MAINTENANCE MANUAL OF ENGINE
2
4. Dismantling the alternator subassembly .................................................................... 83
5. Dismantling/installing the starter ............................................................................... 84
Chapter 6 Fuel supply system.................................................................................................. 85
1. Maintenance equipments and tools ........................................................................... 85
2. Torque requirements ................................................................................................... 85
3. Dismantling the fuel supply system............................................................................. 86
4. Assembling the fuel supply system ............................................................................. 90
Chapter 7 Dismantling/installing and adjusting the accessories ............................................. 92
1. Data and dimension .................................................................................................... 92
2. Dismantling/installing the intake pipe ........................................................................ 93
3. Dismantling/installing the exhaust pipe ...................................................................... 95
4. Dismantling/installing the gear chamber .................................................................... 97
5. Dismantling/installing the flywheel parts ................................................................. 105
Part III Inspection, Adjustment, Fault Diagnosis and Troubleshooting ........................................ 108
Chapter 1 Dynamic Inspection .............................................................................................. 108
1. Overview ................................................................................................................... 108
2. Inspecting engine oil level ......................................................................................... 109
3. Inspecting the coolant level and status ..................................................................... 110
4. Inspecting the fan and belt........................................................................................ 111
5. Inspecting the fuel system......................................................................................... 112
6. Inspecting the air intake and exhaust system ........................................................... 113
7. Inspecting the electric system ................................................................................... 114
Chapter 2 Operating principle ............................................................................................... 115
1. Valve mechanism ....................................................................................................... 115
2. Crank-link mechanism ............................................................................................... 117
3. Lubricating System .................................................................................................... 119
4. Fuel supply system .................................................................................................... 120
5. Cooling system .......................................................................................................... 121
6. Electric system ........................................................................................................... 122
Chapter 3 Inspection and adjustment ................................................................................... 129
1. Inspecting valve clearance (mm) ............................................................................... 129
2. Inspecting cylinder pressure...................................................................................... 130
3. Inspecting the engine oil pressure ............................................................................ 131
4. Inspecting fuel injection pump timing ...................................................................... 133
5. Calibration of the fuel injection pump ...................................................................... 134
6. Inspecting atomization by the fuel injector............................................................... 135
Chapter 4 Fault analysis and troubleshooting ....................................................................... 136
1. White smoke ............................................................................................................. 136
2. Blue smoke ................................................................................................................ 136
3. Black smoke or grey smoke ....................................................................................... 137
4. Insufficient compression pressure of cylinders ......................................................... 137
5. Air intake obstructed ................................................................................................. 138
6. Black smoke ............................................................................................................... 138
7. Abnormal sound from the diesel engine ................................................................... 139
8. The engine cannot be operated normally or flames out frequently ......................... 140
9. Low power ................................................................................................................. 141
10. The engine oil is mixed with water .......................................................................... 142
11. Abrupt increase in speed ......................................................................................... 142
12. Erratic operation...................................................................................................... 143
13. Engine overheat ...................................................................................................... 143
14. Abnormal coolant temperature .............................................................................. 144
15. No engine oil pressure or low pressure ................................................................... 145
16. The engine oil pressure is too high.......................................................................... 145
17. The engine oil temperature is too high ................................................................... 146
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