG) No. of cylinders — bore 90-100 | 4-90-105 | 4-90-1905 | 4-90-10 Menorca 4-90-100 | 4-90-105 | 4-90-1905 | 4-90-10 4-90-105 [Total displacem 267 [ving order ewe} 32 Tene tals a | iean | isan | asa | teat Rated speed (r/min) 2400 2400 | 2400 2500 200 Rated power (kW) 20.4 29.4 204 Max. torque (N-m) 135 152 |. toraue speed Tmin) | 1500-1680 | 1500-1700 | 500-1700 Min, fuel consumption at full Toad ( g/kW-h) Oil consumption ( 1.63 1.63 Min. steady idle speed (r/| min) 030 | 750230 Direction of crank rotati viewed from flywheel end ) Noise dB(A) 110 Cooling system closed cycle, forced water cooling Lubrication system pressured and splashed Starting device 290 Overall dimension Length | 788°726* 726" 6 soxesaie | o98*sa1* *width* height (mm) | no | n9 | 690 eres | 690 Notes:1.C400BPG, C490BT ,C490BG have got the certificate of EPA. II (U.S Environmental Protection Agency) 2.C490BPG, C490BT has got the certifieate of E-mark Ill1.4 Main Characteristic Data 1, Timing (In terms of crankshaft angle) Intake valve open: 11 °before top dead center: Intake valve close: 41°after bottom dead center. Exhaust valve open: 49°before bottom dead center. Exhaust valye close: 11’after top dead center, Cold valve clearance intake valve 0.35mm exhaust valve 0.45mm. Injection advance angle: 1012°CA(C490BPG ,C49UB I’, C490BG); 2121°CA(190BT ,490BD ,B490BT); 171°CA(490B 490BPG ,490BT A490BPG ,B490BPG) + Temperature and pressure requirements: 1), Exhaust temperature 2), Oil temperature: <368k (95°C). 3), Cooing water temperature: 357-368k (85-95 ). 4), Oil pressure at the main oil gallery: 0.2-0.44Mpa, Tightening torques for the main bolts in Nem: head bolt: 117.6-137.2. Connecting rod bolt: 98.1-117.6. Plywheel bolt: 98.1-117.6, Starting claw: 100120. Oil capacity in the oil sump-6L.1.5 Overall Dimensions of Diesel Engine 4908 Front view ( with fan) Exhaust side view Rear viewExhaust side view Rear view ( with clutch)490BT Single Pump Exhaust side view Rear view ( with clutch)490BT Double Pump Intake side view Front view (with fan) Exhaust side viewC490BT‘c490BG:Chapter 2 Operation of the Diesel Engine 2.1 Preparation for the First Operation of the Diesel Engine 2.2 Starting of the Diesel Engine 2.3 Operation of the Diesel Engine 2.4 Shutting Down of the Diesel Engine -- 2.5 Attentions for Engine Operation 2.6 Working Media2.1 Preparation for the first Operation of the Diesel Engine 1), Fil the oil Generally, there’s no off fled In the engine when it is off the line, Customer should fill the oil by hi cf crating the engine. When filling oil, please open the cover of the oil filing port on the cowl of the cylinder head first, take out the oil gange, then fill the oil and check the oil level with the gauge. Check the oil level again after 3 minutes. Oil capacity: make sure the lubricating oil level in the oil sump should be between the upper mark and lower mark on the oil gauge when the lubricating system is filled full ol. ANote! Only clean oil can be filed into engine, make sure no any deposit in the filled oil. Fuel injection pump assembly also needs to be filled with oil. The lubricating oil in the pump case should be between the upper mark and lower mark on the injection pump oil gauge. 2), Fill diesel fuel Users can choose the corresponding diesel fuel for summer or winter according to the temperatures in their local places. The position of the fuel pipe joint position is on the lower part of the injection pump. Before filling into the engine, the diesel fuel should be keep still for more than 72 hours to clear out the water and impurities. 3), Fill evolant Open the cap and the drain cock Fill the coolant to the mark of filler Close the drain cock when the coolant flows out. Screw on the cap 4), Other preparing work before starting the engine Check whether all engine mounting fasteners are in good condition and whether the control handles such as throttle, shut down handle and ete can operate smoothly. > Revolve the crankshaft several turns to check whether all moving parts can move. smoothly. > Check oil sump and injection pump for the oil level. > Check whether the radiator is full of cooling water and there is no leakage at the joints > Check whether the fuel is sufficient, fuel supply is unblocked and there is no leakage at the joints of fuel pipes. Check if the fuel cock at the fuel tank has been turned} open. 5 Check whether the battery has been fully charged and all joints between electri equipments are in good condi > Check all fixing fasteners for varions components (injection pump, fuel suppl pump, fuel filter, water pump, fan, generator and its bracket, v—belt of fan, electriq starting motor, oil filter, water radiator, > Check all joints between air filter, intake rubber pipe ¢ pipe for secu air tightness. > Check if power take off clutch is released. +16eer nt The oll level shall be between the upper and lower marked line 2.2 Starting of the diesel engine 1), Put the speed control lever at its middle speed positi 2), Loose the vent screw on the fuel filter, press the hand fuel supply pump several times to release the air trapped in the fuel system. For a new engine or an engine having stood by for a long period, where a lot of air may have been existed in the fuel system, it may he necessary to loose the vent screw on the injection pump and to press the fuel supply pump repeatedly till all the trapped air is released. If the engine has been operated frequently, this work may be omitted according to the actual situation. 3), Press the start button to start the engine. If it fails to start, the button should be released and restart it after waiting for two or three minutes. If the engine still fails to start after three consecutive attempts, the trouble cause should be found out and dealt with accordingly before starting it again, 4), The starting button should be released immediately after starting. Wateh the speedometer and adjust the speed control lever. Run the engine at 600-8S0rpm idle speed to sce if the engine is working normally. Pay special attention to the oil pressure, which should be higher than 0.05MPa. Then, speed up the engine gradually to 1800 to 2000 rpm at idle load to warm it up. 2.3 Operation of the diesel engine 1), The engine should not take load to work until the water temperature reaches 50°C and oil temperature reaches 40°C. And the rated load should not be taken until the watertemperature goes up to 80°C 2). Load and speed should he increased and decreased smoothly. Generally speaking, it is not allowed to he changed abruptly 3). During the operation of the engine, constantly watch the readings of the ganges on the control board to see whether they show normal values. Pay attention to exhaust smoke and its running sound. If any abnormal thing is found, shut down the engine and check it. 2.4 Shutting down of the diesel engine 1), Before shutting down the engine, gradually reduce its load and speed. Run the engine at idle speed until the water temperature cools down to 70°C. Then operate the shut- down lever to shut down the engine 2), When ambient temperature goes below 5° C in the winter and the water temperature goes below 60°C after shutting down the engine, open the drain cocks on the cylinder block and the radiator to drain the cooling water to avoid freezing and damaging the engine(if anti~freezing fluid has been added, it will not be necessary to do 50). 2.5 Precaution during Engine Operation 1), Operation and maintenance of the engine should be done according to Ue manual, 2), Anew engine or an overhauled engine should not work at full load and high speed It should take a running- in period of 50 hours with light load (<50% of load) and low speed(=2000rpm) before going to its normal operation. 3), Fuel should keep clean, It is recommended to keep the fuel still for one week or more to let the impurities settle down or filter the fuel with silk cloth. 4), Keep a normal water-temperature (70°C-95°C). The oil pressure should be 0.2- O.4MPa at medium speed 5), The engine should be shut down and checked when any abnormal phenomenon happens during the operation 2.6 Working Media 1, Oil Use CD grade oil SAE grade s temperature range swi30 -40— 35°C 10W/30 iswi40 -40— 10°C 20wi40 -30— 15 20/20 -40— 10°C2, Diesel fuel Customers can choose the light diesel fuel according to the actual ambient temperatures at their local plac 3, Coolant Special coolant is needed for some vehicles. In that case, use coolant according to the requirement of the vehicles. For general purposes, use cooling water which meets certain requirements. Cooling water: it's good to be rain water, tap water or clean river water. It's not good to use well water by a nich minerals in the water which will form scale deposited in the cooling system which is harmful to cooling effect and may damage the engine. It may need to add antifreeze into the cooling system to prevent water freezing in cold winter. The most common antifreeze is glycol water solution or alcohol. Filling coolant and precautions: > Fill cooling water up to the mark at the filler. > Pay attention to close the drain cock after water draining from it. > Tighten filler cap. > Start the engine, run it until it reaches normal working temperature thermostat opens and the water pipe of the major circuit apparently grows warmer. } Shut down the engine after the initial operation. Let the engine cool down and cheek the water level. AX Cantion: Be careful of not gutting burnt when you open the (ler cap while the water temperature is still high.Chapter 3. Technical Maintenance of the Diesel Engine 3.1 Maintenance Tools 3.2 Mai ce Periods: 3.3 Technical Maintenance in winter 3.4 Storage for the Eiaintenance To Valve clearance gauge Assembling and dismantling tool for spin-on filter 3.2 Maintenance Periods These maintenance periods are suitable for general situation, if maintenance is required for the vehicles (cars, forklifts, tractors and so on) the shorter maintenance period is applied. When the engine operation should meet local regulations, the maintenance periods and procedures slivuld be modified to ensure right operation A Note: Some maintenance periods should be shortened if the engine is worked in dusty environment or other rigorous conditions. Engine maintenances are classified as follows: 1. Daily maintenance 2. Grade 1 maintenance ( After 50 hours or 2500km ) 3. Grade 2 maintenance ( After 250 hours or 12500km ) 4. Grade 3 maintenance ( After L000 hours or SUUJUKM ) Interva Maintenance Items 1.Cheek the oil sump, air filter and the oil level in the injection pump. If the oil level rises, find out the cause and deal with it; if the oil is not sufficient enough, fill the oll to the specified value. Check the cooling water Ievel in de water tank and fill it if the cooling water is not sufficient enough. When the temperature goes below 5 ‘C, all cooling water shall be drained out after the engine Daily being shutting down (if there is no any antifreeze), faintenance | 3.Check and fix bolts and nuts to eliminate any leakages phenomena. Use the compressed air to eliminate the dust on the cartridge of air filter when working on the occasions with much dust 5. Clean the mud, deposited dust and smear outside of the en; Pay attention to the sound when the engine is running, Watch the exhaust smoke and deal with the caused troubles and abnormal situations.Same as the Daily Maintenance cartridge of air filter and dust bin. | Clean deposited dust on the Renew the oil in the ail filter | 1d adjust the tiglitness of fan belt | Grade1 | 4, Fill the grease lubricant to the water pump bearing ( except the shaft-conneeting water pump). 3. Check a | Maintenance | 5, Check every parts of engine make an adjustment if necessary: | vt the engine to check its operation condition after finishing the | jes and abnormal 6 with the caused tou maintenance and deal | situations. |i. Same as Grade 1 Maintenance. \"s, Renew the oil in injection pump and alr compressor. | «Clean the fuel tank, fuel pump filter sereen and pipe ey | Grade Maintenance | 6, Use the compressed air to generator. Check all the parts abnormal parts, | blow out the deposited dust in the nd deal with the troubles on the | | 7. Adjust the valve clearance and check the valve spring, 8, Check the opening pressure of injector and the atomization quality Adjust them if necessary 1. Same as Grade 2 Maintenance. 2. Clean the cooling system, and wipe off the furring, 3. Clean the oil cooler. | head. Check the leak tightness of valve and Dismantle the cylinder clean the deposited carbon. § | 6. Check eylinder head bolts, tightening torques of connecting rod and Grade 3 main bearing bolts. Ss Maintenance r 7. Check water pump (except the shaft-connecting bearing water q pump). Renew the grease lubricant and replace the water seal if a | necessary’ 8. Check the generator and starting motor. Fill the grease lubricant | 49. Check the injection pump, adjust the advance timing, and adjust the | “injection pump according to the real situation. ind the valve and clean the deposited |10.Check the air compress carbon,3.3 Technical maintenance in wint Please pay special attention fo maintenance of the engine whon the temp below 5 °C. 1, Oil and fuel for winter application should he used. Closely watch water content in the fuel to avoid fuel pipes being plugged. Ws better to fill antifreeze in the cooling system. Or the cooling water should be drained out when the water temperature goes below 40-S0°C after the engine is shut down. 3, It's better not to park the vehicle in the open air in the cold season or cold regions. Otherwise, when start the engine, it is necessary to heat up the cooling water and warm up the engine first and use the air heater. If you get these jobs done, the engine can be started in cold region Maintenance records. Signature! ature Work time Work time stamp stamp 50 3.4 Storage of the Engine 1). If the engine will not he used for a lang time, the oil, cooling water and fuel should be drained out while the engine is still warm and clean the oil sump and screen filter. 2), Do relevant technical maintenance Dismantie the intake and exhaust manifolds. Fill every cylinder with 200g clean oil which Is dehydrate treated through inlet and exhaust ports, and turn the crankshaft to make the vil uniformly adhere on the surfaces of the parts such as valves, cylinder liners and pistons, 4), Wipe away any oil, water traces and dust off the engine surfaces, Smear anticorrosion,oil on the components which are not painted. Don't smear rubber and plastic parts. 5), Outlets of water pipes, intake and exhaust manifolds and muffler should be ju by wood plugs or wrapped with plastic 6). The engine should be stored in a dry and clean place with good ventilation. It's prohibited to put chemicals near the engine. Note: In this way the engine ean he well stored for three months. Beyond this period, the above procedures should be repeatedChapter 4 Adjustment of the diesel engine 4.1 Tightening Sequence of Cylinder Head Bolts 4.2 Checking and Adjustment of Driving Belt 4,3 Notes about Thermostat 4.4 Adjustment of Starting Motor 4.5 Adjustment of Generator 4,6 Expelling Air from Fuel System 4.7 Maintenance of Air Filter 4,8 Draining Out Coolant 4.9 Renewing Spin-on Fuel Filter 4.10 Renewing Mil Filter 4.11 Adjustment of Valve Clearances 4.12 Adjustment of Injection Timing 4.13 Adjustment of Injector 4.14 Adjustment of Injection Pump4.1 Tightening Sequence of Cylinder Head Boits The cylinder head is fixed on the cylinder block with cylinder head bolts. When tightening these bolts, torque wrench should be used and the specified tightening torque value should be reached step by step following the tightening sequence shown in the figure. If the cylinder head uy been dismantled and remounted, the engine should be shut down and the cylinder head bolts should be re-tizhtened (o the specified ghtening torque as well as the valve clearances should be re-adjusted after the engine is warmed up in its first 4.2 Checking and Adjustment of Driving Belt 1), Check the whole belt and renew the broken belt . Engine should work 15 minutes after the new belt is installed and then cheek the tightoning of belt. 3). Driving belt should be kept under a certain tension status. Normally when exerting a force of 29-49N at the middle part of the belt a depressed distance not exceeding 10~ imm is recommended. Too tight belt will lead to excessive wear of bearings in generator, fan and water pump. Too loose belt will lead to drop of speeds of accessories. As a consequence, voltage from generator, air flow from fan and/or water flow from water pump will drop and normal funetion of the engine will be affected 4), Adjust tension of belt © Loosen two fixing bolts. © ‘Turn the generator to the right or left to adjust the tension of belt until it reaches an appropriate value © Tighten the two bolts 4.3 Notes about Thermostat A. Note: it's prohibited to operate an engine without a thermostat. When the temperature of the coolant through the thermostat Yeaches ahout 70%, the thermostat valve should open, and it should fully open when the temperature reaches 85 When checking the thermostat, if necessary, thermostat may be put into water and heat it up gradually, and then check the open temperature and fully open temperature of thermostat valve to see whether they are in the range specified above.4.4 Adjustment of Starting Motor The voltage of starting motor is 12v, power is 2.Skw. It is electro -m: controlled and mechanically driving. When starting an engine, put on the main switch and press down the start push button, and the engine will start to work. If it fails to start, wait till the starting pinion returns to its original position and stands still before trying the second time. 1, Before using the starting motor, check the engine, starting system circuit and the charging situation of the battery Normally, engine can start in just one attempt. The time used tp start the engine each time should not exceed 10 seconds. The time interval between 2 consecutive tries should be longer than 1 minute. It's prohibited to restart the motor while the engine and motor are still moving, otherwise severe crash will happen between pinion and ring gear. After the engine start to work, loose the push button at once and let the pinion return to its original position If the engine atill fails to start after several attempts, do gain before the trouble has been got rid of Adjustment of Generator Don't disconnect the wire from its terminal when the engine is running. Not be confused with the polarities Use compressed air to clean out dust from inside the generator after long time operation 4.6 Expelling Air from PuelSystem When the engine is working, air can enter the system under the followin; circumstances: 1, Drain out fuel from the fuel tank when the engine is stil working, 2. Low pressure fuel pipe or return pipe is broken or a joint hasn't been tightly fixed. Once the air enters the fuel system, it should be expelled before the engine begins to work Take steps as fallows: 1. Open vent plug of fuet filter, and operate the hand delivery pump till there is no ait in the fuel flowing out the vent hole. Tighten the vent plug again. Open vent plug of injection pump, and operate the hand delivery pump till there is no air in the fuet flowing out the vent plug. Tighten the vent plug sagan Maintenance of Air Filter The intake air quality is closely retated to the working environment and the size of air filter. If there is too much dust, relevant measurements should be taken. The maintenance periods should be adjusted according to the actual situation, 3. Relevant detail clean method and maintenance periods should he taken according to the requirement of the vehicle, 264.8 Draining Out Coolant ‘ANote: the coolant should not be drained when the engine fs still hot and the system is h still pressurized. It's very dangerous to drain the coolant under high temperature and hi pressure. 1. -Make sure that the vehicle or the machitie is standing horizontally. 2, Open the filling cap of the radiator. 3. Put a container under the drain cock. Open the drain cock by the side of the cylinder block to drain out coolant. 4. Open the drain plug at the radiator bottom to drain out water in the radiator. If the radiator docs not have a drain plug, just dismantle the hose from the hottom of the radiator 5, Clean the cooling system with clean water a 4.9 Renew Spin-on Fuel Filter 1 Clean the surface of the fuel filter. 4 Loose drain device at the er bottom. Drain water /fuel into a container, Dismantle the filter with special spanner shown or some other similar tools. 4. Threaded adaptor should be tightly fixed with the filter cover. Be sure to keep the inside of filter clean. 5, ‘Smear the sealing of the new fuel filter with a little clean fuel. Tightly fix the new filter on to the fllter cover 6, Expel the air in the fuel filter 4.10 Renew Oil Filter 1, Puta pan under the oil filter to collect the oil drain 2, Di ing out. nner or other similar tools. Make sure that the nantle the oil filter with special spa adaptor is tightly fixed in the filter cover 3. Clean the filter cover 3, Fill clean lubricating oil into the new filter 4, Sthear the sealing of filter with clean lubricatin, hht by hand it can be further serewed in When installing the new filter, after turning ti by only 3/4 turn, Much care should be taken when using the sparmer to avoid damaging the sealing, 6, Make sure there is lubricating oil in the oil sump. Operate the engine and check if there is leakage from the filter. After the engine stops for a while, check the oil level with the oil gauge, fill more lubricating oil if necessary. 4.11 Adjustment of Valve Clearance After repairing or technical maintenance, valve clearances of the engine should be checked and adjusted.ne method of adjusting valve clearances is as follows 1, Take off the cylinder head cover, check and fasten the bolts which hold the rocker bracket. 2, Turn round the crankshaft until the first piston is at its top dead center when the mark at the observing window on the flywheel housing is just in line with the "0"'mark on the flywheel, or the indicating pin on the gear housing cover is just pointing (othe “0” mark on the V belt pulley. = 3. Measure the intake and exhaust valve clearances of the first cylinder with a feeler gauge. Adjust them to 0.35mm and 0.5mm respectively in cold state. Then turn the crankshaft for 180° CA to adjust the other eylinders' valve clearances. Adjustment done as follows: © Take off the cylinder head cover © Shut down the engine and wait for 30 minutes before adjusting valve clearances Oil trmperature should be below 80°C. © Using the feeler gauge to check the valve clearances between @ Adjust the valve clearances in following steps: Loosen nut @ 1 2, Turn bolt® with a screwdriver and tighten nut @ to get correct valve clearances, 3 Check and adjust other valve clearances. 4 Install cylinder head cover Adjust the valves marked ¥ ia (he table. Cylinder Number 1 Valve Exhaust] Intake [Exhaust] Intake [Exhaust] Intake | Exhaust] Intake Rocker Number | 1 Compression TDC of No.l ‘cylinder Cylinder Number Valve Rocker Number 6 Compressing TDC of Nod Cylinder4.12 Adjustment of Injection Timi In order to get the lowest fuel consumption rate and good performance, it's necessary to adjust the injection timing The method of adjusting injection timing is as follows: 1, Release the air trapped in the fuel system. Repeatedly turn the crankshaft to and fro to {ill up the injection pump with fuel. Dismantle No.1 high pressure pipe. Blow away the fuel in the delivery valve adapter. Slowly turn round the crankshaft clockwise and watch the fuel in the adaptor. Stop the crankshaft as soon as the first sign of the fuel moving up is discovered. Check if the mark wl the observing window on the flywheel housing or the indicating pin on the gear housing cuver points to the right timing marks on the flywheel and V belt pulley respectively 3. If the injection advancing angle is not right, loose three M8 nuts that fix the injection pump on the gear housing, Turn the injection pump off the cylinder block if the or otherwise if too small 4.13 Adjustment of Injector The test and adjustment of injector should be done on the test stand. The purpose is to adjust the injector pressure and watch the atomization quality and deal with the troubles The steps for the adjustment of injector 1)Push the handle of the hand pump to raise the fuel pressure to I8MPa; Gradually Push the handle to turther raise to 20.3 to 20.8MPa; watch the nozzle tip to see if there is uny fuel leakage or dripping. Check, wash, or lap the nozzle precision couple if necessary, 2) Take down injector screw cap, tighten or loosen adjusting screw to get the injector Pressure to 20.3-20.8Mpa. Fix the screw cap and check again, 3) Watch the atomization quality. Do the atomization test at a speed af every 1 second each. The fuel atomization should be fine and even. No splashed fuel should be seen and uneven or deflected spray is not allowed. Clear cut sound should be heard when the injection stops. Generally, abnormal injection is caused by sluggish movement of the nozzle needle valve, fuel dripping is caused by damaging of sealing surfaces, branching of spray is aused by carbon deposit at nozzle tip or thermal de 4.14 Adjustment of Injection Pump Injection pump has been checked and adjusted before being released off the line, If there is need to re-adjust, it should be done on a special testing machine by a professional mechaChapter 5 Sketch Maps for Five Main Systems of the Diesel Engine 5.1 Fuel Syst 5.2 Lubt System 5.3 Cooling System 5.4 Gear train System: 5.5 Electrical System5.1 Fuel System Fuel tank i Low Pressure pipe x Leak-off tube Fuel Filter . F [>| Fuel injection pump High pressure pipes Lubricating System 1-Strainer 2-Oil Sump 3-Oil Pump 4-Connecting Rod Bearings 5-Oil Filter 6-Gear Irain 7-Uil Pressure Gauge 8-Valve Rocker Arms 9- Push Kods and Tappets 10- Valve Rocker Arm Shaft 11~Valves 12-Camshaft 13-Oll Galleries 14~Crankshaft ai:5.3 Cooling System of the cylinder hea ' Front of the cylinder he Thermostat Flow chart of the cooling system 4 Gear Train System 4908 ankshaft timing gear 2Injection pump timing gear 3-Timing idle gear 4-Camshaft timing gear490DP-G,A490BPG ,B490BPG ,C490BPG 1-Camshaft timing gear 2-Timing idle gear 3—Injection pump timing gear 4-Crankshaft timing gear 5 Bridge gear 6-Hydraulic pump gear 1- Hydraulic pump gear 2~ Camshaft timing gear 3- Timing idle gear 4. Injection pump timing gear 5 Crankshaft timing gear 490BT ,BA90BT ,C490BT (Single Pump)-Front hydraulic pump gear 2~ Camshaft timing gear 3- Timing idle gear 4 Injection pump timing gear $~ Rear hydraulic pump gear 6~ Crankshaft timing gear ‘490BT,RA9OBT .C490BT( Double Pump) -Preheating Plugs 5~Starting and Preheating 1 Battery 2-Starting Moor 3-Wire 4 Generator Switch 6-Amperemeter 7-Main Switch 8-Regulator 9- GChapter 6 Engine Trouble Shooting 6.1 Engine Fails to Start-- 6.2 Abnormal Oil Pressure 6.3 High Black Exhaust Smoke 6.4 Blue Exhaust Smoke 6.5 High White Exhaust Smoke 6.6 Insufficient Power 6.7 Abnormal Noise 6.8 Severe Vibration 6.9 Engine Over-Heated 6.10 High Oil Consumption 6.11 Speed Going Up Out of Control 6.12 Engine Shutting Down Automatically - 6.13 Rising Oil Level6.1 Engine fails to start Cause of trouble y ¥ aa ull in injector Valve clearance is too small 7 s leak through eylinder hhead gasket Fault in piston ring Low temperature and too oil viscosity Contact with Xinchai service ‘Check fuel supply pipe and repair delivery pump Dismantle the injector and adjust it on test stand Adjust and lap the valve Replace the gasket and fasten bolts Check and adjustlempersuercertaok warm the engine and use specified oil =| No oll reaches rocker arm, off i passage blocked in cylinder Clean and make the oil passage throt bracket ¥ [ contact with Xinchat service station6.3 High exhaust smoke Cause of trouble ‘uz chocked by carbon deposit or seized needle kal, ae or valve leak Intake pipe and air ft are blocked Contact with Xinchai (Cheek, repalr, or replace faulty parts Injection quantity of every eylinde6.4 Blue Exhaust Smoke Cause of trouble Remedies 6.5 Tigh white exhau Cause of troubl Contact with Xinchai service6.6 Insufficient power Cause of trouble6.7 Abnormal noise Cause of trouble Remedies Tov big Injection aavaneing angle resulting " n rhythmic metallic knocking sound ements and cyl 2 oF cylinder line ee Change crankshaft thrust bearing a and ,¢ heard —— Comtact with Xinchai service sta6.8 Severe Vibration ‘Cause of trouble Remedies Great aitterences between sls Wigan Check and adjust the fuel delivery, repair the nozzle, and check the compression ratio in each | leakage and compression ratio eylinder working conditions of different cylinders such as bad atomization eae ~— | ‘Check injection timing. Don't take load until engine [cote wim xn rc 6.9 Engine over-heated Cause of trouble Remedies wetoover | —— Toading, worn eritcal parts or [Find out te case of troubles pa or reajunt wrong adjustment accordingly Faulty cooling system duc to damaged water pump, thermostat ‘or fan, heavy seale deposited in enpine water jacket or radiaiun, : the cause of trouble respectively unt deat] | broken-ylinder head goskets and with accordingly Contact with Xinchai service6.10 High oil consumption Cause of trouble Remedies Low oil viscosit u Stuck ring or inversely fitted i eo | Clean oF F Check and replace related parts Reduce oll temperature; check and adjust | 6.11 Speed going up out of control Cause of trouble Remedies Governor fly-ball holder a seized at low speed position Revsie - 1 = _ = _ Governor control leve | Repair me governor and the tension rod locked at high speed position Great amount of oi enters -| Reduce the oil as mentioned above ‘combustion chamber " Xinchal service station l [cont6.12 Engine shutting down automatically Cause of trouble Remedies Seized piston oF crankshaft jo Repair ir trapped in fuel system causing chocked fuel passage, or faulty fuel Release trapped air, repair fuel supply pump or clean up fuel filter Seized delivery valve of injection pump or governor fly-ball holder, or Repair or replace broken plunger spring 6.13 Rising oil level Cause of trouble Remedies Change water seal cylinder liner ugh faulty erlinder head gasket inder head gasket Water leak theou block oF eylinder head h faulty eylinder ck and repair Seized injector Contact with Ninchai service station 44Appendix] Special Parts List 490BPG No. + par PartNo. 1 _ | oipipe i 5 |__490nPG-02100 2 | Bracket(right) | agompc-15100 3 | Braeketutty 490BPG-15200 [4 _[ Bracketcright) i 490BPG-15100-1 ~ [Brackett 2 490BPG-15200-1 ¢_| Pump timing {suse G-02003 02006 8 | Crankshaft timing ge 02007 490BPG-02009 3-16001 490BPG-16002 490BPG-16003 | 490BPG-16009 490BPG-82001 82002 490RP Washer 490BPG-82003 | Bridge pear 190 BPG-82 17 _| Bridge pea 490BPG-82004 [a8 [ear shan 490BPG-82007 490BPG-82008 490BPG-82009 490BPG-82010 42056-52001 _ [__soonpc-mor2 490BPG: $2013 490BPG-82014490BT No. | Name Fixing bracket Oil dipstick pipe Bolt ter cup to supply Fuel tube from | pump and injection pump Adjusting lever for generator | Camshaft bushing | Rear camshaft bushing Water pipe Timing idle gear Timing gear for crankshaft Camshaft timing 22 | cit sump hottom plate [eee |e 4 90BT-05500 49081-07300 4908-07800 490BT-25100 0 == 4908" 49081-07003L i Gasket 26 [Elbow Intake pipe Intake manifold gasket | Flywheel housing 30 | Flywheel housing gasket 31_| Flywheel housing plug Side bracket Cover Gear housing 36 | gasket 37 | Gasket 38 | End cap 39 | Bearing seat 40 | Air compressor plate 41 | Back plate Adapte Thermostat cover Generator bracket 490BT-09004 490BT-13001 490BT-13002 49061-13008 490BT-| 5001 490BT-160014 490BT-16002 490BT-16003 49087-16005 490BT-16013 490BT-16014 490BT-16015 490BT-16016 490BT-42011 490BT-43001 490BT~53002Part No. A490BPG A490B-03101 A490B-03109 A490B-04001 __ | _ A498B—11001 Piston Rubber pad A498B—11002 GB/T899=1988 Stud M10 50 Injector lead-off pipe 4490B-25100 AA90B-23000 Cylinder high pressure fuel tube uel injector 019103006 Copper pad 2mm) A490B-22001 Fuel injection pump | 4QUTZZ 498B-25001 Leak proof cap 498B 25002 Sebifie ductB490B Name Cylinder body Cylinder liner Piston Crankshaft Push rod Rear main bearing cover | Upper thrust bushing thrust bushing Name Piston B490B 01005 B490B-04001 B490B-05004 B490B-06003 495B—01032A 495B-01023A 495R-01026A, 495B-01022A 495B-01034A Cylinder head cover A498B-11001 Rubber pad | Fuel injection pump A498B—11002 4QT72BZAppendix? Specification af Main Auxiliaries | | Lubricating Oil Pump Rotor Elow Rate L/min Injection Pump t Injector Nozzle Hole Diameter Opening Mpa Water Pump Model L Flow Rate L/min Special Parts For C49 Injection Pump Nozzle Hole Diameter Opening Pressure JBzZS040 29 (1500r/min [Be | squsor/siwa47a Centrifugal 130 (3000r/min ) 0B cate BHAQT9ORD KBAL-POOIF — | Starting Motor || Model | Power kW Voltage V Qpy131sx || Power kW [once FISIA/JFLIA, |J | 350 L | cxz0ss Oil Fitter Starting Motor Model Power kW | Voltage V DJ1309-K Qi Charg Model Power kW Voltage V JPISIASFLIA 350 jus eeeAppendi: x 3 Outsourcing Parts list piston ring | piston main bearin rod bearing | cytnaer tiner cylinder head gasket front and reat vil seals of crankshaft | main cylinder dd, connecting rod bolts 10 11 | oil fiter 12 L Fuel filter Manufae YIZHENG SHUANG HUAN PISTON RING COxL NANJING FEIYAN PISTON RING CO.LID SHANDONG BINZHOU BOHAL PISTON CO.,LTD HANGZHOU XINDA SLMING REARING CO,LTD. SHIJIAZIUANG DIAMONDBUSH BEARING CO.,LTD HANGZHOU VALVE CO.,LTD HENANZHONGYUANENGINE FITTINGS STOCSCO.,LTD HANGZHOU CYLINDER PAD CO..LTD ZIANGSHAN CYLINDER PAD CO.,LTD. TAIZHOU HUADA MACHINE CO,LTD ANHUL COWLTD WUHU XINDA POWDERMTALLURGY | WELFU HIGH-TECHNOLOGY CO..L! SHANGHAI —RIXIN AU MANUFACTURE CO.,LTD ‘OMOBILE FITTING SHANGHAT —RIXIN FITTING MANUFACTURE CO.,LTD AUTOMOBILE