Service Manual For Weichai wp6 (Stage 3) PDF [PDF]

Citation preview

Service Manual for WP6 Engine



Service Manual for Engine



Outline Drawing of WP6 Non-road Three-stage Engineering Machine



Service Manual for Engine



Special Tips ●



Before operating the diesel engine, the operator must carefully read the service manual for diesel engine and operate the machine in strict line with the product service manual.



●



Fuel injection pump and fuel injector are precision parts, which should not be disassembled by the user.



●



The supercharger rotor is high-speed rotating part. When the machine is running, any movable object (such as hand, tool and cotton yarn) is prohibited to approach the turbocharger to prevent personal injury or machine damage. The rotor assembly should not be disassembled.



●



Several bolts like main bearing bolt and connecting rod bolt of the diesel engine have strict torque and number of uses, which should not be arbitrarily loosened and disassembled by the user. The connecting rod bolt is disposable bolt so it can’t be reused.



●



Fill oil or fuel with grade meeting this Manual in the diesel engine. Filter the oil or fuel by a special filter element. The fuel will be precipitated over 72 hours. Before driving, be sure to fill fuel, coolant and oil as required.



●



The diesel engine doesn’t work without air filter to prevent air entering the cylinder without filtering.



●



After cold starting of diesel engine, keep it idle running and gradually speed up. Never suddenly speed up nor keep the idle speed for a long time (3-5 min); after running at high load, never immediately stop the vehicle (except special condition), but stop the vehicle after running at low speed for (5-10) min.



●



Regularly check the coolant to prevent corrosive damage. Replace the coolant in time as per the condition. It’s prohibited to use water and coolant of poor quality as the engine coolant.



●



The repairing of electrical system components must be performed by professional technician of Weichai.



●



To prevent corrosion, the diesel engine should be sealed before delivery. The oil seal period of diesel engine is one year. For over one year, check and take necessary supplementary measures.



●



Please go to normal gas station to fill fuel of specified grade. Use three-stage special diesel oil for three-stage diesel engine. Otherwise, Weichai will assume no responsibility for any problem like excessive emission of diesel engine due to filling improper fuel.



●



In case of fault, the user must contact service state specified by Weichai Power to do disassembly and repairing. In the repairing process, be sure to use spare parts specified by Weichai Power; otherwise, Weichai will assume no responsibility for diesel engine damage caused by using the spare parts other than the ones specified by the Weichai Power.



Service Manual for Engine



Preface This series of diesel engine are high-speed diesel engine independently developed by Weichai Power Co., Ltd. and manufactured by Weichai (Weifang) Medium-duty Diesel Engine Co., Ltd. This series of diesel engine are characterized by compact structure, reliable using, good technical indicators like performance, economy and emission, quick starting, simple operation and convenient maintenance and so on. Especially the advanced emission index can reach international advanced emission standard. This Manual mainly includes attentions for use, maintenance method, common check and adjustment, common fault diagnosis and troubleshooting of WP6 diesel engine. This Manual is systematic and comprehensive, simple and practical. It should be noted that judging the fault of diesel engine is a very meticulous work and requires certain knowledge and experience. Before finding out the basic cause, the diesel engine should not be disassembled generally; otherwise, the fault may not be eliminated, but more serious fault will be caused due to improper assembly after disassembly. Especially, for key parts like electronic control system, supercharger, etc. special instruments and equipment should be used for check and maintenance. Therefore, the user without experience and condition should not arbitrarily disassemble and adjust the diesel engine. With the continuous increasing of diesel engine varieties, any modification should be done without further notice. The user can go to http://www.weichai.com to obtain latest product information. The after-sale service of this product is uniformly granted to Weichai Power Co., Ltd. Suggestions and opinions for further improvement of product from the user are highly appreciated. December 2015



Service Manual for Engine



Contents Chapter I Instructions for Use of Diesel Engine ........................................................... 1 1.1 Outline drawing of diesel engine ................................................................... 1 1.2 Definition of diesel engine models................................................................. 2 1.3 Main technical performance parameters of diesel engine .............................. 3 1.4 Unpacking of diesel engine ............................................................................ 6 1.5 Lifting of diesel engine .................................................................................. 6 1.6 Assembly of diesel engine.............................................................................. 6 1.7 Preparation before starting the diesel engine ................................................. 7 1.8 Starting of diesel engine ................................................................................. 7 1.9 Running of diesel engine ................................................................................ 7 Chapter II Maintenance Guide for Diesel Engine ....................................................... 10 2.1 Fuel, lubricating oil, coolant and auxiliary material .................................... 10 2.1.1 Fuel ...................................................................................................... 10 2.1.2 Diesel engine lubricating oil ............................................................... 10 2.1.3 The antifreezing additive of engine cooling system should be filled as per latest revision ............................................................................. 10 2.1.4 Auxiliary materials .............................................................................. 12 2.2 Daily maintenance ........................................................................................ 14 2.3 Regular maintenance .................................................................................... 18 2.4 Long-term storage maintenance ................................................................... 22 2.4.1 Cleaning............................................................................................... 22 2.4.2 Protection............................................................................................. 22 Chapter III Typical Faults and Troubleshooting of Diesel Engine ............................. 24 3.1 Diagnosis method ......................................................................................... 24 3.2 General fault causes and solutions of diesel engine ..................................... 26 3.2.1 The diesel engine is unable to start ..................................................... 26 3.2.2 The vehicle stops right after startup .................................................... 26 3.2.3 Underpower ......................................................................................... 26 3.2.4 Large fuel consumption ....................................................................... 28 3.2.5 Black smoke in the exhaust gas .......................................................... 29 3.2.6 White and blue smoke in the exhaust gas ........................................... 29 3.2.7 Too much oil at the air inlet and intake pipe of supercharger ............ 31 3.2.8 Unstable speed ...................................................................................... 31



Service Manual for Engine



3.2.9 Too low oil pressure ............................................................................ 31 3.2.10 Too high temperature of cooling water .............................................. 33 3.2.11 Fast abrasion of parts .......................................................................... 33 3.2.12 Big noise ............................................................................................. 34 3.2.13 The starter motor doesn’t work........................................................... 35 3.2.14 Starting motor is short of power ......................................................... 35 3.2.15 The generator fails to completely generate electricity ....................... 35 3.2.16 Insufficient charging of generator ...................................................... 37 3.2.17 Unstable charging current ................................................................... 37 3.2.18 Excessive charging of generator ......................................................... 37 3.2.19 There is abnormal noise from the engine ........................................... 37 Chapter IV Disassembly and Assembly of Engine ..................................................... 40 4.1 General ......................................................................................................... 40 4.1.1 Danger signs ........................................................................................ 40 4.1.2 Safety signs.......................................................................................... 41 4.1.3 Tools used............................................................................................ 43 4.1.4 Attentions for health protection ............................................................ 43 4.1.5 Environmental protection measures .................................................... 44 4.1.6 Attentions for disassembly and assembly of engine ........................... 44 4.2 Cylinder head assembly ............................................................................... 45 4.2.1 Disassembly and assembly of cylinder head assembly ....................... 45 4.2.2 Disassembly, check, maintenance and assembly of cylinder head cover assembly ...................................................................................... 46 4.2.3 Disassembly, check, maintenance and assembly of cylinder head assembly ........................................................................................................ 48 4.3 Body assembly ............................................................................................. 53 4.3.1 Disassembly, check, maintenance and assembly of body assembly... 53 4.3.2 Disassembly, check, maintenance and assembly of body component 56 4.3.3 Disassembly, check, maintenance and assembly of front wall cover . 57 4.3.4 Disassembly, check, maintenance and assembly of flywheel housing60 4.3.5 Disassembly, check, maintenance and assembly of oil pan ................ 62 4.3.6 Disassembly, check, maintenance and assembly of piston nozzle ..... 63 4.3.7 Disassembly, check, maintenance and assembly of thrust plate .......... 64 4.3.8 Disassembly, check, maintenance and assembly of front and rear oil seal ................................................................................................... 65



Service Manual for Engine



4.4 Crank-connecting rod mechanism.......................................................... 67 4.4.1 Disassembly and assembly of crank-connecting rod mechanism ....... 67 4.4.2 Disassembly, check, maintenance and assembly of piston-connecting rod assembly .................................................................... 68 4.4.3 Disassembly, check, maintenance and assembly of crankshaft ........... 71 4.4.4 Disassembly, check, maintenance and assembly of flywheel and gear ring ......................................................................................................... 75 4.4.5 Disassembly, check, maintenance and assembly of torsional damper, crankshaft pulley and hub .............................................................................. 76 4.4.6 Disassembly, check, maintenance and assembly of crankshaft bearing bush ................................................................................. 77 4.5 Valve mechanism ......................................................................................... 80 4.5.1 Disassembly and assembly of valve mechanism .................................. 80 4.5.2 Disassembly, check, maintenance and assembly of camshaft assembly ......................................................................................... 80 4.5.3 Disassembly, check, maintenance and assembly of rocker arm and rockshaft ............................................................................... 83 4.5.4 Disassembly, check, maintenance and assembly of tappet and push rod ......................................................................................................... 85 4.5.5 Disassembly, check, maintenance and assembly of valve ................... 86 4.6 Intake and exhaust system ............................................................................ 88 4.6.1 Disassembly and assembly of intake and exhaust system.................... 88 4.6.2 Disassembly, check, maintenance and assembly of intake pipe ......... 89 4.6.3 Disassembly, check, maintenance and assembly of exhaust pipe ...... 90 4.6.4 Disassembly, check, maintenance and assembly of supercharger system ...................................................................................... 91 4.7 Fuel system ................................................................................................... 95 4.7.1 Disassembly and assembly of fuel system .......................................... 95 4.7.2 Disassembly, check, maintenance and assembly of fuel injection pump ........................................................................................ 96 4.7.3 Disassembly, check, maintenance and assembly of high pressure oil pipe ..................................................................................... 98 4.7.4 Disassembly, check, maintenance and assembly of fuel injector ..... 100 4.7.5 Disassembly, Check, Maintenance and Assembly of Fuel Filter ....... 101 4.7.6 Disassembly, check, maintenance and assembly of



Service Manual for Engine



low-pressure oil pipe ................................................................................... 103 4.8 Cooling system ........................................................................................... 103 4.8.1 Disassembly and assembly of cooling system .................................. 103 4.8.2 Disassembly, check, maintenance and assembly of fan.................... 105 4.8.3 Disassembly, check, maintenance and assembly of water pump ...... 106 4.8.4 Disassembly, check, maintenance and assembly of thermostat ......... 107 4.10 Starting system ........................................................................................... 108 4.10.1 Disassembly and assembly of starting system .................................. 108 4.11 Vehicle accessory system ........................................................................ 109 4.11.1 Disassembly and assembly of vehicle accessory system ................. 109 4.11.2 Disassembly, inspection, maintenance and assembly of generator .. 110 Appendix A DTC Table ............................................................................................ 120 Appendix B Fit Clearance of Main Parts of Diesel Engine ...................................... 191



Key components and points in the assembling of WP6 series engine ASSEMBLING OF CYLINDER LINER Technical requirements： The cylinder liner should be higher than the upper surface of the cylinder block by 0.05~ 0.10mm. ASSEMBLING OF NOZZLE Technical requirements： Tighten the hollow bolt of nozzle with a torque of 10~15N.m； ASSEMBLING OF CYLINDER HEAD AND VALVE MECHANISM Technical requirements The clearance between tappet and tappet hole should be 0.025～0.089 ASSEMBLING OF CAMSHAFT Technical requirements： Tighten (strength is 10.9) the fastening bolt of camshaft thrust plate with a torque of 29-35N.m. Check if the rotation of camshaft is blocked. Feel its axial clearance manually. The axial is 0.1-0.4mm. ASSEMBLING OF CRANKSHAFT AND CRANKCASE Technical requirements Pre-tighten main bearing bolts (M18,14 in total) with the sleeve 17, from the middle to the ends .Tightening torque with a torque wrench to 70N.m ,turn angle 90 °so that the torque to reach 180 ~ 230N.m Check if the rotation of crankshaft is flexible and non-blocking. Feel the crankshaft radial and axial clearance manually. The axial clearance is 0.102-0.305mm. PRE-ASSEMBLING AND FINAL ASSEMBLING OF PISTON Technical requirements： Technical requirements of pre-assembling： The oil ring opening and internal spring opening of the oil ring can not overlap. When assembling the oil ring, the surface marked ”Top” on the two air rings (Trapezoidal ring is on the upper side, tapered ring is on the lower side) should be upward； The angle between the first air ring and the piston pin hole is 30°, the angel among three gas rings is 120°； Connecting rod big end opposites to the piston gap, the angel between piston retainer ring and vertical direction of piston should be 45°） Technical requirements of final assembling Matching number of connecting rod body of connecting rod big end and connecting rod cover should be consistent； Connecting rod bolt （M14×1.5，only be used once）, the first tightening torque is 30N·m，the second turn angle is 60±5°，the last torque should be within the scope of 85~135N·m； Piston assembling order is 3-4-1-6-2-5 ASSEMBLING OF THE FLYWHEEL AND FLYWHEEL HOUSING Technical requirements Technical requirements of assembling flywheel housing: USE 19#socket wrench and 510flat glue。 The tightening order of flywheel housing bolts is shown as the number in right figure, tightening



torque is 110~140N·m，this bolts can be reused twice； Technical requirements of assembling flywheel: Tighten the flywheel bolts diagonally, the first tightening torque is 60+20N·m，and then turn 90°±5°respectively，the torques reach 230~280N·m at same time. Specification of flywheel bolt: M14×1.5（9 in total） ，can be repeated twice. ASSEMBLING OF GEAR CHAMBER Technical requirements： 1）Smear 510 flat glue on mating face of gear chamber and engine block. 2）Adjust asymmetric clamp of the timing gear chamber ; after justification tighten the bolts, torque is 55-60N.m 3）Intermediate gear bolts , tighten symmetrically to 65~70N·m. 4）Turn crankshaft to top dead center of No.1 and No.6 cylinder whenassembling，and align OT line to install; "0-0" on the camshaft timing gear and the crankshaft timing gear "0" corresponds; The crankshaft gear 0 point and intermediate gear 0 alignment. Inspection after assembling: Check the backlash of the circular tooth after assembling timing gear and intermediate gear, among which, the backlash between timing gear and intermediate gear is 0.015-0.33mm ASSEMBLY OF LUBRICATING OIL PUMP Technical requirements： The tightening torque of two bolts（one is M10×55 ，one is M10×30）is 44~58N·m。 ASSEMBLING OF OIL PAN The sealing gasket should be smooth and not distorted. Cross-symmetrically tighten the oil pan bolts and the torque is 22-29N·m ASSEMBLING OF CYLINDER HEAD AND VALVE MECHANISM Clearance between exhaust valve stem and valve guide is 0.3~0.35mm, clearance between intake valve stem and valve guide is 0.2-0.25mm ASSEMBLING OF CYLINDER HEAD The cylinder head gasket should only be used once and must be replaced in case of repair. Tightening order of main bolts: The first tightening torque is 30+5Nm，the second turn 120°clockwise，and turn 90°clockwise in the third time, the torque should be in the range of 240-340Nm； ASSEMBLE THE ROCKET ARM SEAT TO ADJUST VALVE CLEARANCE The clearance between rocket arm and rocket arm shaft is 0.012～0.066mm； Tightening torque of rocket arm seat is 98+10N·m； Tightening torque of hexagon head bolt in cylinder head cover is （22～29）N·m Adjustment of valve clearance: Turn the flywheel to make the No.1 cylinder in outbreak position according to rotating directing of crankshaft, adjust intake valves of No.1, No.2 and No.4 cylinder and exhaust valves of No.1, No.3 and No.5 cylinder successively. Intake valve clearance is 0.20-0.25mm. Exhaust valve clearance is 0.30-0.35mm. Adjust nut torque:（30～45）N·m，turn crankshaft 360°according to rotating direction of crankshaft, and adjust the remaining rocket arm clearance； ASSEMBLING OF WATER OUTLET PIPE, INTAKE AND EXHAUST PIPES Technical requirements：



Smear MoS2 on the sealing ring of exhaust pipe. The tightening torque is 45~50Nm. Bolts not in this range should be replaced ASSEMBLING OF SHOCK ABSORBER AND PULLEY Technical requirements： The torque of crankshaft connecting bolt and pulley is 60+5N·m；



Service Manual for Engine



Chapter I Instructions for Use of Diesel Engine 1.1 Outline drawing of diesel engine



Fig. 1.1-1 View I of WP6 Diesel Engine



Fig. 1.1-2 View II of WP6 Diesel Engine



1



Service Manual for Engine



Fig. 1.1-3 View III of WP6 Diesel Engine



Fig. 1.1-4 View IV of WP6 Diesel Engine



1.2 Definition of diesel engine models



2



Service Manual for Engine



Variant code Emission stage Power code Usage code Product series code



1.3 Main technical performance parameters of diesel engine Table 1.3-1 Main Performance Parameters of Three-stage Electronic Control Diesel Engine WP6 for Engineering Machine (Excavator) Item



Unit



WP6



Engine model



Air



intake



way Displacement Cylinder bore×Stroke Number



of



cylinder Number



WP6G175E301 —



Engine type



Model WP6G190E301



Four-stroke, water-cooling, in-line, direct injection, wet cylinder sleeve, high-speed diesel engine



—



Supercharged and inter-cooling



L



6.75



m×m



105×130



—



6



—



2



—



18:1



—



1-5-3-6-2-4



—



Electronic control pump



of



valve for each cylinder Compression ratio Ignition order Fuel injection device Rated power



kW



129



140 3



Service Manual for Engine Rated speed Maximum torque Maximum torque speed Emission level



r/min



2000



2000



Nm



760



860



r/min



1300-1500



—



Non-road three-stage



4



Service Manual for Engine



Fuel consumption rate at rated



g/(kW·h)



≤250



g/(kW·h)



≤210



g/(kW·h)



≤0.5



power Minimum fuel consumption rate



at



full



load Oil consumption rate Noise at 1m B10



service



life



dB(A)



≤115



≤116



h



6000



L



16 (subject to the scale line of oil dipstick)



Lubricating oil flow in oil pan



5



Service Manual for Engine



1.4 Unpacking of diesel engine After opening the packing case of diesel engine, the user should firstly count the diesel engine and its accessories as per the factory packing list, check the diesel engine for damage and connector for looseness. And then the user should do following operations: (1) Wipe antirust coating, anticorrosive agent, etc. on the exposed part; (2) Drain seal oil in the fuel filter and fuel system spare parts (it’s allowed to start the engine with seal oil in the fuel system not discharged, but the engine operation under load is permitted only when the seal oil in the fuel system is exhausted, the normal diesel oil is supplied). Attention: the oil seal period of diesel engine is one year. For over one year, check and take necessary supplementary measures. (3) Rotate the flywheel and spray solvent in the air inlet till the seal oil in the cylinder is drained. (4) Spray solvent in the supercharger intake and exhaust hole till the seal oil is drained. (5) As per the agreement between the manufacturer and user, fill oil in the oil pan as per regulations; for delivery of oil pan, fill up oil with running-in promoter. It’s suggested that the user should drain the old oil and replace the new oil after running for 50h. (6) As per the agreement between the manufacturer and user, as per the user’s requirement, fill up coolant and check the coolant performance at unpacking. If the antifreezing ability meets -30 oC or35 oC, the PH is 7-8 (neutral) and total hardness is (5-15) d [9~15°f (hardness)], the coolant can be used. If the requirement is not met, drain the coolant and fill the coolant with antifreezing additive.



1.5 Lifting of diesel engine When lifting, keep the crankshaft centerline of engine level and it’s prohibited to incline or lift by one side. The lifting and lowering should be slow (refer to Fig. 1-5).



Wrong



Correct



Fig. 1-5 Lifting Drawing of Diesel Engine



1.6 Assembly of diesel engine



6



Service Manual for Engine Adopt flexible coupling and ensure that the crankshaft centerline of diesel engine is on the same axis with the input axis line of drive device (gearbox, transmission box or generator) and ensure that the crankshaft will not withstand the additional axial force caused by installation.



1.7 Preparation before starting the diesel engine (1) Check the coolant level If the engine is assembled on the machine, but the coolant is insufficient, open the filler cap to fill the coolant. When opening the filler cap with pressure relief valve and exhaust button, if the engine is hot, be sure to press the exhaust button to completely exhaust air and then open the cap. It’s prohibited to fill much coolant when the engine is hot; otherwise, the spare parts may be damaged due to high temperature change. When the starting engine is running (1,000 r/min), keep filling coolant till the specified position and till the liquid level is stable, finally cover the filler cap. (2) Check the fuel level If the engine is assembled on the machine, turn on the power switch and check the fuel level of fuel gauge or check the fuel tank. (3) Check the engine oil level When the oil level is between the upper and lower scale line of oil gauge, if necessary, fill oil from the oil filler. (4) Check whether the diesel engine accessories are reliably connected and eliminate abnormal phenomenon. Check whether the starting system circuit is properly connected and whether the battery is fully charged. Open the fuel tank valve, loosen the bleeder screw on the fuel coarse filter and exhaust air in the fuel system by the hand pump of the fuel pump.



1.8 Starting of diesel engine When the starting condition is available, rotate the electric key to start the diesel engine. If the engine fails to start in (5-10)s, wait for 1min and repeat above starting process. If it’s unable to start the engine for three consecutive times, stop starting the engine, find out the reason, eliminate the fault and start the engine. After the diesel engine starts, pay attention to the readings of all instruments; the oil pressure gauge shall immediately displays the pressure. Never keep the cold engine running at high speed but keep it idle running for a period of time. However, the idle running time should not be too long. Auxiliary starting device should be used for starting the diesel engine at low temperature. Operate the heating device by the relay so as to smoothly start it under -30℃.



1.9 Running of diesel engine



7



Service Manual for Engine (1) After the diesel engine starts, keep it idle running for 3min and then improve the speed to (1,000-1,200) r/min. Add some load and enter the full-load operation when the water is higher than 60℃ and oil temperature is higher than 50℃. The load and speed should be gradually increased to avoid sudden loading and unloading. (2) In the breaking-in period of 50h, the diesel engine is not suitable for working under high load. (3) Slow down for driving on the slope in time. It’s not suitable for working at big torque for a long term. The load should not be too small and the speed should not be too low, which may cause oil carry-over and other faults. (4) For normal use of diesel engine, it’s permitted to keep continuous running at rated power and rated speed. However, at 105% of rated speed and 110% of rated power, maximally 20min is permitted. After unloading, the diesel engine can stop after idle running for (1-2) min. (5) Pay attention to the following reference and check parts below: Pressure of main oil way of lubricating oil: (380~580) kPa; Oil temperature of main oil way (85~105)℃; Coolant water temperature (72~93)℃; Rear exhaust temperature of turbine≤550℃. Check the exhaust color to judge the working quality and load of fuel injector. If the smoke color is not good, stop the vehicle for inspection. Attention: When the diesel engine is working, check the diesel engine for water, air and oil leakage; if any, stop the vehicle and eliminate the fault. (6) The following feature operator of diesel engine should know: ①



The fuel consumption is low when the torque is maximum and the fuel consumption rises with the speed rising.



②



The torque reaches the best value in the medium speed (1,200-1,600) r/min of engine.



③



The engine power increases with the speed rising and reaches the rated power at rated speed.



Attention: To avoid damaging the diesel engine, when the diesel engine is working, the cable connecting diesel engine voltage regulator and battery positive pole should not be dismantled. Different from DC generator, the voltage of AC generator should not be tested by temporary grounding. (7) Attentions for running in cold weather: ①



Fuel: select the diesel oil of different grades as per different outdoor temperature in winter.



②



Lubricating oil: select lubricating oil of different viscosities as per the season.



③



Coolant: fill antifreezing additive in the cooling system and select different grades and proportion as per different outdoor temperature.



8



Service Manual for Engine ④



Starting: in winter, if necessary, adopt the auxiliary starter. After the diesel engine starts, keep it running at high speed after the oil pressure and water temperature are normal.



⑤



Battery: before cold season, be sure to check the electrolyte level, viscosity and unit voltage, if the diesel engine is not used for a long time and under low temperature, take down the battery and keep it in a warm room.



⑥



Parking: for parking in cold weather, firstly disassemble the load and keep it running at idle speed for (1-2) min. Stop the vehicle after water temperature and oil temperature are lowered. pay attention that it’s not allowed to drain the coolant with antifreezing additive after stopping. If there is no antifreezing additive in the coolant, be sure to open the water drain valve or water block at the body, oil cooler cover, radiator, water inlet, etc. to empty the coolant and prevent frost crack of engine.



9



Service Manual for Engine



Chapter II Maintenance Guide for Diesel Engine 2.1 Fuel, lubricating oil, coolant and auxiliary material 2.1.1



Fuel



Summer: 0# diesel oil (GB252) Winter: Generally -10 diesel oil is used; -20 diesel oil is used when the using ambient temperature of diesel engine is lower than -15℃; and -35 diesel oil is selected when the ambient temperature is lower than -30℃. The fuel must comply with C.6 in Annex C of national standard GB 17691-2005 (revised after June 2008).



2.1.2



Diesel engine lubricating oil



Lubricating oil capacity of diesel engine: 16L; the lubricating oil capacity is based on the mark of oil dipstick (the oil capacity for different models may be slightly different). Selection of lubricating oil: to ensure safe and reliable running of the diesel engine, please select the lubricating oil of CH-4 or high quality grade. (It’s recommended using Weichai special oil. For the first time, be sure to use special oil of Weichai Power). It’s revised as the latest form. Ambient temperature



Multigrade oil



Ambient temperature



Fig. 2.1.2-1 Drawing for Lubricating Oil Grade Selection Attention: It’s allowed to replace the low-grade oil with the high-grade oil. When changing the oil each time, replace the oil filter element!



2.1.3 The antifreezing additive of engine cooling system should be filled as per latest revision The antifreezing additive is ethylene glycol. It’s allowed to use home-made long-term antifreezing additive that has reliable quality. For specific using method, refer to relevant instructions. It’s 10



Service Manual for Engine recommended using following two types of long-term antifreezing additive: JFL-336# Long-term antifreezing additive FD-30# Long-term antifreezing additive



11



Service Manual for Engine It should be noted that the long-term antifreezing additive should be replaced regularly as per relevant requirements. Calculation of antifreezing additive (for reference) Total volume of coolant: 40L (assembled in the engine with radiator) Check temperature of current antifreezing solution: -20ºC Minimum antifreezing temperature to be met: -30ºC Calculation method: Find the total volume of coolant “40L” on the horizontal axis, draw a line across the line and find the intersection 1 and 2 of oblique of above -20ºC and -30ºC (refer to Fig. 2.1.4-1). Check: at -20ºC, the volume of antifreezing additive is 13.5L. The difference between the volume of antifreezing additive at -30ºC and at - 20ºC is 4L. For above difference of 4L, add 50% volume to make calculation, and the additional 50% is necessary. Before filling the antifreezing additive, be sure to drain part of coolant, so that the antifreezing additive in the coolant may be discharged. The volume of antifreezing additive added is 4L+50%x4L=6L.



Volume of anti-freezing additive



Lowest freezing temperature



Volume of coolant (L)



Fig. 2.1.4-1 Calculation Charge of Anti-freezing Additive



2.1.4



Auxiliary materials Table 2 -1 Auxiliary material



S/N



Name



Color



Usage and Application



12



Service Manual for Engine Molykote Pulver 1



2



Apply it on the smooth metal surface (such as



(Fine molybdenum



Black



cylinder sleeve external surface) to prevent



powder)



occlusion.



Molykote



Play the lubrication function before the



G_N_plus



Dark grey



lubricating oil pressure is built up



(oil mos 2)



e.g.: apply it on the intake valve stem, etc.



Table 2.1.5-2 Reference Table of Gluing of Diesel Engine Grade



Main Usage



Supplementary



List of Gluing Parts



Instruction



Flywheel housing bolt Camshaft thrust plate bolt Camshaft timing gear bolt Intermediate idle pulley bolt Front end cover bolt



Weichai special 242



Apply



it



thread



surface



prevent



on



the Oil filter seat bolt to Oil cooler bolt



looseness Oil cooler adjusting valve plug



and apply medium Bolt of oil pump oil return pipe As an option, use the force.



fixing device Air



compressor



DriLoc204 thread glue shaft



end for pre-gluing.



thread Suction filter bolt Bolt of sensor and harness fixing device Apply



it



on



Weichai



thread



surface



special 262



lock,



seal



the to and



Cylinder head bolt



prevent looseness. Weichai special 271 Weichai special 277 Weichai special 270



Fasten it to prevent Bowl-shaped plug of oil filler looseness. Sealing



plug between



core and hole Seal



the



cylinder



head top surface



Other bowl-shaped plug Push rod pipe-cylinder head



13



Service Manual for Engine



Matching



surface



between



cylinder block and crankcase Connecting plate between body front and front end cover, rear end and flywheel housing Matching surface between oil Weichai special 518 (510



update



product)



filter seat and crankcase Apply



it



on



the Water pump rear cover-body



bright metal surface front end surface for sealing



Flywheel housing connecting plate-flywheel housing Matching



surface



between



cylinder block and oil cooler cover Matching



surface



between



cylinder block and oil filler cover plate



2.2 Daily maintenance 



Check the coolant level and water temperature



Observe the coolant level through the glass sight hole. If the coolant is insufficient, open the water filler cap to fill in coolant. Attention: Open the filler cap, be sure to press the exhaust button to prevent personal injury due to hot coolant when the engine is hot.



14



Service Manual for Engine



15



Service Manual for Engine Fig. 2- 1 Exhaust Button Expansion tank



Fig. 2-4 Expansion Tank Attention: Before the diesel engine starts, be sure to check the coolant level. 



Check the oil level



Check whether the oil level is in the scale scope of oil dipstick. When the oil level is lower than the scale line of oil dipstick or higher than the upper scale of oil dipstick, it’s not allowed to start the diesel engine. After the diesel engine stops, check the oil level and wait for at least 5min, till the oil flows back to the oil pan.



Oil dipstick



Fig. 2-5 Schematic Diagram of Oil Dipstick Attention: Before the diesel engine starts, check the oil level. 



Check the fuel level



16



Service Manual for Engine Check the fuel level indication in the instrument panel and fill fuel in time. The diesel oil shall meet the regulation. Pay attention to the cleanliness of diesel oil. Before filling, it should be kept for above 72 hours. The diesel oil should be filled in the oil through the built-in filter.



Fig. 2-6 Check the Fuel Page Indication on the Instrument Panel Attention: Before the diesel engine starts, check the diesel oil level. 



Check three leakages



Check the diesel engine external surface for water, air and oil leakage. 



Check the fan



Check the fan blade for damage, the plastic fan for deformation, the iron fan rivet for looseness, the blade for bending and connecting bolt for fastening and ensure that the fan is working reliably. 



Check the belt



The belt is automatically tensioned by the belt pulley. The user can check the belt tension by pressing the belt by hands. Visually check the triangle belt for crack or bruise; if necessary, replace it. 



Check whether the exhaust color is normal



The normal exhaust color is light grey. Find out the reason for color change and eliminate the fault. 



Check whether the sound is normal 17



Service Manual for Engine 



Check whether the speed and vibration are normal



2.3 Regular maintenance 



Replace the oil



Put the diesel engine on the horizontal position. Put a container below the engine to collect oil. Unscrew the drain plug at the bottom of oil pan, empty the oil and screw down the drain plug. Open the filler cap and fill oil through the oil filler. The oil should be filtered by the filter. Observe the scale of oil dipstick till the requirement is met and then assemble the filler cap.



Fig. 2-7 Oil Filler 



Fig. 2-8 Oil Drain Valve



Replace the oil filter or filter element



Replace the oil filter as per following steps: A. Disassemble the bolt connecting old oil cooler module and the body and take down the oil cooler module; B. Before assembling the new oil cooler module, apply the oil on the rubber mat; C. Assemble the new oil cooler module on the body and fasten the bolt; D. Start the diesel engine and check it for oil leakage.



18



Service Manual for Engine



Fig. 2- 9 Oil Filter 



Check and adjust the intake and exhaust valve clearance



Check and adjust the intake and exhaust valve clearance as per following steps: A.



When the diesel engine is in cold state, turn (as per running direction of diesel engine) it to 1,6 cylinder top dead center. At this time, the cutting on the flywheel is aligned with the OT scale on the flywheel housing. Refer to Fig. 2-10.



Flywheel scale line



OT scale line is aligned with flywheel scale line



Fig. 2-10 Flywheel Scale Line B.



Disassemble the valve rocker arm hood on the cylinder cover and judge the compression stroke of 1# or 6# cylinder (clearance between cylinder intake and exhaust valve of compression stroke and rocker arm).



19



Service Manual for Engine



Fig. 2-11 Adjusting the Valve Clearance C.



Use the feeler gauge 1 to check the clearance between rocker arm and valve stem end as per Table 3. The intake valve clearance of WP6 diesel engine is 0.2mm; the exhaust valve clearance is 0.3mm. If the clearance is too big or small, loosen the adjusting nut 2 and adjust the clearance through the adjusting screw 3. Maintain the position of adjusting screw 3. Refer to Fig. 2-11 tightening lock nut 2. Use the feeler gauge to check other clearance again.



Adjusting bolt



Fig. 2-12 Adjusting Screw D.



After checking 1# cylinder or 6# cylinder, rotate it for 360°and keep the 6# or 1# cylinder at working stroke, check and adjust the remaining valve. Table 2.3.3-2 Valve Adjustment Table 1# cylinder



Compression stroke



of



cylinder Compression stroke cylinder 



of



1#



Intake



2#



3#



4#



5#



cylinder



cylinder



cylinder



cylinder



Exhaust



Intake



Exhaust



valve



valve



valve



valve



Exhaust



Intake



Exhaust



Intake



valve



valve



valve



valve



and Intake



exhaust valve It’s unable to



6# make adjustment



Replace the fuel filter element 20



6# cylinder It’s



unable



to



make



adjustment Intake exhaust valve



and



Service Manual for Engine Replace the fuel filter element as per following steps: A.



Disassemble old fuel filter element; If the water vessel on the coarse filter can be reused, take down the water vessel.



B.



Lubricate the seal.



C.



Screw down the filter by hands till the sealing is combined with the interface.



21



Service Manual for Engine D.



Keep twisting the filter (for about 3/4 circles) till the filter is firmly assembled by hands.



E.



Exhaust air till no bubble appears.



F.



Perform leakage test.



Fuel filter



Fig. 2-13 Fuel Filter 



Check the air intake system



Check the intake hose for aging and crack and check whether the hoop is loosened. If necessary, fasten or replace the part and ensure the airtightness of intake system.



2.4 Long-term storage maintenance 2.4.1



Cleaning



Before sealing, all rusty parts should be removed by proper method. All parts (lubricating oil way, lubrication system, supercharger, etc.) processed by protective agent should be thoroughly cleaned.



2.4.2



Protection



(1) After warm-up, empty the oil, clean the oil filter and add antirust oil to the diesel engine oil tank or oil pan. (2) Empty the diesel oil in the fuel system, fill antirust mixed oil to protect the fuel way. (3) If no cooling emulsion is filled in the diesel engine, drain the cooling water, add cooling water emulsion and antirust oil to protect the cooling water chamber. Before sealing, use above emulsion and start it for idle running for (15-25)min as per the starting procedure.



22



Service Manual for Engine (4) Disassemble the cover plate of intake pipe short surface, use the pressure nozzle to spray antirust oil in the intake pipe, rotate the crankshaft by hands while injecting oil so as to open the air valve to make the antirust oil flow to the combustion chamber. Once sealing is completed, never rotate the crankshaft to prevent scratching the oil film on the cylinder wall. (5) Drain oil liquid in the diesel engine, drain the antirust liquid from the base or by a pump, empty the emulsion from the cooling system and open all liquid discharge switches. (6) Disassemble the rocker arm hood and spray antirust oil to the valve spring and rocker arm. (7) Apply the protective oil to all processed parts and easily rusting parts of diesel engine. After above procedures, it can be stored. To prevent moisture and impurity entering the diesel engine, in the transportation process and storage period, cover the open parts like intake, exhaust, cooling pipe of diesel engine by a cover and hood the engine by a plastic hood.



23



Service Manual for Engine



Chapter III Typical Faults and Troubleshooting of Diesel Engine The WP6 series diesel engine is designed and manufactured under strict quality assurance system. Each diesel engine has received specified test. Meanwhile, the diesel engine is a type of precision machine and its function should be guaranteed permanently, which is closely related to normal maintenance. Early failure of diesel engine is generally caused by following reasons: ◆



Operation against rules, improper management and use;



◆



Never perform maintenance as per regulations even replace the maintenance with repairing;



◆



The accessories are manufactured improperly, especially counterfeit and shoddy products purchased will greatly shorten the service life of diesel engine;



◆



The fuel and lubricating oil grade are proper or disqualified.



3.1 Diagnosis method Common diagnosis methods for diesel engine: ◆



Observation method: observe the fault characteristics like smoke exhausting of diesel engine and judge the fault condition (Fig. 9-1);



◆



Auscultation method: judge the fault part and degree as per the abnormal noise of diesel engine (Fig. 9-2).



Fig. 3-1 Observation Method ◆



Fig. 3-2 Auscultation Method



Cylinder deactivation method: Stop one cylinder and judge whether the cylinder is faulty. The method is generally to stop supply oil to the cylinder that is suspected of fault, compare the engine state change before and after cylinder deactivation and further find out the faulty part or shrink the scope.



◆



Comparison method: replace some assemblies or spare parts to confirm the fault.



Attention: 1.



Judging the fault of diesel engine is a very meticulous work. Before finding out the basic cause, the diesel engine should not be disassembled generally; otherwise, the fault may not be eliminated, but more serious fault will be caused due to improper assembly after 24



Service Manual for Engine disassembly. 2.



For key parts like high-pressure oil pump, supercharger, etc., check and maintenance should be done by the personnel with certain experience by special instruments and equipment. Therefore, the user without experience and condition should not arbitrarily disassemble and adjust the diesel engine.



25



Service Manual for Engine



3.2 General fault causes and solutions of diesel engine 3.2.1



The diesel engine is unable to start Fault Cause



Solution



1. Oil way blockage of fuel delivery pump oil filter screen or hose 2 Air in the fuel system



Check and discharge dirt and check the fuel cleanliness Exhaust air, check the joint airtightness and repair it Check the plunger and oil drain valve, repair or replace



3. Fuel injector fault



damaged parts



4. Fuel injector fault



Check the atomization of fuel injector



5. air distribution or oil supply pipe damage or oil leakage 6. High-pressure oil pipe damage and oil leakage



Check and adjust Repair and replace



7. Insufficient compression pressure Check the valve airtightness, cylinder gasket airtightness, of cylinder



piston ring abrasion, repair or replace it



8. Too low temperature



Add auxiliary starting device



3.2.2



The vehicle stops right after startup Disassemble the filter body, clear internal pollutant and water,



1. Fuel filter blockage



if necessary, replace the filter element Check the oil pipe and joint air tightness, check whether the



2. Air in the fuel system



bleeder screw is tightened and exhaust remaining air



3. Fuel delivery pump doesn’t Check the fuel delivery pump piston and valve, clean and work



repair it



4. Poor fuel quality and too much water content 5. Too low idle speed



3.2.3



Clean the filter and replace the fuel Adjust it again



Underpower



1. Air intake blockage (air filter Check the air filter, intake pipe, clean or replace the filter blockage)



element



2. Too high exhaust back pressure 3.



Insufficient



pressure



supercharging system



of



Check the valve timing, check the exhaust pipe for blockage, adjust and repair it Check and eliminate the leakage at the pipe connection part



26



Service Manual for Engine



4.



Abnormal



working



of



supercharger 4.1 Fouling of compressor and turbine flow pass 4.2 Floating bearing failure



Replace the assembly Clean or replace Replace



4.3 Carbon deposit and oil sludge at the back clearance of turbine Clean and compressor 5. Inter-cooler damage and air leakage 6.



Fuel



pipe oil



leakage or



blockage 7. Poor fuel quality 8. Excessive abrasion of fuel injection pump or governor 9. Fuel injection pump smoke limiter diaphragm damage 10. Smoke limiter air pipe damage and leakage



Replace or repair Check the oil pipe and joint airtightness, the filter pollution degree and fuel pipe, repair or clear the fouling and replace the filter element Clean the oil tank, filter parts and oil pipe and replace the fuel Repair or replace Replace and repair Replace



11. Poor atomization of injection Check the fuel injection pressure, carbon deposit in the nozzle 12. Incorrect air distribution or oil supply timing 13. Too low of high speed of speed governor 14. Too high oil level of oil pan 15. Air leakage of cylinder gasket



injection nozzle, adjust and repair it Check and adjust 之 Check and adjust it Check the governor control characteristics and adjust it Check the oil dipstick and drain excessive oil For warm-up, check the compression pressure and replace the damaged cylinder gasket



16. Piston ring abrasion and fracture, too big clearance of Replace the worn parts or overhaul the engine bearing bush 17. Cylinder sleeve or piston Replace the worn parts or overhaul the engine 27



Service Manual for Engine abrasion or scuffing



3.2.4



Large fuel consumption



1. Intake pipe blockage



Check the air filter and intake pipe and clean it



2. Too high exhaust back pressure



Check the exhaust pipe and brake valve and clean it



3. Poor fuel quality



Replace the fuel as per regulations



4. Fuel pipe blockage



Check and repair



5. Oil leakage of fuel pipe



Check and repair



6. Poor atomization of fuel injector



Check and adjust or Repair



7. Incorrect air distribution or oil Adjust the valve clearance and advance angle of fuel supply supply timing



as per regulations



28



Service Manual for Engine



8. Air leakage of cylinder gasket



Check the compression pressure



9. Too big clearance of bearing bush



and



the



engine



needs Check and overhaul



repairing 10. Piston cylinder expansion 11.



Insufficient



pressure



Replace the cylinder sleeve, piston and piston ring of Check and eliminate the leakage at the pipe and connection



supercharging system 12.



Abnormal



working



part of



supercharger 13. Damage or air leakage of intercooler



3.2.5



exhaust back pressure 2. Poor fuel quality supply timing 4. Poor atomization of injection nozzle 5. Too much fuel in the fuel injection pump Insufficient



pressure working



Check, repair or replace Check and adjust (to be done professional factory)



part of



supercharger 8. Inter-cooler damage and air leakage 9. Wrong action point of smoke limiter



3.2.6



Make adjustment as per regulations



of Check and eliminate the leakage at the pipe and connection



supercharging system Abnormal



Clean Wash and replace



3. Incorrect air distribution or oil



7.



Replace or repair



Black smoke in the exhaust gas



1. Intake pipe blockage or high



6.



Check and replace



Check and replace the assembly Replace or repair Make adjustment again (to be done professional factory)



White and blue smoke in the exhaust gas



1. Poor fuel quality and fuel with much water



Replace the fuel



2. Too low temperature of cooling Check the working temperature of thermometer, if necessary, 29



Service Manual for Engine water



replace it



3. Incorrect air distribution or oil supply timing 4. Poor atomization of injection nozzle 5. Low compression pressure, incomplete combustion or piston cylinder expansion 6. Improper matching of piston ring and cylinder sleeve 7.



Piston



ring



opening



not



staggered 8. Piston oil ring failure 9. Too big fit clearance of piston and cylinder sleeve 10. Supercharger seal ring abrasion



Check and adjust Check and repair Check the piston ring, cylinder sleeve, cylinder gasket, and repair it Keep matching Adjust and assemble A Replace Repair and replace Check and replace



30



Service Manual for Engine



11.



Abrasion



of



supercharger



thrust bearing 12. Supercharger oil return pipe blockage



3.2.7



Check and replace Clean or repair



Too much oil at the air inlet and intake pipe of supercharger



1. Supercharger seal failure



Repair or replace the supercharger



2. Oil-gas separator failure



Replace



3. Too high level of oil pan and excessive oil in it



Check and discharge appropriate oil as per regulations



3.2.8 Unstable speed 1. Poor fuel quality or fuel with water or wax 2. Air in the fuel suction pipe



Replace the fuel Check the oil pipe and joint airtightness and exhaust air



3. Abnormal working of speed governor hammer and governing Check and adjust (to be done by professional factory) spring 4. Uneven oil supply 5.



Unstable



atomization



Check and adjust (to be done by professional factory) of



injection nozzle 6.



Spraying



vibration



Check and repair



of Check and clean the compressor passage, discharge the



supercharger



fouling and carbon deposit in the exhaust passage.



7. Supercharger bearing damage



Replace



3.2.9



Too low oil pressure



1. Too low oil level or oil shortage of oil pan 2. Main oil way pressure adjusting valve fault



Check the oil level and check it for oil leakage, and fill oil Check the valve, clean and repair it



3. Blockage or fracture of filter, oil Check and clean the compressor passage, discharge the pip, joint gasket, etc.



fouling and carbon deposit in the exhaust passage.



4. The oil grade fails to meet the Replace the oil as per regulations and select the oil of proper regulations



grade



5. Oil pump oil inlet leakage



Check the oil pipe and joint, repair or replace it



6. The cooling system temperature Check the cooling system work and correct it 31



Service Manual for Engine is too high and the oil temperature is too high 7. The oil filter resistance is too big 8. Oil cooler blockage



Replace a new filter element Check and clean



32



Service Manual for Engine



9. Main oil way blockage 10. Too big clearance of bearing bush or bearing bush damage



Check and clean Check and repair



11. Excessive abrasion of parts and Check the working hour of engine and perform overhaul needed



overhaul



3.2.10 Too high temperature of cooling water 1. Too low level of water tank



Check it for water leakage, and fill water



2. Water tank blockage



Check the water tank, clean or repair it



3. Water pump belt loosened



Adjust the tension force as per regulations



4. Water pump gasket damage and water pump impeller abrasion 5. Thermostat fault 6. Water pipe damage and air in the pipe 7. Too low oil level or oil shortage of oil pan



Check, repair or replace Replace Check the water pipe, joint, gasket, etc. and replace the damaged parts Check the oil level and leakage, repair and fill oil



3.2.11 Fast abrasion of parts 1. The air filter element is disqualified or broken 2. Short circuit of air intake system 3. Too low oil level or oil shortage of oil pan 4. Oil way blockage 5. The oil grade fails to meet the regulation 6. Fracture or abrasion of piston ring



Check and replace qualified filter element Check the intake tube, gasket and connecting pipe sleeve, repair or replace it Check the oil level and leakage, repair and fill oil Clean the oil way Replace the oil as per regulations Replace the damaged parts



7. Abrasion or scuffing of cylinder sleeve Disassemble and check the piston and cylinder sleeve, or piston 8. The oil filter element is not replaced in time 9. Excessive abrasion of parts and overhaul needed



repair or replace it Replace it as per requirements Check the mileage and confirm overhaul



33



Service Manual for Engine 10. The crankshaft is not concentric with the building axis 11. The oil quality fails to meet the requirement



Check the mounting support and repair it Adopt the oil grade meeting the standard



3.2.12 Big noise 1. Poor fuel quality



Replace the fuel



2. Too low cooling water temperature



Check the thermometer, if necessary, replace it



3. Incorrect distribution or oil supply timing



Check, repair and adjust



34



Service Manual for Engine



4. Poor atomization of injection nozzle 5. Too high volume of fuel injection pump 6. Shock absorber abrasion 7. Valve air leakage or improper adjustment 8. Too big gear clearance or tooth fracture 9. Cylinder sleeve or piston abrasion or scuffing



Check, repair and adjust it Check and adjust (to be done by professional factory) Check it for damage, check the connecting bolt condition and replace the damaged parts Disassemble, check and adjust the valve Check and replace the damaged parts Check and repair or replace



10. Push rod bending or fracture



Replace



11. Piston ring fracture or abrasion



Check or replace the damaged parts



3.2.13 The starter motor doesn’t work 1. Insufficient charging of battery



Check, charge or replace the battery



2. Poor contact of connecting wire



Clean the wire and screw down the binding post



3. Fuse blown



Replace the fuse



4. Poor contact of electric brush 5. Short circuit of starter motor



Clean the surface of electric brush or replace the electric brush Repair the motor or replace the assembly



3.2.14 Starting motor is short of power 1. Insufficient charging of battery



Charge or replace the battery



2. Abrasion of bearing sleeve



Replace the assembly



3. Poor contact of electric brush 4. The commutator is not clean or burnt



Clean the surface of electric brush or replace the electric brush Clear the oil stain and use abrasive paper to polish or replace the assembly



5. Terminal desoldering



Weld it again



6. Poor contact of switch



Check the switch and repair it



7. Slipping of clutch due to abrasion



Adjust the working torque of clutch or replace the assembly



3.2.15 The generator fails to completely generate electricity 1. Wire open circuit and short circuit and Check the generator and ammeter wiring and repair it 35



Service Manual for Engine joint loosened 2. Rotor and stator coil open circuit, short circuit or grounding 3. Rectifier tube damage 4. Pole paper insulation damage and wire disconnected



Repair or replace the assembly Replace the assembly Repair



36



Service Manual for Engine



5. Too low voltage of adjuster



Repair



6. Adjustor contact burnt



Repair or replace the assembly



3.2.16 Insufficient charging of generator 1. Wire open-circuit, short-circuit and joint looseness 2. Rotor and stator coil open circuit, short circuit or grounding 3. Looseness of generator belt 4. Generator rectifier tube damage and battery in poor contact 5. Too low voltage of adjuster 6. The magnetic field coil or resistance wire of adjuster is disconnected 7. The battery electrolyte is too little or the battery is old



Repair Repair or replace the assembly Check and adjust the belt tension Repair Adjust Repair or replace Fill electrolyte or replace the battery



3.2.17 Unstable charging current 1. Stator or rotor coil to be subject to open circuit and short circuit 2. Poor contact of electric brush 3. Looseness and poor contact of wiring post



Repair or replace Repair Repair



4. Damage of voltage adjuster



Repair



5. Improper adjustment of voltage



Check and adjust



3.2.18 Excessive charging of generator 1. Internal short circuit of battery



Repair or replace



2. Too high voltage of adjuster



Repair and adjust



3. Poor grounding of adjuster



Repair



4.



Adjuster



contact



malfunction,



pollution, voltage coil or resistance wire Repair or replace disconnected



3.2.19 There is abnormal noise from the engine 1. The generator is improperly assembled



Repair



2. Bearing damage



Replace the bearing 37



Service Manual for Engine 3. Rotary part touches the fixed part



Repair or replace



4. Rectifier short circuit



Replace



38



Service Manual for Engine



5. Stator coil short circuit



Repair or replace



39



Service Manual for Engine



Chapter IV Disassembly and Assembly of Engine 4.1 General Disassembly and assembly of engine should be done in strict line with this Manual. Pay attention to operation of danger signs and safety signs in this Manual to ensure personal safety and avoid accident. The disassembly steps of diesel engine are contrary to the assembly steps. For no special instructions, the Service Manual only selects one for description.



4.1.1



Danger signs The sign is worldly recognized warning sign. In this Manual, the sign is used to emphasize the importance of following information. Confirm that you know the consequence of danger and the prevention method. Behavior violating the warning information may cause property loss, personal injury even personal casualty. The common danger signs are usually used for general warning. In this Manual, the warning information can be classified



into



different



types



as



per



the



dangerous



consequence levels (minor wound, serious injury and death).



Warning



The warning sign represents a potential hazard. If it’s not avoided, it may cause serious injury and death or great property loss. The warning sign represents a potential hazard. If it’s not



Attention



avoided, it may cause light injury or property loss. The warning sign is also used for warning of dangerous operation.



Various attentions provided in the Manual describe how to correctly operate and safely use the engine of our company.



40



Service Manual for Engine However, just reading this Manual can’t eliminate various potential hazards. Correctly understanding the information in the attentions can help the correct use. Warning information in this Manual doesn't cover usage in all possible conditions! If the using procedure and method exceeds the recommended scope of the Manual, please confirm that the operation may not bring any hazard to you, others and the equipment.



4.1.2



Safety signs Symbol



Definition Wear hand protective device Wear ear protective device Wear eye protective device Wear head protective device Wear foot protective device Wear protective mask Wear protective clothing No open fire No smoking Mobile phone prohibited Danger: battery acid fluid Danger: live cable, electric shock danger Inflammables



41



Service Manual for Engine Keep away from hanging heavy objects Fire extinguisher nearby In the using process of engine, there are many potential hazards without warning. Therefore, the Manual is unable to give warning for potential hazards. If the using procedure is not in the recommended scope, ensure that the procedure may not cause any material loss.



42



Service Manual for Engine



4.1.3



Tools used Symbol



Definition 2.5mm hexagon wrench 5mm hexagon wrench



8mm sleeve



Slotted screwdriver Special tool 10mm flat hexagon wrench If the methods or tools used are not in the recommended scope of this Manual, the user must ensure the personal safety and avoid causing life risk to the user or others. The user should also ensure that the using and maintenance method may not cause damage risk or safety hazard.



4.1.4 Attentions for health protection The following “attentions for health protection” aims to lower the pollution risk to engine maintenance personnel, which should be abided by relevant personnel during disassembly and check of engine. a)



Avoid contacting the used oil for a long time.



b)



If possible, please wear the protective clothing and waterproof gloves.



c)



Never put the oily stained rag in the pocket.



d)



Avoid polluting the clothes (especially underwear) by oil.



e)



Frequently clean working clothes, throw away clothes and shoes with oil that is unable to be cleaned.



f)



In case of cutting and injury, please immediately take emergency measures.



g)



Before working, be sure to apply protective cream. When the skin contacts mineral oil, the oil may be easily removed.



h)



Wash hands by soap and hot water or sanitizer and fingernail brush to remove all dirt. If the grease secreted by the skin is washed, the product with lanum can replace the grease secreted by the skin naturally, which is good for moistening the skin.



i)



Never clean the skin by gasoline, kerosene, fuel, thinner or solvent. 43



Service Manual for Engine j)



If you feel uncomfortable, immediately go to the doctor.



k)



If possible, before handling the part, wipe off oil on the part.



l)



When there is risk to eyes, please wear safety goggles or protective mask. Be sure to provide eye flushing liquid at the reachable place.



m) When repairing the engine, oil or other liquid should not be splashed on the ground. If the hydrocarbon or other liquid is accidentally leaked, take necessary measures to hinder the area so as to keep the environment clean and protect the personnel from injury. n)



For handling, storage and recovery of hydrocarbon, ethylene, ethylene glycol or petroleum must comply with the safety and environment standard executed by the country.



4.1.5



Environmental protection measures



For disposal of exhaust oil and hydrocarbon, please comply with relevant environmental protection laws and regulations. Please consult local officials for details.



4.1.6



Attentions for disassembly and assembly of engine



Most accidents relating to use, maintenance and repairing of engine may be caused by the safety rules and basic attentions are not abided by. Therefore, you should know the dangers and take corresponding preventive measures to avoid the accident. To operate, maintain and repair the engine, the operator should receive corresponding training and possess applicable skills and apply proper tools. Violating relevant instructions of this Manual may cause serious accident, even endanger the life. Weichai Power Co., Ltd. is unable to foresee all potential hazards. Meanwhile, rules and descriptions specified in this Manual are not exhaustive. Before maintenance or repairing, please put the signboard of “Do not use” or similar sign on the starter switch. Before using the barring rod, take necessary preventive measures: a)



Ensure that the repairing site and surrounding environment is suitable for safe operation.



b)



Keep the surrounding area of repairing workshop or engine clean.



c)



Before working, please pick off the ring, necklace and watch. Please wear proper working clothes.



d)



Before working, please verify the validity period of corresponding protective devices (glasses, gloves, shoes, mask, working clothes, helmet, etc.).



e)



Never use faulty or improper tools.



Attention: In the maintenance or repairing process, please shut down the engine.



44



Service Manual for Engine



4.2 Cylinder head assembly 4.2.1



Disassembly and assembly of cylinder head assembly



4.2.1.1



Exploded drawing for cylinder head assembly



Cylinder head over combination assembly



Cylinder head combination assembly



Fig. 4-1 Exploded Drawing of Cylinder Head Assembly



45



Service Manual for Engine 4.2.1.2



Disassembly steps for cylinder head assembly



1) Disassemble the hindering objects like fan, drive belt, etc.; 2) Disassemble the crankshaft ventilation device assembly; 3) Disassemble the hanger plate and support bracket; 4) Disassemble the high-pressure oil pipe and fuel return pipe. Refer to disassembly instructions for fuel system; 5) Disassemble the cylinder head cover assembly; 6) Disassemble the rock arm seat assembly; 7) Disassemble the cylinder head bolt; 8) Disassemble the fuel injector; 9) Disassemble the cylinder head assembly; 4.2.1.3



Assembly steps for cylinder head assembly



The assembly steps are contrary to the disassembly steps.



4.2.2 Disassembly, check, maintenance and assembly of cylinder head cover assembly 4.2.2.1



Exploded drawing for cylinder head cover assembly



Hexagon bolt



Sealing washer



Cylinder head cover



Cylinder head cover gasket



Fig. 4-2 Exploded Drawing for Cylinder Head Cover Assembly 4.2.2.2



Disassembly steps for cylinder head cover assembly



1) Orderly loosen the cylinder head cover bolts; 2) Take out the cylinder head cover and cylinder head cover gasket upward.



46



Service Manual for Engine 4.2.2.3



Check and maintenance of cylinder head cover assembly



1) Check the cylinder head cover for crack and other damages, if any, replace new cylinder head cover; 2) If the cylinder head cover gasket is leaked, check the failure condition of cylinder head gasket and replace new cylinder head cover gasket; 3) The cylinder head cover gasket can only be used once. Replace a new part in the repairing process. 4.2.2.4



Assembly steps for cylinder head cover assembly



1) Before assembly, check the cylinder head cover gasket and cylinder head surface for manufacturing or using defects and damages; 2) Use the oil can to spray clean oil at the connection of rocker arm and valve, rocker arm and tappet and two points; 3) Put the cylinder head cover gasket; 4) Put the cylinder head cover; 5) Adjust the cylinder head cover gasket at the middle position of cylinder head cover, align two Ugrooves, keep the gasket exposed out from surrounding of cylinder head cover and keep the Ugroove, bolt and center of gasket bottom on a straight line; 6) Fasten the cylinder head cover bolt, when the torque is 10-15 N·m, pay attention to preventing cylinder head cover gasket deviating from original position in the fastening process.



47



Service Manual for Engine



4.2.3 Disassembly, check, maintenance and assembly of cylinder head assembly 4.2.3.1



Exploded drawing for cylinder head assembly



Valve lock clamp



Hexagon bolt



Guide valve spring Inner hexagon tapered plug Rocker arm seat component



Outer valve spring Inner valve spring Lower valve spring seat Valve stem seal sleeve



Bowl-shaped piston



Valve guide



Doubleend stud Intake valve seat Spring Intake washer valve



Exhaust valve seat Exhaust valve Cylinder head gasket



Hexagon nut



Fig. 4-3 Exploded Drawing for Cylinder Head Assembly 4.2.3.2



Disassembly steps for cylinder head assembly



1) Disassemble the rocker arm seat assembly; 2) Disassemble the cylinder head bolt; 3) Disassemble the cylinder head upward (before disassembly, ensure that the fuel injector is disassembled and the fuel injector head should be protected from damage). During assembly, never shake it to prevent residual coolant and lubricating oil flowing out. If the cylinder head gasket is pasted on the cylinder head, take it down and put the cylinder block back; 4) After disassembling the cylinder head, put it on the paper board or rubber board to avoid abrading the flame face and valve seal surface of cylinder head. To disassemble several cylinder heads, mark the serial number on the cylinder head for convenient analysis and assembly; 5) Take down the cylinder head gasket. To disassemble several cylinder head gaskets, mark the serial number on it. 4.2.3.3



Check and maintenance of cylinder head assembly 48



Service Manual for Engine 1) Cylinder head



49



Service Manual for Engine Before disassembly the cylinder head, check the cylinder head for water, oil and air leakage and other abnormal conditions, so as to confirm the faulty part and correctly analyze the problem. Clean the cylinder head, mainly clean the combustion chamber surface, valve seat, intake and exhaust valve, intake and exhaust pipe and get rid of surface carbon deposit and mucilage glue, and check the surface condition. ①



Appearance check



Carefully check the change changing and crack of cylinder, if any crack, perform dye penetration inspection. ②



Valve sinkage



The valve sinkage is the vertical distance from the valve bottom to the bottom plane of cylinder head. The difference between valve sinkage measured value and valve sinkage required value can reflects the abrasion degree of valve and valve seat. Measure the valve sinkage by a depth micrometer as shown in the figure:



Fig. 4-4 Figure Name For required value of valve sinkage, refer to Table 1. If the valve sinkage exceeds permissible scope and it’s required to replace the cylinder head to ensure the reliability of diesel engine. If the valve sinkage doesn’t exceed the permissible value, disassemble the valve to check the valve and valve seat sealing surface. Check the valve and valve seat sealing surface for obvious abrasion and abnormal damage. Required value of valve sinkage (mm) Intake valve



1.0-1.45



Exhaust valve



1.0-1.45



3 Clearance between valve stem and valve guide ○



The internal surface of valve guide is the contact surface of valve guide and valve. If the clearance between valve guide and valve stem exceeds the permissible value due to abrasion, it may influence the guide effect of valve guide, and lower the working reliability of diesel engine. Measure the inner diameter of valve guide by an ID micrometer as shown in the figure. The OD of guide valve can be measured by the OD micrometer. The permissible clearance between intake and exhaust valve stem and corresponding valve guide should be (0.03~0.06) mm. If the permissible scope is exceeded, 50



Service Manual for Engine replace the cylinder head to ensure the working reliability of diesel engine.



51



Service Manual for Engine



Fig. 4-5 Figure Name ④



Cylinder head gasket



If the cylinder head gasket has air, water and oil leakage, replace new parts. Check the cylinder head gasket for visible damage and analyze the reason. No matter whether the cylinder head has problem, replace new cylinder head gasket when disassembling the cylinder head. 4.2.3.4



Assembly steps for cylinder head assembly



1) Pre-assemble the rocker arm seat assembly; 2) Put the cylinder head gasket and select 1.4mm thick cylinder head gasket. The cylinder head gasket is not reused; 3) Assemble the cylinder head assembly on the body; 4) Loosely assemble the cylinder head bolt; 5) Fasten the cylinder head bolt, tighten it at torque of 30N·m, rotate it for 120°±4°and then rotate it for 120°±4°; 6) The tightening sequence (from 1# cylinder to 6# cylinder)



of cylinder head is shown in the



figure below.



Fig. 4-6 Tightening Bolt Sequence



52



Service Manual for Engine



4.3 Body assembly 4.3.1



Disassembly, check, maintenance and assembly of body assembly



4.3.1.1



Exploded drawing for body assembly



Fig. 4-7 Exploded Drawing for Body Assembly 1-Body; 2, 20-bowl-shaped plug; 3, 4, 5-camshaft liner; 6, 7, 8, 9-plug; 11-cylinder sleeve; 12, 13, 14- O-ring; 15-fixing plate; 16-welding pipe; 17, 31-spring washer; 18-hexagon socket cap screw; 19, 22, 23-round pin; 21-elastic cylindrical pin; 24-shaft; 25, 26-double-end stud; 27, 28, 29-cylinder head bolt; 30-lifting bolt; 32-2 type hexagon nut; 34-hexagon plug 4.3.1.2



Disassembly steps for body assembly



1) Disassemble the cylinder head bolt (Key point 1);



53



Service Manual for Engine 2) Disassemble the welding bend (Key point 2); 3) Disassemble the vertical oil plug and thread sleeve; 4) Disassemble the cylinder sleeve (Key point 3); 5) Disassemble the camshaft sleeve (Key point 4). 4.3.1.3



Check and maintenance of body assembly



Key point 1: Assembly Apply lubricating oil to the supporting surface and thread surface of cylinder head bolt and tighten it as per following specifications: (1) On the assembly line, use the four-axis tightener to tighten it and the tightening procedure is as follows: a. Pre-tighten it to 15N.m b. Tighten it to 60 N.m c. Turn it for 230°±4°. (2) If it’s unable to use four-axis tightener to screw it down, use the torque wrench to tighten it: a. Pre-tighten it by the torque of 30N·m; b. Twist the angle of 120°±4°; c. Twist the angle of 120°±4°again. The tightening sequence of cylinder head bolt is shown in the figure below:



Fig. 4-8 Bolt Tightening Sequence (3) The tightening sequence of cylinder head bolt is: 3# cylinder-4# cylinder-5# cylinder-2# cylinder-1# cylinder-6# cylinder; (4) Control scope of tightening torque of cylinder head bolt: M14-12.9: (230-300)N.m M14-10.9: (190-285)N.m Key point 2: Assembly Assemble greased seal ring on the welding bend, insert it in corresponding hole of body, fix it on the body by the fixing bolt, inner hexagon bolt and spring washer. Key point 3： Check: 1) Measure the protrusion of cylinder sleeve (0.05mm-0.10mm is qualified)



54



Service Manual for Engine Note: the protrusion of cylinder sleeve is the average value in X and Y direction; make measurement when no seal ring is assembled on the body and cylinder sleeve; cylinder sleeve for the same body should be grouped and marked consistently. 2) The matching surface and friction surface should be free of rust, scratch and bump. Before assembly, clean it and apply clean lubricating oil or grease. Assembly: Put the cylinder sleeve on the body, assemble the seal ring at body and cylinder sleeve, put the cylinder sleeve vertically in the hole and use the nylon rod to evenly knock it to place. Key point 4: Disassembly: Disassemble the camshaft liner by a special tool. Pay attention to protecting other liner in the disassembly process. Check: Before liner assembly, be sure to remove and clean grease on the back of liner, back of bushing and matching bottom hole. The liner, bushing and bottom hole should be free of burr, overlapping, scrap iron, etc. Assembly: Apply oil to the body hole, put the camshaft liner on the special tool and assemble it in the body. At this time, align the oil way hole of camshaft liner with the body oil way hole. 4.3.1.4



Assembly steps for body assembly



The assembly steps are contrary to the disassembly steps for body assembly.



55



Service Manual for Engine



4.3.2



Disassembly, check, maintenance and assembly of body component



4.3.2.1



Exploded drawing for body component



Body



Thrust bearing cover



Main bearing cover



Main bearing bolt



Main bearing bolt



Fig. 4-9 Exploded Drawing for Body Component Assembly 4.3.2.2



Disassembly steps for body component



①



Disassemble the main bearing bolt (Key point 1)



②



Disassemble the main bearing cover (Key point 2)



4.3.2.3 Check and maintenance of body assembly Key point 1: Check: Check and clean the body. Including but not limited to: the assembly environment must be clean; check the body processing surface transferred from the body line for bump damage, scratch and rust; in the assembly process, the parts should be free of collision and scratch. Except for special requirement, the part sharp corner and sharp edge must be blunt. Assembly: The 6# cylinder adopts 14 M14-10.9 main bearing bolts. As per the sequence shown in the figure below, from the middle main bearing, it evenly stretches for two ends. Tighten it for two times: apply the torque of 70 N·m for the first time and then twist the bolt for 90°±4°for the second time.



56



Service Manual for Engine



Fig. 4-10 Sequence Drawing for Cylinder Head Bolt Key point 2: Assembly Assemble the thrust bearing cover at the back of body and assemble the non-thrust bearing cover at other positions. During assembly, align two ends, if it’s reversely placed, the main bearing bolt is unable to be screwed in. 4.3.2.4 Assembly steps for body assembly The assembly steps are contrary to the disassembly steps of the body assembly.



4.3.3



Disassembly, check, maintenance and assembly of front wall cover



4.3.3.1 Exploded drawing for front wall cover assembly Front wall cover



Gasket



Cover plate



Bolt



Respirator



Intermediate gear pump



Baffle



Radial seal ring



Intermediate gear component



Fig. 4-11 Exploded Drawing for Front Wall Cover Assembly 4.3.3.2 Disassembly steps for front wall cover ①



Disassemble the respirator;



57



Service Manual for Engine ②



Disassemble the cover plate;



③



Disassemble the intermediate gear parts (Key point 1);



④



Disassemble the plug screw;



⑤



Disassemble the front wall cover (Key point 2);



⑥



Disassemble the radial seal ring (Key point 3).



4.3.3.3 Check and maintenance of front wall cover Key point 1: Check: 1) After fixing the gear, stir the gear by hands. The clearance is obvious and no blockage is felt in the rotating process. 2) Check the clearance between intermediate gear and timing gear, which is generally 0.015~0.30mm. Assembly: 1) Assemble the intermediate gear shaft and intermediate gear assembly, and drop proper oil on the intermediate gear shaft; 2) Assemble the intermediate gear assembly and keep the intermediate hole and pin shaft concentric; 3) Assemble the baffle, fastening bolt and triangle flange cover plate. The tightening torque of fastening bolt is 65-70N.m. Key point 2: Check: Check whether the front wall cover is clean, whether the matching surface has bump and burr and whether the seal ring is damaged. Assembly: 1) Knock the locating pin to corresponding position; 2) Glue the matching surface of front wall cover, the gluing should be even without breakage; 3) Align the pin hole, put the front wall cover and slightly knock the edge of front wall cover by a nylon rod to keep the front wall cover and body matched; 4) Insert corresponding screw hole in the bolt, assemble corresponding washer and tighten it by a pneumatic wrench and open end wrench.



58



Service Manual for Engine



Key point 3:



59



Service Manual for Engine Assembly: Before assembling the oil seal and seal ring, check it and ensure that there is no damage and dirt on the assembly surface. When assembling tight oil seal and seal ring, apply clean oil on the shaft and slowly press it by a special tool, and evenly apply force to the surrounding part of oil seal and seal ring. Disassembly: After the oil seal is disassembled, replace a new oil seal. 4.3.3.4 Assembly steps for front wall cover The assembly steps are contrary to the disassembly steps of front wall cover.



4.3.4



Disassembly, check, maintenance and assembly of flywheel housing



4.3.4.1 Exploded drawing for flywheel housing assembly



Flywheel housing



Flywheel housing bolt



Fig. 4-12 Exploded Drawing for Flywheel Housing Assembly 4.3.4.2 Disassembly steps for flywheel housing ① Disassemble the flywheel housing fastening bolt (Key point 1); ② Disassemble the flywheel housing observation window fastening bolt and observation hole cover; ③ Disassemble the speed sensor; ④ Disassemble the flywheel housing (Key point 2). 4.3.4.3 Check and maintenance of flywheel housing Key point 1: Assembly



60



Service Manual for Engine Check whether the flywheel is clean. Use the 240# fine oil stone to remove the burr of corresponding matching surface of body. Clean it by alcohol and glue the matching surface of flywheel and body. Use 12 M10-10.9 hexagon bolts, 6 M12-10.9 hexagon bolts, 17mm and 19mm socket wrench. Step 1: pre-assemble the bolt; Step 2: respectively tighten the M10 bolt in the arrow direction shown in the figure. The tightening torque is 80-85Nm. Tighten M12 bolt as per the order 1-2-3-4-5-6 and the tightening torque is 140145Nm.



Attention: before screwing above strengthening bolts, apply lubricating oil to the thread and supporting surface. 4.3.4.4



Assembly steps for flywheel housing



The assembly steps are contrary to the disassembly steps of flywheel housing.



61



Service Manual for Engine



4.3.5



Disassembly, check, maintenance and assembly of oil pan



4.3.5.1 Exploded drawing for oil pan assembly



Oil pan



Drain plug



Fig. 4-13 Exploded Drawing for Oil Pan Assembly 4.3.5.2 Disassembly steps for oil pan ①



Turn over the diesel engine and keep the oil pan upward (Key point 1);



②



Disassemble the fastening bolt of oil pan (Key point 2);



③



Disassemble the oil pan and sealing gasket.



④



Disassemble the magnetic plug and composite gasket.



4.3.5.3 Check and maintenance of oil pan Key point 1：Disassembly Before disassembling the oil pan, empty the oil. Put the oil container below the drain plug of oil pan and use the plug wrench to loosen the drain plug and drain the oil. Key point 2：Assembly 1) Glue the body matching surface along the inside of thread hole; 2) Move the oil pan toward the body matching surface. When the oil pan contacts with the body, slightly put it to avoid damaging the contact surface;



62



Service Manual for Engine 3) Insert the bolt and gasket and use the pneumatic wrench to tighten the bolt. The tightening bolt is 20-355Nm. 4.3.5.4 Assembly steps for oil pan The assembly steps are contrary to the disassembly steps of oil pan.



4.3.6



Disassembly, check, maintenance and assembly of piston nozzle



4.3.6.1 Exploded drawing for piston nozzle assembly



Gasket Spring washer Hexagon bolt



Seal ring Nozzle component



Fig. 4-14 Exploded Drawing for Piston Nozzle Assembly 4.3.6.2 Disassembly steps for piston nozzle ①



Disassemble the hexagon bolt (Key point 1);



②



Disassemble the nozzle assembly (Key point 2);



4.3.6.3 Check and maintenance of piston nozzle Key point 1: Assembly ①_ Tighten the fuel injection nozzle assembly by the bolt with spring washer and pressing plate; ②



Press the concave surface of fuel injection nozzle end by the pressing plate;



③



Tighten the bolt: set the TOKU pneumatic wrench at 2 position.



Key point 2: Check Check the O-ring for damage and check the body nozzle hole for cleanliness without burr.



63



Service Manual for Engine 4.3.6.4 Assembly steps for piston nozzle The assembly steps are contrary to the disassembly steps of piston nozzle.



4.3.7 Disassembly, check, maintenance and assembly of thrust plate 4.3.7.1 Exploded drawing for thrust plate assembly



Thrust plate



Fig. 4-15 Exploded Drawing for Thrust Plate Assembly 4.3.7.2 Disassembly steps for thrust plate ① Disassemble the main bearing cover (refer to 3.3.2); ② Disassemble the crankshaft (refer to 3.4.3); ③ Disassemble the thrust plate (Key point 1). 4.3.7.3 Check and maintenance of thrust plate Key point 1: Assembly If the thrust plate is be used in pair, during assembly, keep the thrust plate oil groove outward and put the “small ear” for preventing mis-assembly at the corresponding position of thrust bearing cover. 4.3.7.4 Assembly steps for thrust plate The assembly steps are contrary to the disassembly steps of thrust plate.



64



Service Manual for Engine



4.3.8 Disassembly, check, maintenance and assembly of front and rear oil seal 4.3.8.1 Exploded drawing for front and rear oil seal assembly



Front oil seal



Machine body



Rear oil seal



Fig. 4-16 Exploded Drawing for Front and Rear Oil Seal Assembly 4.3.8.2 Disassembly steps for front and rear oil seal 1) Disassemble the front wall cover (refer to 3.3.3); 2) Disassemble the front oil seal (refer to 3.3.3); 3) Disassemble the rear oil seal cover (Key point 1); 4) Disassemble the rear oil seal (Key point 2). 4.3.8.3 Check and maintenance of front and rear oil seal Key point 1： Check Check the matching surface of rear oil seal cover and body for cleaning and bump damage. Assembly 1) Wipe the matching surface and knock it into two locating pins by a hammer; 2) Glue the joint of rear oil seal cover;



65



Service Manual for Engine



Key point 2： Check Check the seal ring sticky ring sealing surface for damage and oil seal rubber for damage. Check the rear oil seal cover is clean and whether the processing surface has obvious scratch. Assembly Glue the outer ring of front oil seal (radial seal ring) and press it in the rear oil seal cover by a special tool. Attention: after assembly, the seal ring couldn’t be damaged and the seal ring outer end should be level with the oil seal cover. 4.3.8.4 Assembly steps for front and rear oil seal The assembly steps are contrary to the disassembly steps of front and rear oil seal.



66



Service Manual for Engine



4.4 Crank-connecting rod mechanism 4.4.1



Disassembly and assembly of crank-connecting rod mechanism



4.4.1.1 Exploded drawing for crank-connecting rod mechanism Piston-connecting rod assembly Torsional damper Crankshaft pulley Hub fastening bolt



Hub



Torsional damper fastening bolt



Crankshaft timing gear



Flywheel



Crankshaft



Bearing



Flywheel bolt Main shaft bushing



Flywheel gear ring



Fig. 4-17 Exploded Drawing for Crank-connecting Rod Mechanism 4.4.1.2 Disassembly steps for crank-connecting rod mechanism ①



Make inspection before disassembly. Check the axial clearance of connecting rod, and the tightening torque of connecting rod bolt; Lower the engine inclined side, turn the piston to be dismantled to the lower dead center, disassemble the connecting rod bolt and connecting cover; turn it to the upper dead center and knock it out by a hammer. Be careful to avoid clamping the cylinder block by the big end of connecting rod. Disassemble other pistons by the same method and put it orderly as per the number.



②



Unscrew the front end torsional absorber fastening bolt and hub fastening bolt and take down the crankshaft pulley, torsional absorber and hub.



③



Unscrew the flywheel bolt and take down the flywheel assembly, bearing and other parts.



4.4.1.3 Assembly steps for crank-connecting rod mechanism The assembly steps are contrary to the disassembly steps.



67



Service Manual for Engine



4.4.2 Disassembly, check, maintenance and assembly of pistonconnecting rod assembly 4.4.2.1 Exploded drawing for piston-connecting rod assembly



Piston rod part



Machine body assembly



Piston rod part Crankshaft



Fig. 4-18 Schematic Diagram for Piston-connecting Rod Assembly Top ring



compression



Second compression ring



Piston pin Piston pin retainer ring



Oil ring



Piston Connecting rod body Elastic locating pin Connecting rod bushing Connecting rod cover



Connecting rod upper bushing Connecting rod lower bushing



Connecting rod bolt



Fig. 4-19 Exploded Drawing for Piston-connecting Rod Assembly



68



Service Manual for Engine 4.4.2.2 Disassembly steps for piston-connecting rod assembly ①



Make inspection before disassembly. Check the axial clearance of connecting rod, and the tightening torque of connecting rod bolt.



②



Lower the engine inclined side, turn the piston to be dismantled to the lower dead center, disassemble the connecting rod bolt and connecting cover;



③



Turn it to the upper dead center and knock it out by a hammer. Be careful to avoid clamping the cylinder block by the big end of connecting rod.



④



Disassemble other pistons by the same method and put it orderly as per the number.



⑤



Use the internal circlip plier to carefully disassemble the elastic washer at both sides of piston and push the piston out and take down the connecting rod body. Number the piston pin and connecting rod body and put it orderly.



⑥



Use the piston ring assembly pliers to respectively disassemble the top ring, second ring and oil ring and mark it respectively.



4.4.2.3 Check and maintenance of piston-connecting rod assembly ①



Check the circular bead and piston pin seat at the piston combustion chamber throat for crack. Check the skirt section and head of piston for scuffing; and check whether the piston pin hole is normally abraded.



②



Check whether the external circle of piston ring is abnormally abraded and check whether the upper and lower end of piston ring is abnormally abraded.



③



Check whether the external circle of piston pin is abnormally abraded.



④



Check the bottom hole of big end, stem body and small head oil hole of connecting rod for crack; check whether the connecting rod busing alloy is abnormally abraded or peeling off; check whether the side of connecting rod is abnormally abraded and check the bending condition of connecting rod.



⑤



Check the abrasion condition of connecting rod bearing bush and check the alloy layer for color fading, peeling, slipping, etc.



4.4.2.4 Assembly steps for piston-connecting rod assembly ①



Use the internal circlip pliers to assemble the elastic washer in the piston retainer ring groove, rotate the stopper ring and completely assemble it. The retainer ring angle surface should be inward. The piston pin retainer ring opening should be upward.



②



Insert the small end of connecting rod in the inner cavity of piston, align the small end of connecting rod with the piston pin hole and assemble the piston pin finally assemble the piston pin retainer ring of the other side. Pay attention that the oblique incision direction should be the same with the oil inlet of piston cooling oil way. Apply proper clean lubricating oil before assembling the small end hole of connecting rod and piston pin. 69



Service Manual for Engine ③



Properly arrange the piston connecting rod components as per the cylinder number and use the piston ring assembly pliers to assemble the oil ring, second compression ring and top compression ring in the piston ring groove. The “TOP” of piston ring is upward and the piston ring and freely rotate in the ring groove.



④_ Wipe the inner wall of cylinder, crankshaft connecting lever, and piston connecting rod component and apply clean lubricating oil to the kinematic pair parts. ⑤_ Adjust the ring opening direction: assemble the top ring opening at the position 30°deviating from the centerline of piston pin; the second ring opening and top ring opening should be staggered for 120°. The oil ring opening and top and second compression ring should be staggered for 120°, which should be at the perpendicular bisector of piston ring centerline, as shown in the figure below.



70



Service Manual for Engine



Second compression ring



Top compression ring



Horizontal direction of piston pin



Oil ring



Fig. 4-20 Schematic Diagram for Opening Angle of Piston Ring Assembly ⑥



Turn the vehicle to make 1# and 6# cylinder near the lower dead center. Assemble the 1# and 6# cylinder piston part and loosely assemble the connecting rod bolt. The separation surface of connecting rod should face the left of cylinder block (i.e. oil cooler). The piston cylinder number is the same as the cylinder number. The connecting rod cap and connecting rod body should be used jointly. Apply clean lubricating oil before assembling the connecting rod bolt.



⑦



Tighten the connecting rod bolt: firstly twist it and then apply the torque of 30Nm to symmetrically tighten it finally rotate it for 58°~65°. Meanwhile, reach the torque of (85-135) Nm. Assemble other cylinders by the same methods.



4.4.3 Disassembly, check, maintenance and assembly of crankshaft 4.4.3.1 Exploded drawing for crankshaft system assembly



Torsional Crankshaft pulley damper



Wheel hub



Crankshaft timing gear



Flywheel



Crankshaft



Bearing



Hub fastening bolt



Torsional fastening bolt



damper



Flywheel ring gear



Flywheel bolt



Main shaft bushing



Fig. 4-21 Exploded Drawing for Crankshaft System Assembly 4.4.3.2 Disassembly steps for crankshaft ①



Keep the engine crankcase upward, disassemble the main bearing bolts and put them orderly.



②



Take down the crankshaft and flywheel and take out the front and back thrust plate and flywheel end bearing. Take out the oil seal: put the crankshaft on the bracket (for long-term 71



Service Manual for Engine placing, the crankshaft should be vertically placed).



72



Service Manual for Engine ③



Put all parts disassembled by category.



4.4.3.3 Check and maintenance of crankshaft ①



Check the round part of main journal and connecting rod neck for crack. For the connection of crankshaft and bearing bush, check and dredge the oil duct and check it for crack and other abnormalities.



②



Check the abrasion condition of main journal and connecting rod journal; and check it for line shape, metal peeling and crack.



③



Check the abrasion condition of front and rear oil seal.



④



Check the main bearing bolt for thread damage and other failure modes.



⑤



Check the flange bolt hole for crack.



⑥



Check the abrasion degree of crankshaft journal, bending and torsion condition of crankshaft.



4.4.3.4 Assembly steps for crankshaft ①



Wipe the bottom hole of cylinder block.



②



Clean the bottom hole of upper bearing bush cylinder block and clear the impurity at the bushing opening.



2.1. Before pressing the upper bearing bush, strictly check it for damage, if any; abandon it rather than do repairing for reuse. 2.2. After assembling the upper bearing bush, align it with the oil hole and groove with the cylinder block. The one with deviation exceeds 1/5-1/4 of the oil hole should not be assembled. The upper bearing bush should be completely fitted with the bottom hole of cylinder block. ③



Apply proper clean lubricating oil to the inner surface of upper bearing bush.



④



Apply oil to the lower plane of cylinder block and wipe it. The lower surface of cylinder block should be free of grease.



⑤



Apply the gluing line on the lower plane of cylinder block, evenly and continuously apply the sealant by the rubber roll



⑥ Lift the crankshaft and blow the oil hole by the compressed air and wipe the main journal and connecting rod journal by a towel, and slightly lower it down to the cylinder block. In this process, the crankshaft should not be damaged. ⑦



Wipe the upper thrust plate and press it in the cylinder block. The oil groove of upper thrust plate should be outward (toward the crankshaft).



⑧



On the basis of ensuring flat oil seal without torsion and deformation, use a special tool to put the oil seal flatly in the seal ring groove at the lower level of the cylinder block.



⑨



Press the lower main journal and lower thrust place in the crankcase (keep the oil groove face the crankshaft) and assemble the crankcase.



⑩



Apply clean lubricating oil at the bolt supporting surface of crankcase and thread of main 73



Service Manual for Engine bearing bolt; loosen the main bearing bolt and then tighten all main bearing bolts as per the sequence shown in Fig. 4.



74



Service Manual for Engine



Fig. 4-22 Tightening Sequence of Main Bearing Bolts ⑪ Tighten it by two times, firstly apply torque of 70Nm and then twist the bolt for 90°±4° to complete the crankshaft assembly.



4.4.4 Disassembly, check, maintenance and assembly of flywheel and gear ring 4.4.4.1 Exploded drawing for flywheel assembly



Flywheel Crankshaft Locating pin



Bearing



Flywheel bolt



Flywheel ring gear



Fig. 4-23 Exploded Drawing of Flywheel Assembly 4.4.4.2 Disassembly steps for flywheel and gear ring The disassembly steps are contrary to the assembly steps.



75



Service Manual for Engine 4.4.4.3 Check and maintenance of flywheel and gear ring ①



Check the flywheel bolt for thread damage and other failure modes.



②



Check the flywheel surface for crushing.



③



Check the flywheel gear ring for damage.



4.4.4.4 Assembly steps for flywheel and gear ring ①



Tighten the flywheel gear ring and the flywheel by the bolt.



②



Insert the cylindrical pin to the crankshaft rear end and be sure to insert it to the bottom.



③



Insert the flywheel guide rod in the crankshaft thread hole, assemble the flywheel components and tighten the flywheel bolt diagonally.



Apply lubricating oil to the flywheel bolt thread and pressure bearing surface. Flywheel bolt: bolt specification of M16-12.9 grade, (6 pieces) Tightening torque: (285~295) Nm, test value: (285~340)Nm.



4.4.5 Disassembly, check, maintenance and assembly of torsional damper, crankshaft pulley and hub 4.4.5.1 Exploded drawing for torsional damper, crankshaft pulley and hub assembly



Crankshaft Torsional damper



Crankshaft timing gear



Hub



Crankshaft pulley Hub fastening bolt



Torsional damper fastening bolt



Fig. 4-24 Exploded Drawing for Torsional Damper and Crankshaft Pulley, and Hub Assembly 4.4.5.2 Disassembly steps for torsional damper and crankshaft pulley Unscrew the pulley bolt and take down the pulley and absorber orderly. 4.4.5.3 Check and maintenance of torsional absorber, crankshaft pulley and hub ① Check the absorber for collision and deformation.



76



Service Manual for Engine ②



Check the crankshaft pulley and hub for damage and the bolt tightening part for crushing.



③



Check the hub and torsional absorber fastening bolt for damage.



4.4.5.4 Assembly steps for torsional absorber and crankshaft pulley After assembling the timing gear, assemble the hub, torsional absorber and crankshaft pulley orderly: ①_ Tighten the hub on the crankshaft by the hub fastening bolt. Crankshaft hub fastening bolt: specification of M16-12.9 grade (4 pieces); tightening torque: (300~310) Nm, test value: (300360) Nm. ②



Tighten the crankshaft pulley and torsional absorber on the hub by the torsional absorber fastening bolt: torsional absorber fastening bolt: specification of M10-10.9 grade (6 pieces); tightening torque: (65-70) Nm, test value: (65-80) Nm.



4.4.6 Disassembly, check, maintenance and assembly of crankshaft bearing bush 4.4.6.1 Exploded drawing for crankshaft bearing bush assembly Spindle lower bushing



Crankshaft



Spindle upper bushing



Fig. 4-25 Exploded Drawing for Crankshaft Bearing Bush Assembly 4.4.6.2 Disassembly steps for crankshaft bearing bush Push the bearing bush out from the side and mark the bearing bush disassembled and align it with the base hole of body and crankcase. 4.4.6.3 Check and maintenance of crankshaft bearing bush ① Clean the bearing bush and check the abrasion condition of bearing bush. ② Check the bearing bush for metal peeling off, locating pin damage and horizontal crack. 77



Service Manual for Engine 4.4.6.4 Assembly steps for crankshaft bearing bush ①



Firstly clean and wipe the main bearing bush and assembly bottom hole.



78



Service Manual for Engine ② If no new bearing bush is replaced, assemble the original bearing bush in the body (upper bush) and crankcase (lower bush) orderly. Pay attention to distinguishing the upper and lower bush. The one with oil groove is upper bush. If the new bush is replaced, directly assemble it. During assembly, pay attention to align the lip and apply little oil.



79



Service Manual for Engine



4.5 Valve mechanism 4.5.1 Disassembly and assembly of valve mechanism 4.5.1.1 Exploded drawing for valve mechanism assembly



Hexagon nut



Rocker arm seat



Hexagon screw



Valve lock clamp



Butterfly elastic washer Circlip for shaft Inner valve spring Outer valve spring Lower valve Air compressor drive spring gear Camshaft



Rocker arm Adjusting Guide valve screwspring Valve stem seal sleeve Cylinder head Valve Intake and exhaust valve tappet



Crankshaft timing gear Hexagon socket cap screw Flange Hexagon flange bearing surface toothed bolt Hexagon flange bearing surface toothed bolt



Body



Sector plate



Fig. 4-26 Exploded Drawing for Valve Mechanism Assembly 4.5.1.2 Disassembly steps for valve mechanism ①



Disassemble the rocker arm and rocker shaft; refer to the disassembly steps for rocker arm and rocker shaft for details;



②



Disassemble the intake and exhaust valve; refer to the disassembly steps for intake and exhaust valve for details;



③



Disassemble the tappet and push rod; refer to the disassembly steps for tappet and push rod for details;



④



Disassemble camshaft and camshaft timing gear; refer to the disassembly steps for camshaft and camshaft timing gear for details;



⑤



Disassemble the intermediate gear; refer to the disassembly steps for intermediate gear for details.



4.5.1.3 Assembly steps for valve mechanism The assembly steps are contrary to the disassembly steps in 3.5.1.2.



4.5.2 Disassembly, check, maintenance and assembly of camshaft assembly



80



Service Manual for Engine 4.5.2.1 Exploded drawing for camshaft assembly Compressor drive gear Camshaft Camshaft timing gear



Hexagon socket cap screw



Flange



Hexagon flange bearing surface toothed bolt



Hexagon flange bearing surface toothed bolt



Body



Sector plate



Fig. 4-27 Exploded Drawing for Camshaft Assembly



81



Service Manual for Engine



4.5.2.3 Check and maintenance of camshaft ①



Check the cam surface contacting the tappet for abrasion. Check the main journal for blockage and abrasion;



②



Check the timing gear fastening hexagon bolt for bending and deformation. Check the camshaft timing gear and compressor drive gear for clamping or serious abrasion of teeth.



4.5.2.4 Assembly steps for camshaft After assembly, check the camshaft, timing gear and compressor drive gear, in case of abrasion or other big deviation of parameter, do repairing or replace a new camshaft, timing gear and compressor drive gear. ①_ Check it for burr and collision damage and ensure no rust, scratch and impurity like scrap iron; ②



Apply proper clean oil to the camshaft hole and tappet hole and assemble the tappet. Refer to assembly steps for tappet, assemble the camshaft and apply even force in the pushing process of camshaft. Never damage the camshaft surface and body hole. The camshaft end with thread should be at the front wall cover side.



③



Assemble the sector plate and the tightening torque of bolt is (35±10) N·m. Do painting for sealing after tightening.



④



Assemble the camshaft at the front of body, assemble the gasket, flange, washer and hexagon bolt, measure the camshaft axial clearance of 0.1-0.29mm. If the camshaft axial clearance is too small, check whether there is burr between the camshaft and sector plate. After the burr is removed, the axial clearance of rear camshaft is not in the above scope, replace the camshaft.



⑤



Rotate the crankshaft, keep the timing gear 0 point close to the camshaft. Put the compressor drive gear on the camshaft and assemble the camshaft timing gear on the camshaft gear, keep the camshaft gear 0 point and crankshaft timing gear 0 connected;



⑥



Assemble the gear meshing point, align it and make self-inspection, mark the camshaft timing gear, crankshaft timing gear 0 position by the marker pen.



⑦



After aligning the asymmetrical hole, apply sealant KB277 on the clean and oil-free camshaft gear bolt and insert it through the flange hole and then screw it down to the camshaft. Tighten the timing gear fastening bolt by the pneumatic wrench and then pre-tighten the connecting bolt between camshaft timing gear and air compressor drive gear. Use the torque wrench to tighten the gear connecting bolt. The tightening torque of M10 bolt is 85N·m-90N·m; tightening torque of M8 bolt is 55N·m-60.5 N·m. after reaching the tightening torque, do painting and sealing; rotate the crankshaft and check whether the gear 0 point is properly meshed.



82



Service Manual for Engine



4.5.3 Disassembly, check, maintenance and assembly of rocker arm and rockshaft 4.5.3.1 Exploded drawing for rocker arm and rockshaft assembly Hexagonal head bolt



Rocker arm Butterfly elastic washer support



Hexagon nut



Rocker arm External retaining ring



Adjusting screw



Cylinder head



Fig. 4-28 Exploded Drawing for Rocker Arm and Rockshaft Assembly 4.5.3.2 Disassembly steps for rocker arm and rockshaft ①



Rotate crankshaft and observe whether the rocker arm can rotate freely.



②



Measure the valve clearance and check the valve clearance for change.



③



If the rocker arm rotation is not flexible or the valve clearance is great, loosen the hexagon bolt and slightly take down the rocker arm seat, circlip for shaft, butterfly elastic washer, rocker arm and butterfly elastic washer, mark it to avoid mixing the rocker arms of different cylinders.



4.5.3.4 Assembly steps for rocker arm and rockshaft ①



Check the part assembled for cleaning, damage, scratch and rusting;



②



Assemble the rocker arm adjusting screw and bolt, screw down the screw to the bottom and screw the lock nut to 2-3 screw pitches;



③



Apply proper lubricating oil to the rocker arm seat and rocker arm inner hole, and orderly assemble the butterfly elastic washer, rocker arm assembly, butterfly elastic washer, and circlip for shaft on the rocker arm seat;



83



Service Manual for Engine ④_ After that, assemble the rocker arm seat on the cylinder head by the hexagon bolt; ⑤_ Assemble the valve push rod. Refer to the assembly process of valve push rod for details; ⑥_ Assemble the rocker arm seat component and tighten it, align the concave head of rocker arm adjusting screw with the valve push road ball head, tighten the hexagon bolt with the tightening torque of 40~45N·m; 



Check and adjust the intake and exhaust valve clearance.



①_ Rotate the crankshaft till the phase indicator points at the phase disc 0 point; observe the crankshaft timing gear 0 point and meshing camshaft gear 0 point. At this time, adjust the valve clearance from the front end number 1-2-3-6-7-10 rocker arms and adjust the intake valve; firstly plug 0.2mm feeler gauge and use the torque wrench to screw down the nut. Tightening torque: 20±5 N·m. After adjustment, the plug gauge can be naturally extracted. Use the 0.25mm feeler gauge to check the clearance, but it’s unable to pass smoothly. Adjust the exhaust valve: firstly use the 0.3mm feeler gauge, and then use the torque wrench to screw down the nut. Tightening torque: 20±5 N·m. After adjustment, the plug gauge can be naturally extracted. And then use the 0.35mm feeler gauge to check the clearance, but it’s unable to pass smoothly. ②_ Rotate the crankshaft till the phase indicator points at the phase disc 0 point; observe 180°of crankshaft timing gear 0 point and meshing camshaft gear 0 point. At this time, adjust the valve clearance from the front end number 4-5-8-9-11-12 rocker arms, and adopt the same method as ①. Valve clearance adjustment is added in routine maintenance for the first 100h,and the cycle is 1000h



84



Service Manual for Engine



4.5.4 rod



Disassembly, check, maintenance and assembly of tappet and push



4.5.4.1 Exploded drawing for tappet and push rod assembly



Cylinder head



Push rod



Machine body



Tappet



Fig. 4-29 Exploded Drawing for Tappet and Push Rod Assembly 4.5.4.2 Disassembly steps for tappet and push rod ①



After unloading the rocker arm and rocker shaft, directly take out the push rod and put it orderly;



②



After disassembling the camshaft, take out the tappet from the lower part of body and put it orderly.



85



Service Manual for Engine 4.5.4.3 Check and maintenance of tappet and push rod ①



Clean the push rod and tappet;



②



Check whether the oil channel of tappet and push rod for smoothness;



③



Check the push rod for bending and check the abrasion degree of external surface;



④



Check the push rod ball head and concave head for abrasion;



⑥_ Check the tappet surface and bottom for abrasion; ⑥



Check the concave head in the tappet for abrasion.



4.5.4.4 Assembly steps for tappet and push rod ①



Check whether the tappet and push rod are faulty, if any, replace them. Before assembling the tappet, be sure to blow off by the compressed air and check the oil hole for smoothness;



②



Evenly apply clean lubricating oil to the body tappet hole and valve tappet external circle;



③ Slightly put the tappet in the tappet hole from the lower part of body, the tappet can freely rotate in the tappet hole and the hand resistance is even. Assemble the camshaft. Refer to the assembly steps for camshaft for details; ④_ Assemble the rocker arm seat on the cylinder head, and check whether the push rod is clean and the welding is proper; ⑤_ Apply clean lubricating oil to the push rod and be sure to maintain sufficient lubricating oil at the ball head; ⑥



Assemble the push rod and slightly insert it through the cylinder head and to the tappet.



4.5.5 Disassembly, check, maintenance and assembly of valve 4.5.5.1 Exploded drawing for valve assembly Valve spring upper seat



Valve lock clamp Valve internal spring



Valve external spring



Valve steam seal sleeve



Valve spring lower seat Cylinder head



Intake valve



Exhaust valve



Fig. 4-30 Exploded Drawing for Valve Assembly



86



Service Manual for Engine 4.5.5.2 Disassembly steps for valve ①



Use the valve spring compressor or valve overhead pliers or other tools to press the valve spring, take out the valve lock clamp and take out the guide valve spring, internal and external valve spring;



②



Take out the valve from the valve seat.



4.5.5.3 Check and maintenance of valve ①



Check the valve stem and valve stem end for abrasion;



②



Check the valve cone for abrasion or damage;



③



Check the valve cone for carbon deposit;



④



Check the valve disc surface for carbon deposit and sintering.



4.5.6 gear



Disassembly, check, maintenance and assembly of intermediate



4.5.6.1 Exploded drawing for intermediate gear assembly



Intermediate gear shaft



Baffle



Intermediate gear component



Shaft



Hexagon bolt



Fig. 4-31 Exploded Drawing for Intermediate Gear Assembly 4.5.6.2 Disassembly steps for intermediate gear ①



Mark the bolt and confirm whether the bolt is rotating.



②



Disassemble 4 M10 hexagon bolts of intermediate gear and take down the gasket.



③



Screw a M8 bolt in the intermediate gear shift, pull it out and pay attention to preventing intermediate gear falling off. Disassemble the intermediate gear with the idler shaft.



87



Service Manual for Engine 4.5.6.3 Check and maintenance of intermediate gear ①



Whether the bolt thread is good;



②



Check all gears for teeth falling and breakage, check whether the bolt bearing surface for crushing and thread hole or through-hole of gear for deformation;



③



Check the intermediate gear shaft and intermediate gear liner or shaft and intermediate gear shaft for abnormal abrasion. Check whether all oil holes are blocked by dirt.



4.5.6.4 Assembly steps for intermediate gear ①



Assemble the front wall cover assembly on the body as required.



②



Assemble the intermediate gear assembly: Assemble the intermediate gear shaft and intermediate gear assembly and drop proper oil on the intermediate gear shaft.



③



Put the intermediate gear assembly in the front wall cover, align it and insert the oil shaft.



④



Properly put the baffle and fasten it by bolt. The tightening torque is 65-70 N.m.



⑤



After fixing the gear, stir the gear by a hand and check it for clearance or gear blockage.



4.6 Intake and exhaust system 4.6.1 Disassembly and assembly of intake and exhaust system 4.6.1.1 Exploded drawing for intake and exhaust system assembly



Turbocharger Supercharger return pipe



fuel Engine pipe



exhaust



Engine intake pipe



Fig. 4-32 Exploded Drawing for Intake and Exhaust System Assembly



88



Service Manual for Engine 4.6.1.2 Disassembly steps for intake and exhaust system 1) Disassemble the supercharge intake pipe and exhaust pipe and loosen the oil inlet and return pipe bolt; 2) Disassemble the turbocharger; 3) Disassemble the EGR water and air channel connecting pipe; 4) Disassemble the EGR cooler, EGR valve component and disassemble the EGR coolant bracket. 5) Take down the supercharger oil inlet and outlet pipe and disassemble the exhaust pipe; 6) Orderly loosen the exhaust pipe fastening bolt and take down the exhaust pipe and gasket; 7) Orderly loosen the intake pipe fastening bolt and take down the intake pipe assembly. 4.6.1.3 Assembly steps for intake and exhaust system The assembly steps are contrary to the disassembly steps.



4.6.2



Disassembly, check, maintenance and assembly of intake pipe



4.6.2.1 Exploded drawing for intake pipe assembly Intake pipe Air pipe



inlet Heater Air pipe



inlet



Blanking cap



Gasket Joint



Fig. 4-33 Exploded Drawing for Intake Pipe Assembly 4.6.2.2 Disassembly steps for intake pipe 1) Loosen the hexagon bolt and take down the intake pipe and gasket; 2) Loosen the hexagon bolt and take down the heater and gasket; 3) Loosen the intake pipe fastening bolt and taken down the intake pipe and gasket;



89



Service Manual for Engine 4) Orderly loosen the intake pipe bolt and take down the intake pipe and gasket. 4.6.2.3 Check and maintenance of intake pipe 1) Check the intake pipe for casting defects, if any, replace the new intake pipe. 2) Check the intake pipe gasket for deformation, fracture, loss, etc. if any, replace it. 4.6.2.4 Assembly steps for intake pipe The assembly steps are contrary to the disassembly steps. The recommended tightening torque for intake pipe bolt is 23N·m.



4.6.3



Disassembly, check, maintenance and assembly of exhaust pipe



4.6.3.1 Exploded drawing for exhaust pipe assembly



Exhaust pipe connecting pipe



Double-end stud



Lock nut



Exhaust pipe



Fig. 4-34 Exploded Drawing for Exhaust Pipe Assembly 4.6.3.2 Disassembly steps for exhaust pipe 1) Loosen the hexagon bolt and take down the exhaust pipe, supercharger gasket and EGR exhaust flange gasket. 2) Orderly loosen the exhaust pipe fastening bolt and take down the exhaust pipe and gasket. 4.6.3.3 Check and maintenance of exhaust pipe 1) Check the exhaust pipe body for crack and other damages and check the flange for deformation, if any, replace a new exhaust pipe. 2) Check the exhaust pipe flange for leakage, if any, replace a new exhaust pipe gasket. 3) Check the exhaust pipe gasket for deformation, fracture, loss, etc. if any, replace it. 90



Service Manual for Engine 4) Check the supercharger gasket for deformation, fracture, loss, etc. if any, replace it. 4.6.3.4 Assembly steps for exhaust pipe The assembly steps are contrary to the disassembly steps. Attentions for assembly: 1) Apply the bite-preventing agent (molybdic sulfide) to the exhaust pipe bolt. The tightening torque is 65-80N·m. The exhaust pipe bolt can be maximally reused for two times.



4.6.4 Disassembly, check, maintenance and assembly of supercharger system 4.6.4.1 Exploded drawing for supercharger system assembly



Turbocharger Supercharger gasket



Nut



Double-end stud



Fig. 4-35 Exploded Drawing for Supercharger System Assembly 4.6.4.2 Disassembly steps for supercharger system The disassembly steps are contrary to the assembly steps. 4.6.4.3 Check and maintenance of supercharger system 1. Check the running condition of rotor Slightly move the air compressor impeller by a hand, it’s normal if it rotates above one round. If it quickly stops, it means abnormal abrasion of bearing or the rotary part collides with the fixed part or it’s blocked. Analyze the reason and eliminate the fault. 2. Check the rotor displacement Put the mutlimeter measuring head at the compressor end, push and pull the rotary shaft along the 91



Service Manual for Engine shaft, measure and record the difference in the meter, as shown in Fig. 4.6.4.3-1.



92



Service Manual for Engine The rotor displacement should be within 0.088~0.118mm, if the value is exceeded, it means that the thrust bearing or thrust plate and bearing body are abraded. Analyze the reason and eliminate the fault.



Fig. 4-36 Diagram for Axial Clearance Measurement 3. Radial clearance check of compressor impeller Press or spit the compressor impeller by a hand in the radial direction. Measure the minimum and maximum clearance between compressor impellor and compressor volute casing by the feeler gauge, as shown in Fig. 4.6.4.3-2. The value is within 0.4-0.8mm. If the scope is exceeded, check the bearing and eliminate the fault. Note: make the measurement when the supercharger is cold.



Fig. 4-37 Diagram for Axial Clearance Measurement 93



Service Manual for Engine Daily maintenance: 1. Check the connection of supercharger and engine pipe for looseness and eliminate the fault in time.



94



Service Manual for Engine 2. Check the supercharger for air and oil leakage and eliminate the fault in time. 3. Check the fastening screw of supercharger for looseness and eliminate the fault in time. 4. Check the air filter, if there is much dust, clean it in time. 4.6.4.4 Assembly steps for supercharger system 1. Assemble the supercharger gasket on the exhaust pipe flange. 2. Put the supercharger gasket on the exhaust pipe flange surface and assemble the supercharger assembly, loosely assemble 2 types full-metal hexagon locking nut and screw it down. 3. Pour proper clean lubricating oil to the supercharger oil inlet and wipe the overflowing lubricating oil. 4. Assemble the gasket, double-end stud and connect the silencer. 5. All gaskets can only be used once. Replace a new part in the repairing process.



4.7 Fuel system 4.7.1



Disassembly and assembly of fuel system



4.7.1.1 Exploded drawing for fuel system assembly Fuel injector



High-pressure oil pipe



Fuel filter



Fuel injection pump



Fig. 4-38 Exploded Drawing for Fuel System Assembly 4.7.1.2 Disassembly steps for fuel system ①



Disassemble the pipe and bracing wire connecting the fuel system and vehicle.



②



Disassemble the low-pressure oil pipe component. Refer to disassembly instructions of lowpressure oil pipe for details.



95



Service Manual for Engine ③ Disassemble the smoke limiter air pipe. ④ Disassemble the high-pressure oil pipe component. ⑤ Disassemble the filter component; refer to disassembly instructions of filter for details. ⑥ Disassemble the fuel injector component; refer to disassembly instructions of fuel injector. ⑦ Disassemble the front wall cover upper cover plate; refer to disassembly instructions of front wall cover. ⑧ Disassemble the fuel injection pump component; refer to disassembly instructions of fuel injection pump. 4.7.1.3 Assembly steps for fuel system The assembly steps are contrary to the disassembly steps.



4.7.2 Disassembly, check, maintenance and assembly of fuel injection pump 4.7.2.1 Exploded drawing for fuel injection pump assembly Fuel injection pump Fuel injection pump gear



Fuel injection pump fuel return pipe



Fig. 4-39 Exploded Drawing for Fuel Injection Pump Assembly 4.7.2.2 Disassembly steps for fuel injection pump ① Disassemble the pipe and bracing wire connecting the fuel injection pump and vehicle. ② Disassemble the hollow bolt connecting the fuel injection pump and low-pressure oil pipe. ③ Disassemble the hollow bolt connecting the fuel injection pump and smoke limiter air pipe. ④ Disassemble the hollow bolt connecting the fuel injection pump and fuel injector fuel return pipe. ⑤ Disassemble the connecting nut between the fuel injection pump and high-pressure oil pipe in order. 96



Service Manual for Engine ⑥ Disassemble the hollow bolt connecting the fuel injection pump and lubricating oil pipe.



97



Service Manual for Engine ⑦ Disassemble the front wall upper cover plate. Refer to disassembly instructions for front wall cover. ⑧ Disassemble the fuel pump bolt to disassemble the fuel injection pump gear and pressing plate. ⑨ Disassemble the fixing nut between fuel injection pump and front wall cover to disassemble the fuel injection pump. 4.7.2.3 Check and maintenance of fuel injection pump ① Check the fuel injection pump for crack and oil leakage, if so, replace it and feed it back to the manufacturer as per corresponding flow. ② Check the lead seal on the fuel injection pump for damage; if so, replace the fuel pump or adjust the fuel volume on the fuel pump seat stand. ③ Check the smoke limiter air pipe for crack and joints at two ends for air leakage. If there is crack, replace the smoke limiter air pipe. If there is air leakage at two ends, replace the hollow bolt gasket at two ends. ④ Check the lubricating oil pipe for leakage; if so, replace the lubricating oil pipe or hollow bolt gasket at two ends as per the leakage position. 4.7.2.4 Assembly steps for fuel injection pump The assembly steps are contrary to the disassembly steps. When assembling the fuel pump gear, turn the engine disc to correct advance angle of fuel supply and rotate the fuel pump camshaft to ensure that the fuel is supplied to the first cylinder (from the driving end), and finally screw down the fixing bolt of fuel injection pump gear.



4.7.3 pipe



Disassembly, check, maintenance and assembly of high pressure oil



4.7.3.1 Exploded drawing for high-pressure oil pipe assembly



Fig. 4-40 Exploded Drawing for Fuel Pump Assembly 4.7.3.2 Disassembly steps for high-pressure oil pipe ① Disassemble the connecting nut of high-pressure oil pipe and fuel injector of each cylinder in 98



Service Manual for Engine order. ② Disassemble the connecting nut of high-pressure oil pipe and fuel injector of each cylinder in order. 4.7.3.3 Check and maintenance of high-pressure oil pipe ① Check the high-pressure oil for crack and oil leakage and so on, if so, replace the high-pressure oil pipe and feed back as per corresponding flow. ② Check the joint cone surface of two ends of high-pressure oil pipe and ensure good cone surface.



99



Service Manual for Engine 4.7.3.4 Assembly steps for high-pressure oil pipe The assembly steps are contrary to the disassembly steps. Keep the high-pressure oil pipe clean and intact.



4.7.4



Disassembly, check, maintenance and assembly of fuel injector



4.7.4.1 Exploded drawing for fuel injector assembly Compression bolt Spherical washer



Hollow bolt



Fuel injector block Fuel injector



Fig. 4-41 Exploded Drawing for Fuel Injector Assembly 4.7.4.2 Disassembly steps for fuel injector ① Disassemble the hollow bolt connecting the fuel injector of each cylinder and fuel injector oil return pipe. ② Disassemble the fuel injector compression bolt and take down the fuel injector pressing plate. ③ Disassemble the fuel injector by a special tool. 4.7.4.3 Check and maintenance of fuel injector ① Check the copper seal washer. In case of excessive deformation or other damage, replace it and clean the fuel injector seat hole surface, clean the carbon deposit and other impurities on it so as to ensure sealing. Properly assemble the fuel injector, seal washer and adjusting gasket on it to ensure that the lower cone surface and tip protrusion of nozzle body meets the requirement. ② Check the fuel injector oil return pipe for damage and oil leakage; if any, replace it. 4.7.4.4 Disassembly steps for fuel injector The assembly steps are contrary to the disassembly steps.



100



Service Manual for Engine



4.7.5 Disassembly, Check, Maintenance and Assembly of Fuel Filter 4.7.5.1 Exploded Drawing for Fuel Filter Assembly



Fuel filter



Fig. 4-42 Exploded Drawing for Fuel Injection Pump Assembly 4.7.5.2 Disassembly steps for fuel filter ① Disassemble the hollow bolt connecting the fuel fine filter or coarse filter and the low-pressure oil pipe. ② Disassemble the bolt connecting fuel filter or coarse filter and fixing bracket. ③ Further disconnect the fuel filter element and filter base. 4.7.5.3 Check and maintenance of fuel filter ① Check whether the fuel filter is good. ② Check the connection of fuel filter and filter base for oil leakage, if so, replace the affected parts. ③ Check the fuel filter for blockage, if so, replace the filter element. When replacing the filter element, fill clean diesel oil in the new filter element, keep the filter base clean and apply lubricating oil to the rubber gasket. After the rubber gasket contacts the base, screw it down for 3/41 circle to seal it; finally disassemble the bleeder screw on the filter base and press the hand pump on the fuel injection pump to exhaust air in the filter. 4.7.5.4 Assembly steps for fuel filter The assembly steps are contrary to the disassembly steps. When replacing the filter element, fill clean diesel oil in the new filter element, keep the filter base clean and apply lubricating oil to the rubber gasket. After the rubber gasket contacts the base, screw it down for 3/4-1 circle to seal it; finally disassemble the bleeder screw on the filter base and press the hand pump on the fuel 101



Service Manual for Engine injection pump to exhaust air in the filter.



102



Service Manual for Engine



4.7.6 pipe



Disassembly, check, maintenance and assembly of low-pressure oil



4.7.6.1 Exploded drawing for low-pressure oil pipe assembly Refer to Fig. 4.7.5-1 Exploded drawing for fuel system assembly. 4.7.6.2 Disassembly steps for low-pressure oil pipe ①Disassemble the low-pressure oil pipe fixing cylinder head and the fixing bracket on the body. ②Disassemble the hollow bolt connecting low-pressure oil pipe and fuel injection pump. ③Disassemble the hollow bolt connecting the low-pressure oil pipe and fuel fine filter or coarse filter. 4.7.6.3 Check and maintenance of low-pressure oil pipe ①Check the low-pressure oil pipe appearance for oil leakage; if so, replace it and feed it back to the manufacturer as per corresponding procedure. ②Check the connector at two ends of low-pressure oil pipe for oil leakage; if so, replace the hollow bolt seal washer. 4.7.6.4 Assembly steps for low-pressure oil pipe The assembly steps are contrary to the disassembly steps.



4.8 Cooling system 4.8.1



Disassembly and assembly of cooling system



4.8.1.1 Exploded drawing for cooling system assembly The function of cooling system is to ensure the continuous working of diesel engine at proper temperature. Forced circulating cooling is to provide the best guarantee for quickly reaching the operating temperature. The cooling system consists of water pump, fan, expansion tank, water tank, thermostat, etc.



103



Service Manual for Engine



Water pump Fan



Belt



Air heater



Intermediate cushion



Air heater



Pressure limiting valve cover Expansion tank



Therm ostat



Water outlet



Water pump



Cylinder head Oil cooler



Radiator



Air compressor



Fan



Diesel engine body



Fig. 4-43 Drawing for WP6 Series Diesel Engine Cooling Line 4.8.1.2 Disassembly steps for cooling system ①Disassemble the fan and connecting disc. Refer to the disassembly instructions of fan. ②Disassemble the tensioning wheel. ③Disassemble the belt. ④Disassemble the generator, generator bracket, crankshaft belt pulley, and shock absorber.



104



Service Manual for Engine ⑤Disassemble the thermostat. Refer to the disassembly instructions of thermostat. Disassemble the water inlet. ⑥Disassemble the air compressor and hydraulic pump. ⑦Disassemble the water pump pipe joint and water pump. Refer to disassembly instructions of water pump for details. ⑧Disassemble the intermediate cushion of water pump. 4.8.1.3 Assembly steps for cooling system The assembly steps are contrary to the disassembly steps.



4.8.2



Disassembly, check, maintenance and assembly of fan



4.8.2.1 Exploded drawing for fan assembly



Fan



Fig. 4-44 Exploded Drawing for Fan Assembly 4.8.2.2 Disassembly steps for fan ①Disassemble the screw and washer connecting the fan and connecting disc to disassemble the fan. ②Disassemble the connecting screw washer of connecting disc and belt pulley. ③Disassemble the connecting disc. ④Disassemble the belt pulley. 4.8.2.3 Check and maintenance of fan Check the fan, connecting disc and belt pulley for crack and other damages. 4.8.2.4 Assembly steps for fan The assembly steps are contrary to the disassembly steps. 105



Service Manual for Engine



4.8.3



Disassembly, check, maintenance and assembly of water pump



4.8.3.1 Exploded drawing for water pump assembly



Double click Double click Water pump it to edit the it to edit the text text bolt



Double click it to edit the text



Fig. 4-45 Exploded Drawing for Water Pump Assembly 4.8.3.2 Disassembly steps for water pump ①Disassemble the water pump belt pulley. ②Disassemble the hose and hoop connecting the water inlet and thermostat; ③Disassemble the hexagon bolt and spring washer on the water pump to disassemble the water pump. ④Disassemble the water pump gasket and water pump intermediate cushion. 4.8.3.3 Check and maintenance of water pump ①Check the water pump gasket for fracture and other damages; if so, replace it. ②Check the bolt and stud for thread scratch and other damages; if so, replace it. ③Check the water pump and intermediate cushion for crack and other damages; if so, replace it. 4.8.3.4 Assembly steps for water pump The specific assembly steps are contrary to the disassembly steps.



106



Service Manual for Engine



4.8.4 Disassembly, check, maintenance and assembly of thermostat 4.8.4.1 Exploded drawing for thermostat assembly



Thermosta t cover



Hoop



Fig. 4-46 Exploded Drawing for Thermostat Assembly 4.8.4.2 Disassembly steps for thermostat ①Disassemble the hoop connecting the upper hose and cooling pipe and thermostat. ②Disassemble the hoop connecting lower hose and water pump and thermostat. ③Disassemble the thermostat. ④Disassemble two coolant connecting hose. 4.8.4.3 Check and maintenance of thermostat ①Check the hoop for failure and damage, if so, replace it. ②Check the coolant connecting hose for crack and other damages; if so, replace it. ③Check the thermostat for crack and other damages; if so, replace it. 4.8.4.4 Assembly steps for thermostat The specific assembly steps are contrary to the disassembly steps.



107



Service Manual for Engine



4.10 Starting system 4.10.1 Disassembly and assembly of starting system 4.10.1.1 Exploded drawing for starting system



1-Starter 2-Hexagon bolt



3-Spring washer



4-Flywheel ring gear



Fig. 4-47 Exploded Drawing for Starting System 4.10.1.2 Disassembly steps for starting system ①Disassemble the hexagon bolt 2 and spring washer 3; ② Grasp the starter 1 by two hands and take it down along the rotation axis of starter gear. 4.10.1.3 Check and maintenance of starter Check whether the starter gear is damaged, if so, replace it. 4.10.1.4 Assembly steps for starting system The assembly steps are contrary to the disassembly steps.



108



Service Manual for Engine



4.11



Vehicle accessory system



4.11.1 Disassembly and assembly of vehicle accessory system 4.11.1.1 Exploded drawing for vehicle accessory system



Generator



Generator bracket Generator gasket Generator bolt



Fig. 4-48 Exploded Drawing for Vehicle Accessory System 4.11.1.2 Disassembly steps of vehicle accessory system 1. Disassemble the generator components ①Loosen the generator tension nut and bolt and nut hinged with the tensioning block, take down the nut, and tighten the bolt and tensioning block. ② Disassemble another fixing bolt of generator, rotate the generator body and take down the poly V-belt, fixing bolt and generator. 4.11.1.3 Assembly steps for vehicle accessory system 1. Assemble the generator components ①Put the generator on the generator bracket and loosely assemble it on the bracket and tie rod with the fixing bolt. ②Assemble the generator poly V-belt. ③Adjust the generator position and tighten the generator poly V-belt by the generator tightening bolt, and lock the fixing bolt and nut of generator.



109



Service Manual for Engine



4.11.2 Disassembly, inspection, maintenance and assembly of generator 4.11.2.1 Exploded drawing for generator assembly



Generator



Generator bracket Generator gasket Generator bolt



1-Generator mounting support



2-Poly V-belt 3-Generator



4- Generator tightening component



Fig. 4-49 Exploded Drawing for Generator Assembly 4.11.2.2 Disassembly steps of generator ①Disassemble the tightening nut of generator, tighten the bolt and nut connected with the bolt cushion, take down the nut, and tighten the bolt and bolt cushion; ②Disassemble another fixing bolt of the generator, rotate the generator body and take down the front belt of the generator. ③Disassemble the fixing bolt and generator and the generator bracket. ★Attention: The disassembly and repairing of generator must be done by professionals. For assembly, check the insulation pad and insulation sleeve for integrity, if damaged, be sure to replace it! the positive terminal of generator and housing should not be shorted; otherwise, it’s prohibited to loading to cause serious vehicle accident. 4.11.2.3 Fault diagnosis and maintenance of generator 1. Fault judgment flow of generator For guaranteed repairing, the user should firstly test and judge whether it’s generator fault. Tool: test light and flow chart shown in Fig. 3.11.2-2.



110



Service Manual for Engine



Turn on the power switch of vehicle and connect the test light at terminal B+ and E (negative pole) of generator



No Whether the test light illuminates



It means that there is no voltage at terminal B+ of generator and the wire connecting the positive pole of battery is faulty



Yes Connect terminal E with terminal D+ of generator No It means that the internal electrical wiring at terminal D+ of generator is faulty



Whether the test light illuminates Yes Start the engine



Yes The test light illuminates



Generator fault No



No fault of generator



Fig. 4-50 Flowchart for Judgment of Generator Fault 2.



Fault diagnosis and troubleshooting of the charging system



a) Charging fault Fault 1: Charging fault Vehicle Phenomenon



Fault Detection



Solution ①_ Check whether the generator indicator has



(1) The key is at ON a Check the charging voltage to ground, if no, replace the indicator or and



the



indicator illuminate



charging indicator



check the circuit.



doesn’t b Check the excitation ② If yes, it means that the generator speed circuit for open circuit



governor or rotor is faulty, repair or replace the motor



(2) When the engine a The indicator power is at idle speed, the is low or the parallel charging



indicator excitation resistance is



doesn’t go out but loosened goes out at high b The engine idle speed speed



①_ It’s suggested using 2-6W bulb or repairing the circuit ②Adjust the idle speed of engine



is too low 111



Service Manual for Engine ①If the voltage at the generator indicator end is very low, it means that the excitation circuit indicator power is too low or the circuit is virtually connected. Adjust the indicator power or check the circuit connector or joint. a Check whether the ②If the terminal voltage of generator indicator is zero, it voltage to ground of means that there is short circuit to ground at the generator excitation excitation wire generator terminal, check the circuit. end is within 1-3V;



③If the terminal voltage of generator indicator is battery voltage, it means that the excitation circuit is faulty, and the generator governor and excitation pipe may be damaged. Be sure to modify the excitation circuit and connect the repaired generator. ①_ If the voltage to ground of terminal B+ is zero, check whether the positive and negative leads from



(3) When the



generator to battery are connected.



generator



is



② If the voltage to ground of terminal B+ is lower than



working,



the



the battery voltage, check all joints of positive and



charging



negative lead from the generator to the battery for



indicator



looseness or the battery for damage. Recommended



doesn’t go out



detection method: connect a 2W indicator between b Check whether the generator output terminal B+ and excitation terminal voltage to ground of D+/L to observe the working condition of indicator and generator



output eliminate fault:



terminal B+ is the ①_ If the indicator brightness is normal, and the battery



voltage



about 24V



of indicator goes out after the engine is started. The generator output voltage is 27-28.5V; the vehicle excitation line is faulty and needs repairing. ②If the indicator brightness is normal and the indicator doesn’t go out after the engine is started, the generator output voltage is 27-28.5V; the generator adjuster is faulty and needs repairing. ③ If the indicator brightness is normal and the indicator doesn’t go out after the engine is started, the generator output voltage is battery voltage; the generator adjuster, 112



Service Manual for Engine rectifier bridge, stator or internal wiring may be faulty and need repairing or replacing. b) Too low charging voltage Fault 2: Too low charging voltage Vehicle Phenomenon



Fault Detection



Solution



113



Service Manual for Engine



Learn whether the generator



output



power and vehicle appliance



are



properly matched. a



generally between 27.8 and 28.4. if the voltage is normal, it means that the voltmeter or voltmeter sampling point is faulty and needs repairing or replacing.



the ①_ The idle speed of motor should be higher than



Check



voltmeter



for 1,600RPM. ②The speed of generator driving the air conditioner



damage. b



Measure the B+ terminal voltage of generator, which is



the working at high power should be ≥2000rpm or the



Check



generator speed.



voltage should be about 27V.



c Check the quality ①_ Check the generator and relevant wheel system belt and The



battery



charging



is



always insufficient. The



charging



voltage is low and the voltage drop at open load is obvious.



tensioning quality, and be sure to replace the belt with coking, tooth



condition



of loss, fracture, deformation, sinking, etc.



generator



and ②Tighten the generator and relevant wheel system belt



relevant



wheel ★Attention: if the belt that needs to replace the belt is



system drive belt. d



Check



dual belt driving, be sure to replace the two belts! the



generator belt pulley.



If it’s loosened, tighten it. ①_ For working at high load, if the voltage difference is



e Check whether the higher than 1V (if the wire is thin, the voltage drop is wire is properly used great), replace the wire and



measure



the Within 35A, S ≥6mm2



Within 70A, S ≥12mm2



generator and battery Within 100A, S ≥20mm2 Within 150A, S ≥25mm2 ② For working at high load, the wire or connector is hot,



terminal voltage



replace the wire or connector. f Check whether the wire



and



connection



bolt of



charging system is loosened,



oxidized,



virtually



connected



and generates high heat



①_ The lead with oxidized surface should be assembled after the grounding bolt housing surface is polished. ②Tighten the loose nut and wiring piece and tighten the connector again. ★Attention: For the reassembled or tightened part, after the engine is running for 3-5 minutes under high load, check whether it’s very hot.



g Test the phase If the phase terminal (W/R/AC) output voltage is quite 114



Service Manual for Engine output



voltage



of different from the normal output value, the generator



generator (about a rectifier bridge or stator is faulty, repair or replace it. half



of



output



voltage of terminal B+)



115



Service Manual for Engine



After charging of 10 minutes, if the charging current



h Check whether the



drops to about 10A, and the charging current is always



battery charging is



30-90A, it means that the battery is damaged and needs



normal



repairing or replacing.



c) Too high charging voltage Fault 3: Too high charging voltage Vehicle Phenomenon



Fault Detection



Solution Measure the B+ terminal voltage of generator, which



a Check the voltmeter for is generally between 27 and 28.4V. if the voltage is damage



normal, it means that the voltmeter calibration value error is big and needs repairing or replacing.



b Check the wire and connecting charging



part



of



system



and



1 For poor contact and loose wire, tighten it and check the wiring bolt for ○ looseness,



virtual tighten the connector again.



connection and overheat, ②For short circuit, connect the wire again. and check whether the The



voltmeter wire



shows



and



generator



high housing is short circuit. ①_ Observe whether the charging current of battery



voltage



changes (from 50A to within 10A) greatly in short time in the charging process, if not, replace the c Check the battery for battery as quickly as possible; ②Observe whether the battery surface is clean and



normal working.



dry, the wiring pole and clamp are properly matched; if damaged, be sure to replace it as quickly as possible. d Test the phase output If the phase terminal (W/R/AC) output voltage is voltage



of



(about



half



generator quite different from the normal output value, the of



B+ voltage drop is great when the generator has load.



terminal output voltage)



The generator rectifier bridge or stator is faulty and 116



Service Manual for Engine needs repairing or replacing. e Complete above checks



Replace the generator adjuster, rotor or machine.



117



Service Manual for Engine The fault isn’t eliminated d) Unstable charging voltage Fault 4: Unstable charging voltage Vehicle



Fault Detection



Phenomenon When



Solution



the a Generator or relevant wheel system Tighten the generator and relevant



engine



is belt is too loose and bouncing



working



wheel system belt



b The connection of charging wire is Check the connectors fastening the



properly,



the loose and in poor contact



charging wire



voltmeter



c The collector ring has dirt or the



indicates



electric brush is excessively abraded or Clear the dirt or replace the electric



charging the



but the electric brush spring is too soft and brush and electric brush spring pointer broken



swings left and right



so



it’s



unable to see the



reading



clearly (or the charging



d Adjuster damage



Replace the adjuster



indicator illuminates and goes



out



intermittently) e) Abnormal noise of generator Fault 5: Abnormal noise of generator Vehicle Phenomenon



Fault Detection



Solution



a The generator fixing support is Abnormal noise deformed or the external machines are in the running too close process generator



of b The generator belt is loose and slipping c The generator belt pulley is loose 118



Improve the mounting bracket strength and adjust the mounting state Replace the engine belt Fasten the belt pulley



Service Manual for Engine d The generator shaft is lacking of oil or damaged e Deep abnormal noise in the generator f Howling in the generator varies with the speed.



Replace the generator bearing The stator coil is short circuit, so replace it If the noise is generated by stator iron core vibration, replace the stator component.



119



Service Manual for Engine



Appendix A DTC Table Description



Flash code



P code



Related parts



Problem



Fault cause



Solution



The reference voltage of analog-digital converter is



P060B



higher than the upper threshold The reference



The



voltage of



flashing



analog-digital



lamp is



converter is



P060B



illumina



lower than the lower



ting and 1-1-1



ECU



the



threshold



engine



The test pulse



executes



voltage of



the limp



analog-digital



home



converter is



ECU internal chip fault



Replace the ECU



mode



P060B



higher than the upper threshold In certain time, only



P060B



some dataflow is converted The voltage of accelerator pedal 1 is higher than the upper threshold



Accelerat 2-2-1



P0123



or pedal sensor 1



The



1. The accelerator



1. Power on



accelera



pedal signal 1 in



and measure the



tor



the vehicle harness



voltage to ground



malfunc



is short to power



of pedal



tions



supply.



connector 4 pin,



and the



2. Accelerator



it’s normal if the



120



Service Manual for Engine engine



pedal fault



voltage is 5V; 2.



is



3. The pedal signal



Power on to



running



1 pin 1.79 is



check the voltage



at 1,000



subject to open



of accelerator



rounds



circuit



pedal, the APP1



The voltage of



1. The accelerator



voltage is 0.5-



accelerator



pedal signal 1 in



0.8V when the



the vehicle harness



pedal is not



is short to ground.



pressed, and the



lower



2. Accelerator



APP1 voltage is



threshold



pedal fault



3.2-4.0V when



pedal 1 is lower than the



P0122



the pedal is pressed, it’s normal; otherwise, replace the accelerator pedal; 3. Power off and



The two-time signal relation



1. The accelerator



check the voltage



between



pedal signal line in



to ground of



the vehicle harness



pedal connector 6



is faulty



pin, it’s normal if



accelerator



2. Accelerator



the voltage is 0V;



pedal 2 is



pedal fault



4. Power off and



accelerator pedal 1 and



P2135



measure the



unbelievable



resistance to ground of connector 6 pin, it’s normal if the resistance is＞ 1MΩ.



121



Service Manual for Engine



1. The accelerator



1. Power on and



pedal signal 2 in



measure the



The voltage of



the vehicle harness



voltage to ground



accelerator



is short to power



of pedal



supply.



connector 3 pin,



2. Accelerator



it’s normal if the



the upper



pedal fault



voltage is 5V; 2.



threshold



3. Pedal signal 1



Power on and



pin 1.80 is subject



measure the



to open circuit



voltage of



pedal 2 is



P0223



higher than



The voltage of accelerator pedal 2 is



P0222



lower than the lower threshold



Accelerat 2-2-1



1. The accelerator



accelerator pedal,



pedal signal 2 in



the APP2 voltage



the vehicle harness



is 0.3- 0.4V when



is short to ground.



the pedal is not



2. Accelerator



pressed, and the



pedal fault



APP2 voltage is 1.6-2.0V when



or pedal



the pedal is



sensor 2



pressed, it’s normal; otherwise, replace the



The 1/2 signal relation



1. The accelerator



accelerator pedal;



between



pedal signal line in



3. Power off and



the vehicle harness



measure the



is faulty



voltage to ground



accelerator



2. Accelerator



of pedal



pedal 1 is



pedal fault



connector 1 pin,



accelerator pedal 2 and



P2135



it’s normal if the



unbelievable



voltage is 0V; 4. Power off and measure the resistance to ground of 122



Service Manual for Engine connector 1 pin, it’s normal if the resistance is0MΩ. The voltage of atmospheric



1. Check whether



pressure



the voltage of



sensor is



P2229 Check whether the



higher than the upper



Atmosphe



threshold The voltage of



ric 2-3-2



pressure



atmospheric



sensor (in



pressure



the ECU)



sensor is



Abnorm



voltage of ECU



al



power line is



atmosph



normal or the



eric



internal



pressure



atmospheric



test



pressure sensor of



P2228



ECU is damaged



lower than the lower



ECU power line is normal; 2. Check the atmospheric pressure display in plain and the normal value is 1,000hPa. If the deviation is too big, replace the



threshold



ECU. P0000



123



Service Manual for Engine



Signal of atmospheric pressure sensor from CAN is unbelievable The signal of atmospheric pressure sensor and



P2227



intake pressure sensor is unbelievable



1. Check the accelerator pedal sensor, the APP1 voltage is 0.50.8V and the APP2 voltage is 0.3-0.4V when Brake The signal of accelerator and brake is unbelievable



2-2-5



P2299



switch,



Acceler



accelerato



ator



r pedal



malfunc



position



tions



sensor



Brake switch, accelerator pedal position sensor or relevant circuit are faulty



the pedal is not pressed, the APP1 voltage is 3.2-4.0V and the APP2 voltage is 1.6-2.0V when the pedal is pressed, it’s normal. 2. The resistance of brake switch is ＞1MΩ when the pedal is



124



Service Manual for Engine completely loosened and the resistance is -0Ω when the pedal is pressed, it’s normal; 3. Power on to check the 1.41 voltage to ground when the brake switch is released, it’s normal if it’s 0V; the voltage to ground of 1.41 when the brake switch is pressed is 23-28V, it means that the brake circuit is normal. 1. Power off and



Intake The intake heater is normally ON



3-2-2



P0540



heater



The



grille or



intake



intake



heater



heater



doesn’t



relay



work.



circuit



The intake heater



measure the



griller is damaged



resistance



or the intake heater



between the



relay circuit is



vehicle harness



subject to open



1.55 and 1.59 and



circuit.



the heater relay joint 1 and 2,



125



Service Manual for Engine



The voltage is higher than the threshold



P1020



when the



1. The



intake heater is ON.



3-2-3



intake heater



1. Intake



(ON) is lower



P1021



heater



than the lower



grille



threshold



2. Intake



The voltage of



heater



intake heater



grille



(OFF) is



P1022



higher than



circuit and its harness



the upper



The voltage of



resistance is - 0Ω;



heater



The voltage of



threshold



It’s normal if the



intake



2. Measure the



grille



resistance of



works



intake heater



abnorma



grille, it’s normal



lly.



if the resistance is



2.



- 0.4Ω;



The



3. Measure the



intake



voltage to ground



heater



of heater relay



driving



joint, it’s normal



circuit



if the voltage is -



works



3-2-3



0V;



abnorma



intake heater



lly.



(OFF) is



P1023



lower than the lower threshold



Power off and measure the Intake heater is short to power supply



Intake heater is short to



P0542 3-2-1



The



Intake heater is



voltage to ground



Intake



intake



short to power



of intake heater



heater



heater



supply.



relay, it’s normal



circuit



doesn’t



if the voltage is



work.



0V.



P0541



126



Intake heater is



Power off,



short to ground.



unplug the



Service Manual for Engine ground



vehicle connector and relay joint, and measure the resistance to ground of joint 2; it’s normal if the resistance is -0Ω. 1. Power off and unplug ECU sensor connector and intake pressure sensor



The voltage of intake



Intake



pressure



pressure



sensor is



2-3-1



P0238



sensor



higher than



and its



the upper



harness



The intake pressure is abnorma l.



threshold



connector. The intake pressure



Measure the



connector internal



resistance of 2.34



circuit or harness is



docking



short to power



connector 4



supply.



terminal, it’s normal if the resistance is -0Ω; 2. Measure the resistance of connector terminal 3 and 4,



127



Service Manual for Engine it’s normal if the resistance is ＞ 1MΩ; 3. Power off and unplug the intake pressure connector and measure the voltage to ground of connector 4, it’s normal if the voltage is -0V; 1. Power off and unplug the ECU sensor connector and oil pressure sensor connector; check the connection of The voltage of



2.34 connector 4



intake



The intake pressure



terminal; it's



pressure



connector internal



normal if the



circuit or harness is



resistance is -0Ω;



lower than the



short to power



2. Measure the



lower



supply.



resistance



sensor is



P0237



threshold



between sensor connector 1 and 4, it’s normal if the resistance is ＞1MΩ; 3. Power off and unplug the intake temperature 128



Service Manual for Engine sensor connector; measure the voltage to ground of connector 4 terminal; it’s normal if the voltage is -0V; Intake



Check whether



pressure sensor signal



The intake pressure the intake



P0235



sensor is damaged



from CAN is



signal is normal.



unbelievable.



Check whether



The intake



the intake



pressure sensor and atmospheric pressure



pressure sensor



P0236



The intake pressure



pressure and



sensor and



atmospheric



atmospheric pressure sensor is



sensor signal



aging.



is



pressure is normal; otherwise, replace the



unbelievable.



sensor.



129



Service Manual for Engine



The original battery voltage is



P0563



higher than the upper threshold.



ECU is



1. Power off to



damage



check the battery



d or



voltage; it’s



unable



normal if the



to work



battery voltage is



properly



23-28V; 2. Power



.



off and unplug



ECU



ECU power



power



harness and joint is



harness, 1-2-4



faulty and the



connector



battery is aging or



, battery



The original



or



battery voltage is



P0562



lower than the



generator



the generator is ECU



damaged.



malfunc



connector and battery power line, check the circuit connection; it’s normal if the resistance is 0Ω;



tions



lower



the ECU vehicle



3. Power on to check the voltage



threshold.



to ground of ECU positive pole, it’s normal if the voltage is -24V.



The brake



Brake



signal from



signal



CAN is unbelievable



2-2-3



P0571



relay and its circuit



1. It’s



1. Power off to



unable



check the



to enter



connection



the



between brake



cruise



1. The brake signal



signal joint and



mode.



relay is faulty; 2.



vehicle line 1.41



2. It’s



The brake signal



and 1.04; 2.



unable



relay circuit is



Check the



to judge



faulty.



resistance to



the



ground of brake



reasona



signal joint 1 and



bility of



2; it’s normal if



accelera



the resistance is



130



Service Manual for Engine tor and



＞1MΩ; 3. Check



brake.



the resistance of



3. The



brake signal



brake



switch pin, the



lamp



resistance is＞



priority



1MΩ when the



function



clutch is not



is



pressed, it’s



invalid.



normal if the resistance is -0Ω when the clutch is not pressed.



Brake main and auxiliary switch signal



P0504



1.



CAN bus



Check the



brake signal



is



Check the clutch switch signal



unbelievable. The cold



The cold



starting



start



indicator is



3-3-2



P1635



indicator



short to power



harness



supply.



and



The cold start indicato r works properly .



131



The cold start indicator 1.38 is short to positive pole of power supply.



Power on the ECU, unplug the cold start indicator connector, measure the



Service Manual for Engine



voltage to ground of low end 1.38, it’s normal if the voltage is -0V. Power off the vehicle, unplug the cold start The cold



indicator



starting indicator is



The cold start P1636



short to



connector, and



indicator 1.38 pin



measure the



is short to ground.



resistance to



ground.



ground of low end 1.38, it’s normal if the joint or



resistance is -0Ω;



cold start



1. Power on the



indicator



ECU, unplug the



is



cold start



damaged



indicator The cold start indicator harness is



There is no cold starting indicator



subject to open P1637



circuit and the flash code



signal.



indicator is damaged.



connector and measure the voltage between 1.04 and 1.38; it’s normal if the voltage is -21V; 2. Measure the resistance of flash code indicator; it's normal if the resistance is＜ 2KΩ.



The cold starting



P1638



132



The resistance of



Measure the



cold start indicator



resistance of cold



Service Manual for Engine indicator



is improper.



start indicator;



exceeds the



it’s normal if the



temperature.



resistance of common lamp is 40-50Ω and the resistance of LED is -1.6KΩ. Power off the ECU, unplug the



The voltage of



water



cooling water temperature sensor is



P0118



higher than the upper



Water temperatu



2-4-1



re sensor



threshold.



and its harness



Sensor signal line



temperature



The



2.15 is short to



sensor joint and



water



positive pole of



measure the



temperat



power supply.



voltage to ground



ure is



of terminal 1; it’s



abnorma



normal if the



l.



voltage is -0V;



The voltage of cooling water temperature



P0117



sensor



133



Sensor signal line



Turn off the



2.15 is short to



vehicle, unplug



ground.



the water



Service Manual for Engine



temperature sensor joint and measure the



is lower than



resistance to



the lower



ground of signal



threshold.



terminal 2.15; it’s normal if the resistance is -0Ω;



The cooling



Check the



water



CAN bus



temperature



P0115



sensor signal



communication fault



from CAN is unbelievable.



connection of CAN bus and whether the joint is short to ground. 1. Check the connection between clutch joint and vehicle



It’s



Clutch



The clutch signal from CAN is unbelievable.



signal and 2-2-2



P0704



its relevant harness



line 1.66 and



unable



1.04; 2. Check



to



the resistance to



activate



ground of clutch



the



The clutch circuit



joint; it’s normal



cruise



is subject to open



if the resistance is



function



circuit or short



＞1MΩ; 3. Check



and the



circuit.



the resistance of



driving



clutch switch pin;



perform



it’s normal if the



ance is



resistance is -0Ω



affected.



when the clutch is not pressed and the resistance is ＞1MΩ when the clutch is pressed.



134



Service Manual for Engine The clutch



The clutch signal



state signal is



P0704



from CAN bus is



unbelievable.



unbelievable.



Check the clutch switch signal. 1. Power off and unplug the connector, check the connection of 1.32, 1.47 and



Vehicle



The vehicle ON/OFF button is stuck.



ON/OFF 3-4-3



P2530



switch and its harness



The vehicle ON/OF F switch malfunc tions.



1.29 at vehicle Vehicle ON/OFF switch and its harness are faulty.



ON/OFF joint 1 and 2; it’s normal if the resistance is -0Ω; 2. Measure the resistance to ground of two terminals of vehicle ON/OFF joint;



135



Service Manual for Engine it’s normal if the resistance is＞ 1MΩ; 3. Measure whether the switch is good and use the multimeter to separately test it. It’s normal if the two contacts are connected when the switch is pressed and the two contacts are disconnected when the switch is released. There is no



1. Check the



camshaft



P0340



camshaft sensor



signal.



for looseness; 2. Power off and



1-1-3 The camshaft signal is unreliable.



measure the



P0341



Looseness of



resistance from



Crankshaf



The



crankshaft sensor



connector 2.09



t sensor



engine



or crankshaft



and 2.10 to joint



and its



power is



sensor harness



1 and 2; it’s



harness



limited.



short circuit or



normal when the



open circuit



resistance is - 0Ω; 3. Measure the resistance to ground from sensor joint 1 and 2 to the vehicle;



136



Service Manual for Engine it’s normal if the resistance is＞ 1MΩ; 4. Use an oscilloscope to measure whether the crankshaft and camshaft synchronization is normal; if not, it may be caused by gear ring or oil pump gear installation or processing fault.



137



Service Manual for Engine



There is only



1. Check the



camshaft



crankshaft sensor



signal and it



P0008



for looseness;



enters limp



2. Power off and



home state.



measure the resistance from



There is no



the sensor



crankshaft



P0335



connector 2.23



signal.



and 2.19 to the joint 1 and 2; it’s normal if the



Crankshaf t sensor



1-1-4



and its



1-1-2



harness gear ring.



The crankshaft



resistance is -0Ω;



sensor is loosened



3. Measure the



or the crankshaft



resistance to



The



sensor harness is



ground from



engine



subject to short



sensor joint 1 and



power is



circuit or open



2 to the vehicle;



limited.



circuit or the gear



it’s normal if the



ring is improperly



resistance is＞



installed or



1MΩ;



processed



4. Use an



The crankshaft



P0336



signal is



oscilloscope to



unbelievable.



measure whether the crankshaft and camshaft synchronization is normal; if not, it may be caused by gear ring or oil pump gear installation or processing fault.



The crankshaft and



5-4-1



P0016



Crankshaf



The



Crankshaft and



1. Check the



t and



engine



camshaft sensor



crankshaft and



138



Service Manual for Engine camshaft



camshaft



power is



and its harness,



camshaft for



signal



sensor



limited.



gear ring or oil



looseness;



deviation



and its



pump gear is



2. Check the



exceeds the



harness,



improperly



crankshaft and



threshold.



gear ring



installed or



camshaft harness



or oil



processed.



for normality;



pump



3. Check



gear is



whether the gear



improperl



ring and oil pump



y installed



gear is properly



or



installed;



processed



4. Use the



.



oscilloscope to observe the synchronization signal is normal. The



Check whether



engine The engine speed exceeds



2-2-6



P0219



the limit.



returns



The engine down



Speed



to idle



slope speed is too



sensor



speed,



high or the speed



even



sensor is faulty.



shuts



the pulse number of speed sensor is normal and whether the speed is normal at the idle speed.



down. The exhaust



Power off and



brake



unplug V4 joint



butterfly valve is short to power supply or exceeds the



P0478



brake



3-1-1



solenoid



temperature



valve



The exhaust brake



Exhaust



to measure the



The exhaust



Exhaust brake



brake



drive circuit and its



doesn’t



harness



work



P0477



voltage to ground of terminal 4; it’s normal if the voltage is 0V. Power off and unplug V4 joint



butterfly valve



to measure the 139



Service Manual for Engine is short to



resistance to



ground.



ground of terminal 4; it’s normal if the resistance is 0Ω.



140



Service Manual for Engine



1. The exhaust brake drive circuit



The exhaust brake butterfly valve is subject to open circuit



P0476



is subject to open



1. Check the



circuit



connection of



2. The exhaust



exhaust brake



brake



drive circuit;



electromagnetic



2. Check whether



valve is damaged



the exhaust brake electromagnetic



The exhaust brake



The exhaust brake



butterfly valve



drive circuit is



exceeds the



valve works properly.



overloaded



temperature. The oil



The



volume torque



engine



conversion is



1-2-5



P1007



ECU data



unbelievable.



power is limited.



The data scaling FMTC MAP is



Modify the data



non-monotonous. Power off the ECU, unplug the



Fan actuator



The fan



(PWM wave)



P0692



is short to power supply. 3-1-2



Fan actuator (PWM wave) is short to



P0691



is



Fan actuator (PWM wave) is short to power



fan actuator connector and measure the voltage to ground



Fan



unable



electroma



to work



gnetic



properly



it’s normal if the



harness,



and the



voltage is -0V;



joint or



engine



clutch



temperat



supply.



of low end 2.01;



Turn off the vehicle, unplug



ure is



Fan actuator



the fan actuator



high.



(PWM wave) is



connector and



short to ground.



measure the



ground.



resistance to ground of low 141



Service Manual for Engine end 2.01; it’s normal if the resistance is 0Ω; 1. Turn off the EC and measure the connection of Fan actuator (PWM wave) is subject to



Fan actuator P0480



open circuit.



sensor connector



(PWM wave) is



and joint; it’s



subject to open



normal if the



circuit.



resistance is 0Ω; 2. Check whether the fan clutch is damaged.



Fan actuator



Fan actuator



(PWM wave)



(PWM wave)



exceeds the



P0483



exceeds the



temperature.



temperature.



142



1. Check the fan actuator harness; 2. Check the fan clutch for damage.



Service Manual for Engine



1. Power on and check the voltage to ground of fan speed sensor joint 3; it’s normal if the voltage is 5V; 2. Power off and



The cooling



unplug the joint



fan speed is



and measure the



higher than



voltage to ground



the upper



1. The fan speed



of speed sensor



The fan



sensor is faulty



join 2; it’s normal



Fan speed



speed is



2. The fan sensor



if the voltage is



sensor



unbeliev



harness is faulty



0V;



able.



3. The fan clutch is



3. Power off and



faulty



unplug the sensor



threshold. P0526 3-1-2 P0527 The cooling fan speed is



connector and



lower than the



joint; and



lower



measure the



threshold.



resistance to ground of joint 2; it’s normal if the resistance is 0Ω; 4. Check the fan clutch for damage. The electrom



The electromagnet ic clutch relay is short to power supply.



Electroma 2-1-6



P1008



gnetic clutch fan



agnetic clutch fan is unable to work properly 143



Power off, The electromagnetic clutch fan relay harness is short to power supply.



unplug the sensor joint and measure the voltage to ground of joint 1 and 2; it’s normal if the voltage is 0V;



Service Manual for Engine .



Power off, unplug the sensor



The



The



electromagnet



electromagnetic



ic clutch



P1009



clutch fan relay



replay is short



harness is short to



to ground.



ground.



connector and joint; and measure the resistance to ground of joint 1 and 2; it’s normal if the resistance is ＞1MΩ;



The oil with water indicato r



The oil with water sensor detects water



2-1-1



P2269



in the oil.



Oil with



illumina



The diesel coarse



Maintain the



water



tes and



filter ponding is



diesel coarse



sensor



gives



full.



filter.



out water temperat ure alarm. The oil with



Indicator 1



water



(oil with water indicator) is short to power supply.



3-3-4



P1623



indicator harness, joint or lamp is damaged



Power on the



The oil



ECU, unplug the



with water



Water in oil



indicato



indicator 1.56 pin



r is



is short to positive



unable



pole of power



to work



supply.



properly .



144



oil with water indicator connector, and measure the voltage to ground of low-end 1.56; it’s normal if the voltage is -0V.



Service Manual for Engine



Turn off the vehicle, unplug the oil with water Indicator 1



indicator



(oil with water indicator) is



P1624



short to



Water in oil



connector and



indicator 1.56 pin



measure the



is short to ground.



resistance to



ground.



ground of low end 1.56; it’s normal if the resistance is -0Ω; 1. Power on the ECU, unplug the flash code indicator connector and measure the



Indicator 1



The oil with water



(oil with water



indicator harness is



indicator) line



P1625



broken or the flash



is subject to



code indicator is



open circuit.



damaged.



voltage of connector 1.04 and 1.56; it’s normal if the voltage is -24V; 2. Measure the resistance of the flash code indicator; it’s normal if the resistance is＜ 2KΩ.



Indicator 1 (oil with water indicator)



P1626



exceeds the 145



The resistance of



Measure the



oil with water



resistance of oil



indicator is



with water



improper.



indicator; it’s



Service Manual for Engine temperature.



normal if the resistance of common lamp is 40-50Ω and the resistance of LED is -1.6KΩ. Check whether



CJ940 communicatio n is interfered



2-6-3



P060A



with



ECU



Engine



internal



flameou



chip



t



ECU power ECU internal chip



connection is



fault



normal, if normal, replace the ECU.



EEPROM



Accumu



P062F



reading error EEPROM



lation informat



P062F



writing error



EEPROM (Electroni



EEPROM



2-6-5



c erasable read only



uses



P062F



alternative



memory)



ion like Fuel consum ption/mi



Refresh the ECU ————



and maintain 20 safterrun time.



leage, etc. cannot



value.



be recorded System



Power off and



repairing fault System repairing fault



2-6-1



P0607



ECU



Engine



internal



limp



chip fault



home



ECU internal chip fault



restart the ECU, replace the ECU if the problem still exists.



146



Service Manual for Engine



System



ECU



repairing fault CJ940 voltage is too high. CJ940 voltage



During welding, as



P1607 ECU 2-6-3



internal P1608



is too low.



chip fault



the vehicle harness ECU



is not



damage



disconnected, the



Replace the ECU



ECU internal chip is broken down. 1. Power off, unplug the ECU sensor connector and intake temperature sensor connector; and check the connection of 2.36 connector 2



The voltage of



The



intake temperature sensor is higher than the upper



Intake 2-3-3



P0098



temperatu re sensor



intake temperat ure is abnorma l.



threshold.



The intake temperature connector is subject to internal short circuit or the harness is short to power supply.



terminal; it’s normal if the resistance is -0Ω; 2. Measure the resistance of sensor connector terminal 2 and 3; it’s normal if the resistance is＞ 1MΩ; 3. Power off, unplug the intake temperature connector and measure the voltage to ground of connector 2;



147



Service Manual for Engine it’s normal if the voltage is -0V; 1. Power off, unplug the ECU sensor connector and oil pressure sensor connector The voltage of



The intake



and check the



intake



temperature



connection of



temperature



connector is



2.36 connector 2



subject to internal



terminal; it’s



lower than the



short circuit or the



normal if the



lower



harness is short to



resistance is -0Ω;



threshold.



the battery.



sensor is



P0097



2. Measure the resistance of sensor connector 1 and 2; it’s normal if the resistance is>1MΩ;



148



Service Manual for Engine



3. Power off, unplug the intake temperature sensor connector and measure the voltage to ground of connector terminal 2; it’s normal if the voltage is -0V; The intake



Check whether



temperature sensor voltage



P0099



signal from CAN is



The intake



the intake



temperature sensor



temperature



is damaged.



sensor signal is normal.



unbelievable. The ideal fuel injection time



P1300



is limited by



The supercharger



Superchar



is damaged or



ger



unmatched.



the current. The ideal fuel injection time is limited by



High1-5-5



P1301



the fuel



pressure oil pump



volume.



The engine



High-pressure oil



power is



pump is damaged.



limited.



Check the supercharger.



Check the highpressure oil pump.



The ideal fuel injection time



P1302



is limited by



ECU



ECU damage



Replace the ECU



1. The



Among 1, 2 and 3



1. Power off,



fuel



cylinder, the fuel



unplug 1, 2 and 3



injector high end is



cylinder joint,



short to power



and measure the



software



the software. Among 1, 2 and 3 cylinder, the fuel injector



1, 2 and 3 1-5-1



P1203



cylinder fuel injector



injector of a 149



Service Manual for Engine high end is



harness



cylinder



supply or ground.



voltage to ground



doesn’t



of joint 1; it’s



supply or



work.



normal if the



ground.



2. The



voltage is 0V;



engine



2. Measure the



perform



resistance to



ance is



ground of joint 1;



affected.



it’s normal if the



short to power



Among 1, 2



3. In



resistance is＞



series



1MΩ.



conditio



1. Power off,



n, the



unplug 1, 2 and 3



engine



cylinder joint,



is shut



and measure the



down.



voltage to ground



and 3 cylinder, the fuel injector



P1204



low end is short to



Among 1, 2 and 3



of joint 2; it’s



cylinder, the fuel



normal if the



injector low end is



voltage is 0V;



short to ground.



2. Measure the resistance to



ground.



ground of joint 2; it’s normal if the resistance is＞ 1MΩ.



150



Service Manual for Engine



1. Power off and check the circuit connection from fuel injector connector to



Among 1, 2 and 3



Among 1, 2 and 3



cylinder, the



cylinder, the fuel



P1209



fuel injector is



injector is subject



subject to



to open circuit.



open circuit.



joint. 2. Unplug the fuel injector joint and measure the resistance of two terminals of fuel injector; it’s normal if the resistance is 0.21Ω. 1. Power off,



1. The fuel



unplug the 4, 5



injector



and 6 cylinder joints and



of a Among 4, 5



cylinder



and 6



doesn’t



cylinder, the



4, 5 and 6



fuel injector high end is short to power



P120B 1-5-2



cylinder fuel injector



supply or



harness



ground.



work. 2. The engine perform ance is



measure the Among 4, 5 and 6 cylinder, the fuel injector high end is short to power supply or ground.



and 6



P120C



of joint 1 terminal; it’s normal if the voltage is 0V; 2. Measure the resistance to



affected. 3. In



ground of joint 1;



series



it’s normal if the



conditio



resistance is ＞ 1MΩ.



n, the Among 4, 5



voltage to ground



engine



Among 4, 5 and 6



1. Power off,



is shut



cylinder, the fuel



unplug the 4, 5



151



Service Manual for Engine cylinder, the



down



fuel injector



injector low end is



and 6 cylinder



short to ground.



joint and measure



low end is



the voltage to



short to



ground of joint 2;



ground.



it’s normal if the voltage is 0V; 2. Measure the resistance to ground of joint 2; it’s normal if the resistance is＞ 1MΩ. 1. Power off and



Among 4, 5



check the circuit



and 6 cylinder, the fuel injector is



P1211



subject to open circuit.



Among 4, 5 and 6



connection from



cylinder, the fuel



fuel injector



injector is subject



connector to



to open circuit.



joint; 2. Unplug the fuel injector joint and



152



Service Manual for Engine



measure the resistance between two terminals of fuel injector; it’s normal if the resistance is 0.21Ω. Power off, unplug the ECU fuel injector connector and use



The fuel



the multimeter to



injector 1 low



P0262



end is short to



measure the voltage to ground



power supply.



of fuel injector 1



The



low end 3.13 pin;



engine power is



Fuel injector 1



insuffici



harness or joint



Fuel



ent, the



contact is poor;



injector 1



speed is



harness abrasion



harness



unstable



causes open circuit



Fuel injector 1



or it’s in



or/and cylinder



high end and



limp



head short circuit.



1-4-1



low end are



P0261



subject to



home state.



short circuit.



it’s normal if the voltage is -0V; Power off, unplug the ECU fuel injector connector 1 joint 1 and 2 and use the multimeter to measure the resistance to ground of joint 1 and 2; it’s normal if the resistance is ＞1MΩ.



Fuel injector 1 is subject to



Power off, P0201



unplug the ECU



open circuit



fuel injector 153



Service Manual for Engine connector, fuel injector 1 joint 1 and 2, and use the multimeter to measure the resistance of ECU fuel injector connector 3.04 and 3.13 pin to fuel injector joints 1 and 2; it’s normal if the resistance is - 0Ω. Power off,



short to power supply.



P0265 1-4-2



unplug the ECU



engine



fuel injector



power is



Fuel injector 2



connector and use



insuffici



harness or joint



the multimeter to



Fuel



ent, the



contact is poor;



measure the



injector 2



speed is



harness abrasion



voltage to ground



harness



unstable



causes open circuit



of fuel injector 2



or it’s in



or/and cylinder



low end 3.06 pin;



limp



head short circuit.



it’s normal if the



Fuel injector 2 low end is



The



home Fuel injector 2 high end



P0264



state.



154



voltage is 0V.



Service Manual for Engine



Power off, unplug the ECU fuel injector connector, and fuel injector 2 joint 1 and 2, and



And low end



use the



are subject to



multimeter to



short circuit.



measure the resistance of fuel injector joint 1 and 2; it’s normal if the resistance is ＞1MΩ. Power off, unplug the ECU fuel injector connector and fuel injector 2 joint 1 and 2, and use the multimeter to



Fuel injector 2



P0202



open circuit



measure the resistance of ECU fuel injector connector 3.11 and 3.06 pin to the fuel injector joint 1 and 2; it’s normal if the resistance is - 0Ω.



Fuel injector 3 low end is



1-4-3



P0268



Fuel



The



Fuel injector 3



Power off,



injector 3



engine



harness or joint



unplug the ECU



155



Service Manual for Engine short to the



harness



power supply.



power is



contact is poor;



fuel injector



insuffici



harness abrasion



connector and use



ent, the



causes open circuit



the multimeter to



speed is



or/and cylinder



measure the



unstable



head short circuit.



voltage to ground



or it’s in



of fuel injector 3



limp



low end 3.12 pin;



home



it’s normal if the



state.



voltage is -0V. Power off, unplug the ECU fuel injector connector, and fuel injector 3



Fuel injector 3



joint 1 and 2, and



high end and low end are



use the



P0267



mutlimeter to



subject to



measure the



short circuit.



resistance of fuel injector joint 1 and 2; it’s normal if the resistance is ＞1MΩ; Power off,



Fuel injector 3 is subject to



unplug the ECU



P0203



fuel injector



open circuit



connector



156



Service Manual for Engine



and fuel injector 3 joint 1 and 2, and use the multimeter to measure the resistance of ECU fuel injector connector 3.05 and 3.12 pin to fuel injector joint 1 and 2; it’s normal if the resistance is -0Ω. Power off, unplug the ECU fuel injector connector and use



Fuel injector 4



the multimeter to



low end is



P0271



short to the power supply.



1-4-4



Fuel injector 4 high end and low end are



P0270



The



measure voltage



engine



to ground of fuel



power is



Fuel injector 4



injector 4 low



insuffici



harness or joint



end 3.14 pin; it’s



Fuel



ent, the



contact is poor;



normal if the



injector 4



speed is



harness abrasion



voltage is -0V.



harness



unstable



causes open circuit



Power off,



or it’s in



or/and cylinder



unplug the ECU



limp



head short circuit.



fuel injector



home



connector and



state.



fuel injector 4 joint 1 and 2; and



subject to



use the



short circuit.



multimeter to measure the resistance of fuel 157



Service Manual for Engine injector joint 1 and 2; it’s normal if the resistance is ＞1MΩ. Power off, unplug the ECU fuel injector connector and fuel injector 4 joint 1 and 2, and use the multimeter to



Fuel injector 4 is subject to



measure the



P0204



resistance of



open circuit



ECU fuel injector connector 3.03 and 3.14 pin to fuel injector joint 1 and 2; it’s normal if the resistance is - 0Ω. Fuel injector 5 harness or joint



Fuel injector 5 low end is short to the power supply.



1-4-5



P0274



Fuel



contact is poor;



injector 5



harness abrasion



harness



causes open circuit or/and cylinder head short circuit.



158



Power off, unplug the ECU fuel injector connector



Service Manual for Engine



And use the multimeter to measure the voltage to ground of fuel injector 5 low end 3.16 pin; it’s normal if the voltage is -0V. Power off, unplug the ECU fuel injector



Fuel injector 5 high end and low end are



P0273



subject to short circuit.



The



connector and



engine



fuel injector 5



power is



joint 1 and 2, and



insuffici



use the



ent, the



multimeter to



speed is



measure the



unstable



resistance of fuel



or it’s in



injector joint 1



limp



and 2; it’s normal



home



if the resistance is



state.



＞1MΩ. Power off, unplug the ECU fuel injector connector and



Fuel injector 5 open circuit



fuel injector 5 P0205



joint 1 and 2, and use the multimeter to measure the resistance of ECU fuel injector 159



Service Manual for Engine connector 3.01 and 3.16 pin to fuel injector joint 1 and 2; it’s normal if the resistance is - 0Ω. Power off, unplug the ECU fuel injector Fuel injector 6 low end is



P0277



short to the power supply. 1-4-6



Fuel injector 6 high end and low end are



P0276



The



connector and use



engine



the multimeter to



power is



Fuel injector 6



measure the



insuffici



harness or joint



voltage to ground



Fuel



ent, the



contact is poor;



of fuel injector 6



injector 6



speed is



harness abrasion



low end 3.16 pin;



harness



unstable



causes open circuit



it’s normal if the



or it’s in



or/and cylinder



voltage is -0V.



limp



head short circuit.



Power off,



home



unplug the ECU



state.



fuel injector connector and



subject to



fuel injector 6



short circuit.



joint 1 and 2,



160



Service Manual for Engine



and use the multimeter to measure resistance of fuel injector joint 1 and 2; it’s normal if the resistance is ＞1MΩ. Power off, unplug the ECU fuel injector connector and fuel injector 6 joint 1 and 2, and use the multimeter to



Fuel injector 6



P0206



open circuit



measure the resistance of ECU fuel injector connector 3.02 and 3.15 pin to fuel injector joint 1 and 2; it’s normal if the resistance is - 0Ω.



The number of cylinder



Check the fuel



under normal operation is less than the minimum



1-5-4



P1225



Fuel



The



injector



engine



harness



stops



number of



The fuel injector harness of over 3 cylinders is subject to short circuit or open circuit.



cylinder for the system 161



injector harness of each cylinder as per above check method of fuel injector harness.



Service Manual for Engine running. Check the cruise button switch and its harness; 1. As per the pin drawing, check the harness connection; it’s 1. Press several cruise switches in The cruising signal is



3-4-1



P0564



unreliable.



Cruise switch



The



the same time;



cruising



2. The button



function



triggering time is



can’t be



too long;



realized.



3. The button switch circuit is faulty.



normal if the resistance is -0Ω; 2. As per the pin drawing, check the switch voltage under normal state; it’s normal if only OFF switch has high level; 3. In the same time, check the state of 4 switches; and check whether 2 switches or above are pressed in the same time.



ECU1.04 pin



Main relay 2 is short to power supply



1-3-2



P0687



ECU1.04



Neutral



connects to



switch,



external power supply



162



Service Manual for Engine



Power off and measure the



Pin is short to power supply.



brake, clutch, etc.



P0686



ground.



pin and frame grounding wire; it’s normal if the



tion and



voltage is 0V.



with oil



is short to



supply.



voltage of 1.04



malfunc the oil



Main relay 2



or is short to power



ECU1.04



indicato



pin is



r is



short to



illumina



ground.



ting.



Components like neutral switch, AC switch and brake switch and so on connecting the ECU 1.04 pin are short to ground.



Power off and measure the resistance of 1.04 pin and frame grounding wire; it’s normal when the resistance is ＞1MΩ. Power off, unplug the ECU



ECU1.62



Multi-power fuel-saving switch is short



P154A



to power supply.



and 1.65



Multi-power fuel-



pin are



saving switch or



short to



harness is short to



the power



Multi-



supply



power



power supply.



fuel-saving switch is short to ground.



and 1.65 P154B



Multi-power fuelsaving switch or



pin are



harness is short to



short to



the battery.



ground.



pin; it’s normal if



unplug the ECU



malfunc tions



of 1.62 or 1.65



Power off,



switch ECU1.62



voltage to ground



0V.



saving



Multi-power



and measure the



the voltage is -



fuel3-2-7



vehicle connector



vehicle connector; and measure the resistance to ground of 1.62 or 1.65 pin; it’s normal if the



163



Service Manual for Engine resistance is ＞ 1MΩ. Multi-power



Multi-



Multi-power fuel-



fuel-saving



power



saving switch is



Replace a new



fuel-



aging or the



multi-power fuel-



is



saving



resistance is



saving switch.



unbelievable.



switch



unmatched.



switch signal



P154C



Check the voltage of ECU positive



Main relay 1 is short to



P160E



power supply.



ECU 1-3-2



power line



Main relay 1 is short to



P160F



ECU is



pole (1.02, 1.03,



unable



1.08 and 1.09) to



to



ECU negative



supply power and the engine



Vehicle connector or ECU power line is faulty



pole (1.05, 1.06, 1.10 and 1.11); it’s normal if the voltage is about



is



24V.



unable



Check the voltage



to start.



to ground of ECU positive pole



ground.



(1.02, 1.03,



1.08 and 1.09); it’s normal if the voltage is about 24V. The engine System communicatio n fault



ECU 2-6-4



P060C



internal chip



flames out (restart it after powerin g off) 164



Other causes like abnormal voltage of ECU



Replace the ECU



Service Manual for Engine 1. Power off, unplug the ECU sensor connector and fuel pressure sensor connector and measure the connection of 2.27 connector 4 terminal; it’s normal if the resistance is -0Ω; The voltage of



The oil pressure



2. Measure the



oil pressure



connector is



resistance of



subject to internal



sensor connector



short circuit or the



terminal 3 and 4;



The oil



harness is short to



it’s normal if



Sensor



pressure



power supply.



resistance is＞



connector



is



1MΩ;



or harness



unbeliev



3. Power off,



able.



unplug the oil



sensor is



P0523



higher than the upper limit. 2-4-3



pressure sensor connector and measure the voltage to ground of connector 4 terminal; it’s normal if the voltage is -0V; The oil pressure



The voltage of



connector is



oil pressure sensor is



subject to internal



P0522



short circuit or the



lower than the



harness is short to



lower limit.



power supply. 165



1. Power off, unplug the ECU sensor connector and oil pressure sensor connector; and measure the connection of



Service Manual for Engine 2.27 connector 4 terminal; it’s normal if the resistance is -0Ω;



166



Service Manual for Engine



2. Measure the resistance of sensor connector 1 and 4; it’s normal if the resistance is＞ 1MΩ; 3. Power off, unplug the oil pressure sensor connector and measure the voltage to ground of connector 4 terminal; it’s normal if the voltage is -0V;



Sensor



The oil pressure sensor signal



The oil pressure connector is



connector P0520



subject to internal



or harness



short circuit or the



or CAN



is unreliable.



harness is short to



bus signal



ground.



As per the above method, check the oil pressure sensor connector and harness; and check the CAN bus and message. 1. Power off,



The oil pressure is too high or the oil temperature signal is unreliable.



P0521



The internal pin 4



unplug the ECU



Oil



and 3 of oil



sensor connector



pressure



pressure connector



and oil pressure



sensor



is subject to short



sensor connector;



connector



circuit or the signal



and measure the



or harness



line is short to



connection of



power supply.



2.27 connector 4 terminal; it’s



167



Service Manual for Engine normal if the resistance is-0Ω; 2. Power off, unplug the oil pressure sensor connector and measure the voltage to ground of connector 4 terminal; it’s normal if the voltage is-0V; The oil



1. Check the oil



level is



level;



low or oil



2. Power off,



pressure sensor The oil pressure is too low.



connector P0524



and harness is subject to



Engine limp home state



open



The oil level is too



unplug the ECU



low or the oil



sensor connector



temperature sensor



and oil pressure



connector and



sensor connector;



harness are subject



and measure the



to open circuit or



communication



short to ground.



of 2.27 connector



circuit or



4 terminal; it’s



short to



normal if the



ground.



resistance is -0Ω;



168



Service Manual for Engine



3. Power off, unplug the oil pressure sensor connector and measure the voltage to ground of connector 4 terminal; it’s normal if the voltage is -0V; 1. Power off, unplug the ECU sensor connector and oil temperature sensor connector; and measure the connection of The voltage of



The oil



oil temperature sensor is higher than the upper



2-4-4



P0198



The oil



temperature



Sensor



temperat



connector is



connector



e is



subject to internal



or harness



unbeliev



short circuit or the



able.



harness is short to



threshold.



the battery.



2.28 connector 2 terminal; it’s normal if the resistance is -0Ω; 2. Power off, unplug the oil temperature sensor connector; and measure the voltage to ground of connector 2 terminal; it's normal if the voltage is -0V; 3. Measure the resistance of oil



169



Service Manual for Engine temperature connector 2 and 3, it’s normal if the resistance is ＞1MΩ. 1. Power off, unplug the ECU sensor connector



The voltage of oil temperature sensor is



P0197



lower than the lower threshold.



The oil



and oil



temperature



temperature



connector is



sensor connector;



subject to internal



and measure the



short circuit or the



connection of



harness is short to



2.28 connector 2



the battery.



terminal; it’s normal if the resistance is -0Ω;



170



Service Manual for Engine



2. Measure the resistance of sensor connector 1 and 2; it’s normal if the resistance is＞ 1MΩ; 3. Measure the voltage to ground of connector 2 terminal; it’s normal if the voltage is -0V; 1. Check whether the water temperature sensor is normal; 2. Power off, unplug the ECU Oil



water temperature signal



and oil



temperatu



temperature and cooling



sensor connector



Water



P100D



re, oil



Water temperature



temperatu



and oil temperature



re sensor



and its harness



and its



temperature sensor connector and measure the connection of 2.28 connector 2



harness



terminal; it’s normal if the resistance is 0Ω; 3. Power off, unplug the oil temperature sensor connector 171



Service Manual for Engine and measure the voltage to ground of connector 2 terminal; it’s normal if the voltage is-0V; 4. Measure the resistance of oil temperature connector 2 and 3; it’s normal if the resistance is ＞ 1MΩ. 1. Check the oil level; 2. Power The oil



The oil level is too



level is The oil temperature exceeds the limit.



P0196



too low or



The oil



the oil



temperat



temperatu



ure is



re sensor



too



connector



high.



and



low or the oil temperature sensor connector and harness are subject to open circuit or short to power supply.



harness



off, unplug the ECU sensor connector and oil temperature sensor connector and measure the connection of 2.28 connector 2 terminal; it’s normal if the resistance is -0Ω;



172



Service Manual for Engine



3. Power off, unplug the oil temperature sensor connector and measure the voltage to ground of connector 2 terminal; it’s normal if the voltage is -0V; 4. Measure the resistance of sensor connector 2 and 3; it’s normal if the resistance is＞ 1MΩ. The fuel injector



ECU



powering time



restarts



exceeds the over-speed monitor



P1613



ECU



or engine



2-6-2



stops



setting value. The engine



Under reversed towing, the charging time of



Stop the vehicle,



fuel injector is too



and restart the



long and the ECU



engine one



is internally faulty.



minute after



Reversed towing



powering off.



Speed



ECU



sensor



restarts



The voltage of



Oil



1.



Power on the EC,



sensor power



pressure



Engine



unplug the oil



temperatu



perform



re and



ance is



the upper



intake



limited;



threshold.



pressure



2. Oil



pressure



temperatu



pressure



temperature



speed is



P1614



unbelievable.



supply 1 is higher than



The voltage of



1-3-1



P0643



P0642



173



cause high speed or speed sensor fault



Sensor harness fault



pressure temperature sensor, and intake



Service Manual for Engine sensor power



re sensor



temperat



sensor connector



supply 1 is



ure



3 pin 2.32 and



lower than the



and



2.33, measure the



lower



intake



voltage to



threshold.



pressure



ground; it’s



temperat



normal if the



ure



voltage is 5V.



sensor malfunc tion The voltage of sensor power



Acceler



supply 2 is



ator



P0653



higher than



Accelerat



pedal



the upper



or pedal



malfunc



threshold.



APP2



tions



power



and the



sensor power



supply



engine



supply 2 is



module



speed is



The voltage of



1-3-1



P0652



lower than the



Power on the ECU, unplug the accelerator pedal Accelerator pedal



connector and



line or connector is



measure the



faulty.



voltage to ground of 3 pin 1.84; it’s normal if the



1,000



voltage is 5V.



rpm.



lower threshold. Accelerat or pedal



The voltage of sensor power supply 3 is higher than the upper threshold.



1-3-1



P0699



APP1 and



The



Accelerator pedal



rail



accelera



or rail pressure



pressure



tor pedal



sensor pressure



sensor



malfunc



harness or



power



tions.



connector is faulty.



supply module



174



Power on the ECU, unplug the accelerator pedal and measure the voltage to ground of 4 pin 1.77;



Service Manual for Engine



The engine speed is 1,000,



unplug the rail



the rail



pressure sensor



The voltage of



pressure



connector and



sensor power



display



measure the



is



voltage to ground



abnorma



of terminal 3 pin



lower



l and the



2.33; it’s normal



threshold.



engine



if the voltage is



is in



5V.



supply 3 is



P0698



lower than the



limp home state. Power off the ECU, unplug the The flash code



The flash code indicator is



P1619



short to power supply.



The flash code indicator harness, joint or



3-3-1



the flash code indicator is



The flash code indicator is short to



P161A



indicator drive The



circuit 1.30 is short



flash



to positive pole of



code



power supply.



indicato



ground.



measure the voltage to ground of low end 1.30;



Turn off the



to work



damaged



connector and



voltage is -0V;



unable



.



indicator



it’s normal if the



r is



properly



flash code



vehicle, unplug The flash code



the flash code



indicator drive



indicator



circuit 1.30 is short



connector and



to ground.



measure the resistance to ground of low



175



Service Manual for Engine end 1.30; it’s normal if the resistance is-0Ω; 1. Power on the ECU, unplug the flash code indicator connector and The flash code



The flash code indicator is subject to



indicator harness is P161B



open or the flash code indicator is



open circuit.



damaged.



measure the voltage of 1.22 and 1.30; it’s normal if the voltage is -24V; 2. Measure the resistance of flash code indicator; it’s normal if the resistance is＜ 2KΩ. Measure the resistance of the flash code



The flash code indicator exceeds the



P161C



temperature.



The resistance of



indicator, it’s



flash code



normal if the



indicator is



resistance of



improper.



common lamp is 40-50Ω and the resistance of LED is -1.6KΩ.



176



Service Manual for Engine



Turn on the key Fuse blown, T15 signal error



1-2-3



P2533



T15 line or key switch fault



to check the The



voltage of pin



engine



Fuse blown, T15



1.40; it’s normal



is



line or key switch



if the voltage is -



unable



fault



24V; otherwise,



to start.



check the circuit from the pin 1.40 to battery. 1. Turn off the key and check whether the 1.61 pin is live; the normal voltage is



T50 turn-on



T50 line



switch



or key



exceeds the



1-2-2



P2530



limit.



switch is stuck



0V; if it’s live, it T50 switch fault



T50 line or key switch



means that the circuit is open to ground; 2. Turn on the key and return it, if the 1.61 pin is still live, it means that the key switch is faulty.



The time deviation



ECU



It’s



Power off and



between time



internal



stopped



restart the ECU;



processin



and



system meter



g unit



unable



if the fault still



is higher than



error



to start.



exists.



Speed



The



sensor



speed is



and its



too high



processor and



1-1-5



P0607



ECU body fault



replace the ECU



the threshold. Speed 1 is higher than the maximum



3-2-4



P0501



177



Speed sensor and its harness fault



1. Power off to check the connection



Service Manual for Engine threshold.



harness



and it’s



between sensor



unable



1.70 and 1.71 and



to shut



connector;



down.



2. Replace the speed sensor. 1. Check the



VSS or SPS



Speed



sensor signal



P1510



is invalid.



sensor, CAN bus



The



1. CAN bus fault



CAN bus



speed is



2. Speed sensor



2. Check the



unbeliev



and its harness



harness



able.



fault



3. Replace the speed sensor 1. Check the



The voltage of speed sensor 2 is higher than the upper threshold.



3-2-4



P2158



Speed



The



sensor



speed is



Speed sensor and



between sensor



and its



unbeliev



its harness fault



1.70 and 1.71 and



harness



able.



178



connection



connector;



Service Manual for Engine



The voltage of 2. Replace the



speed 2 sensor is lower than



speed sensor.



P2160



the lower threshold 1. Check the The speed



Speed



signal from



P2157



Can is invalid.



sensor, CAN bus



1. CAN bus fault



CAN bus



2. Speed sensor



2. Check the



and its harness



harness



fault



3. Replace the speed sensor



The voltage signal of



Speed



speed 2 sensor



P2159



is



sensor harness



Speed sensor and



Check the speed



its harness fault



sensor line



unbelievable. The speed 3 signal pulse width is



P1511



higher than the upper threshold. The speed 3 signal pulse width is lower



3-2-4



P1512



than the lower



The



Speed sensor pulse



Speed



speed is



is too wide or



sensor



unbeliev



narrow or the cycle



able.



is unmatched.



threshold. The speed signal average cycle is lower



P1513



than the threshold. 179



Replace the matched speed sensor



Service Manual for Engine SPI communicatio



ECU 4-1-4



P0607



n error



internal



——



————



chip Power off and



The air



measure the



conditioner compressor is



voltage to ground



P0647



short to power



The air



supply.



condition er



3-1-3



compress



The air



or line is



conditioner compressor is



Replace the ECU



P0646



faulty.



of relay pin 2.11;



The air



it’s normal if the



conditio ner



The air conditioner



compres



compressor line is



sor



faulty.



doesn’t work.



short to



voltage is -0V; Power off and measure the resistance to ground of relay pin 2.11; it’s normal if the



ground.



resistance is＞ 1MΩ;



180



Service Manual for Engine



Check whether the air conditioner The air



compressor



conditioner compressor



P0645



relay is subject to



Air conditioner



appliance is



compressor line is



connected; if it’s



subject to open



connected,



circuit.



measure the



open circuit.



resistance of relay; it’s normal if the resistance is-0Ω.



The air conditioner



Air conditioner



compressor



P0645



relay exceeds



compressor line is faulty.



the



Power off and check whether the relay is damage.



temperature. Power off and measure the resistance The fuel meter



The fuel metering



is subject to



P0251



open circuit. 1-3-5



unit is subject to open circuit



between sensor connector terminal 2.13, 2.12, 2.14 and



Fuel



Engine



metering



limp



joint 3, 1 and 2;



unit



home



it’s normal if the resistance is - 0Ω; The high end of



The fuel meter is short to



fuel metering unit



P0254



line is short to



power supply.



power supply.



181



Power off and measure the voltage to ground of fuel metering unit joint 1



Service Manual for Engine terminal 3.09; it’s normal if the voltage is – 0V; Power off and measure the The low end of



The fuel meter is short to



fuel metering unit



P0253



line is short to



ground.



power supply.



resistance to ground of fuel metering unit joint 1 terminal 3.09; it’s normal if the resistance is - 0Ω; Power off and measure the



The voltage of



voltage to ground



fuel meter is higher than the upper



1-3-5



P025D



threshold.



Fuel



Engine



metering



limp



unit



home



The fuel metering unit line is faulty.



of fuel metering unit joint 1 terminal 3.09; it’s normal if the voltage is – 0V;



P025C



182



Service Manual for Engine



Power off and measure the



The voltage of



resistance of fuel



fuel meter is



metering unit



lower than the



joint 1 terminal



lower



3.09 ; it’s normal



threshold.



if the resistance is -0Ω;



The common rail pressure



P100E



relief valve is



1. Check the high



opened.



High and



The rail



low



pressure required time exceeds the limit.



1. High and low



P100F 1-3-4



pressure oil way; fuel metering



When the



unit; rail



pressure



pressure oil way is Engine



faulty;



perform



2. The rail pressure



ance is



sensor is faulty;



limited



3. The fuel metering unit is



pressure



fluctuates, the common rail



P1010



faulty.



sensor



and low pressure oil way; 2. Confirm whether the rail pressure sensor is normal; 3. Confirm whether the fuel metering unit is normal.



pressure relief valve isn’t opened.



Power off to The voltage of



check the voltage



rail pressure sensor is higher than



1-3-3



P0193



the upper threshold.



Rail



Engine



pressure



perform



sensor



ance is



harness



limited



The rail pressure



to ground of rail



sensor harness is



pressure sensor



short to power



joint 2 terminal



supply.



2.14; it’s normal if the voltage is 0V;



The voltage of



P0192



The rail pressure 183



Power off to



Service Manual for Engine rail pressure



sensor harness is



check the



sensor is



short to ground.



resistance to



lower than the



ground of rail



lower



pressure sensor



threshold.



joint 2 terminal 2.14; it’s normal if the resistance is ＞1MΩ;



The rail pressure deviation is higher than



2-5-1



P1011



the upper threshold. The rail pressure deviation is



1. Check the high



higher than



High and



the upper threshold and



2-5-2



P1012



the fuel



low pressure oil way



injection



and



volume



relevant



exceeds the



and low pressure Engine perform ance is limited



part fault



limit.



High and low



2. Check the rail



pressure oil way



pressure sensor



and relevant part



3.



Check the



fuel metering unit 4. Check the fuel injector



The rail pressure deviation is lower than the lower



oil way



2-5-4



P1013



threshold and the fuel injection volume is 184



Service Manual for Engine lower than the threshold. The rail pressure peak is lower than



2-5-3



P0087



the lower threshold.



185



Service Manual for Engine



The rail pressure peak is higher than



2-5-3



P0088



2-5-5



P1014



2-5-8



P4123



2-5-6



P1018



the upper threshold. The oil dosage unit setting under super speed is unbelievable At idle running, the variable modification of the oil volume metering unit is wrong. The fuel volume of fuel meter is higher than the threshold. Power off to check the voltage



The high end of starter motor is short to power



P0617 1-2-1



supply.



The high end of starter



The



The starting relay



to ground of



Starting



starter in



high-end circuit is



starting relay



relay and



unable



short to power



joint 1 terminal



its



to work



supply.



1.37; it’s normal



harness



properly



if the voltage is –



.



0V;



P0616



186



The starting relay



Power off to



high-end circuit is



check the



Service Manual for Engine motor is short



short to ground.



to ground.



resistance to ground of starting relay joint 1 terminal 1.37; it’s normal if the resistance is - 0Ω; Power off to check the voltage



The low end of starter motor is short



P1638



to power supply.



The starting relay



to ground of



low-end circuit is



starting relay



short to power



joint 2 terminal



supply.



1.51; it’s normal if the voltage is – 0V; Power off to check the



The low end of starter motor is short



The starting relay 1-2-1



P1639



low-end circuit is short to ground.



to ground.



resistance to ground of starting relay joint 2 terminal 1.51; it’s normal if the resistance is - 0Ω; 1.



Power off



and check the The starter motor is subject to



resistance of P163A



open circuit.



Starting relay and



connector



its harness



terminal 1.37 and 1.51 to the starting relay joint 1 and 2;



187



Service Manual for Engine it’s normal if the resistance is -0Ω; 2. Measure the resistance of two terminals of relay; it’s normal if the resistance is -0Ω. The



Check relevant



Water



water



The cooling



temperatu



temperat



water



re sensor,



ure is



Cooling system



engine



too high



problem



cooling



and the



system



power is



temperature is



2-4-2



P0217



too high.



components of cooling system like fan, intercooler, water tank, thermostat, etc.



limited 1.



1.



harness, the



The output



accelerator pedal



voltage of remote accelerator



P1C20



pedal 1 is higher than the upper



In the vehicle



2-2-9



threshold.



Remote



Remote



accelerato



accelera



r and its



tor



harness



failure



Cut off the



power supply, check the voltage to ground of



signal line 1 is



pedal signal line



short to power



1 pin, if the



supply. 2. The



voltage is-0V, it’s



accelerator pedal is



normal;



faulty. 3. The pedal



2. Check the



signal line 1 pin



accelerator; if



2.21 is subject to



necessary,



open circuit



replace the accelerator pedal.



The output voltage of remote



P1C21



accelerator 188



1. In the vehicle



1. Cut off the



harness, the



power supply,



accelerator pedal



check the



signal line 1 is



resistance to



Service Manual for Engine pedal 1 is



short to ground. 2.



ground of pedal



lower than the



The accelerator



signal line 1 pin,



lower



pedal is faulty



if the resistance is ＞1MΩ, it’s



threshold.



normal; 2. Check the accelerator; if necessary, replace the accelerator pedal. The two-time



1. Check the pin



signal relation between remote accelerator



1. In the vehicle



harness



harness, the



connection; 2.



accelerator pedal



Check the



signal line is



accelerator; if



faulty. 2. The



necessary,



accelerator pedal is



replace the



faulty



accelerator



P1C22



pedal 1 and remote accelerator pedal 2 is



pedal。



unbelievable. 1.



2-2-9



P1C23



189



In the vehicle



1. Cut off the



harness, the



power supply,



accelerator pedal



check the voltage



signal line 4 is



to ground of



short to power



pedal signal line



supply.



1 pin,



Service Manual for Engine



The output



2.



voltage of



The



accelerator pedal is



remote



faulty. 3. The pedal



accelerator



signal line 1 pin



pedal 2 is



2.22 is subject to



higher than



open circuit.



the upper



If the voltage is0V, it’s normal; 2. Check the accelerator; if necessary, replace the accelerator pedal.



threshold. 1. Cut off the power supply, check the



The output voltage of remote accelerator pedal 2 is



P1C24



lower than the lower threshold.



1. In the vehicle



resistance to



harness, the



ground of pedal



accelerator pedal



signal line 1 pin,



signal line 1 is



if the resistance is



short to ground.



＞1MΩ, it’s



2. The accelerator



normal; 2. Check



pedal is faulty.



the accelerator; if necessary, replace the accelerator pedal.



The 1/2 signal relation



1. In the vehicle



between



harness, the



remote accelerator pedal 2 and



accelerator pedal P1C25



signal line is faulty.



remote



2. The accelerator



accelerator



pedal is faulty.



pedal 1 is unbelievable.



190



1. Check the pin harness connection; 2. Check the accelerator; if necessary, replace the accelerator pedal.



Service Manual for Engine



Appendix B Fit Clearance of Main Parts of Diesel Engine (Reference value) S/N



Item



Theoretical value



1



Main bearing clearance



0.08-0.11



2



Connecting rod bearing clearance



0.07-0.10



3



Axial clearance of crankshaft



0.04-0.25



4



Plane axial clearance of connecting rod



0.30-0.50



5 6 7



8



9



10 11



Clearance between connecting rod small end bushing and piston pin Clearance between piston pin seat and piston pin Clearance between valve steam and valve guide Working



clearance



of



cold piston ring opening



End clearance of cold piston ring



0.03-0.08 0.003-0.015 0.03-0.06



Top ring



0.35-0.55



Second ring



0.75-1.05



Oil ring



0.3-0.6



Top ring Second ring



0.06-0.095



Oil ring



0.05-0.085



The value of valve bottom below the cylinder end plane The value of cylinder sleeve top higher than the plane



1.0-1.45 0.05-0.10



12



Camshaft bearing clearance



0.10-0.29



13



Camshaft bearing clearance



0.04-0.08



14



Clearance between valve tappet and tappet hole



0.006-0.035



Clearance between piston top and bottom 15



plane



of



cylinder



head



(compression



0.88-1.11



clearance) 16



The value of piston top higher than the upper plane of body 191



0.25-0.57



Service Manual for Engine 17



Valve clearance (cold Intake



0.2~0.3



state)



0.3~0.4



Exhaust



192



Service Manual for Engine



18 19 20



Clearance between rocker arm and rocker shaft



0.016-0.052



Clearance of secondary Radial



0.03-0.07



balance mechanism



0.20-0.40



Axial



Side clearance between timing gear and intermediate gear



193



0.07-0.24