User Manual of Diesel Engine
Contents
1. 1 Whether the color of the exhaust gas is normal or not If the engine exhausts black smoke continuously stop to check it at once If ignore this symptom it leads to engine run in a bad condition It will shorten the service life of the engine under the overload check the antifreeze if sufficient It s an additional pump to service station for is added to water item for the KM376ZQC checking If the antifreeze Send the VE 2 The abnormal working sound during the running If there is abnormal working sound during the running stop the engine right away If you continue to run the engine it will result in serious damage accidents Check all the bolts and nuts if loosened or not Find out the reason of the fault and eliminate the trouble 3 Avoid running the engine in the resonance range Due to the intrinsic structure factor the working machinery may resonate this product in certain rotary speed range It will make the vibration of the engine become very incredible So avoid running the engine near this rotary speed If continue to run the engine at this case it will result in serious damage accidents Periodically check interval Per100 hrs Per200 hrs Per300 hrs 4 A Add the cooling water to the cooling water tank Inspect the cooling water whether is enough or not during the running And supply the cooling water to the water tank in time B Check the amount of the cooling water at the export hole whether2. 2 3 Main Adjusting Data Table Normal adjusting data value Limit value Specification Non compression space height inside the cylinder 0 7 1 0mm When the piston is at the upper dead Fuel delivery timing point the stroke of fuel pump plunger is 0 97 0 03mm or 0 89 0 03mm Fuel spraying pressure two bundle 14 1 14 5Mpa pink eis Open at BTDC16 10 Valve close close at ABDC 40 10 and open phase Open at BBDC52 10 EXNAUSEVANG close at ATDC 14 10 Valve clearance Intake 0 25 0 05mm cold state exhaust 0 3 0 05mm 13 5 14Mpa green and Valve intake amp exhaust joint ring width Tart amm Press the belt down 6 7mm with Belt tension 10kg pressure New belt press down 5 6mm Lube oil pressure 0 4 0 6Mpa idle speed 20 15Mpa Lube oil temperature 60 C 110 C Exhaust temperature lt 750 C 9 5 The running is not stable 1 Check the air leakage and remedy the fault then eliminate the air in the fuel system 2 The speed regulating slide cushion lost 2 Send the oil pump to the service station its flexility 1 There is some air in the fuel system 3 The speed regulating level is worn or 3 Send the oil pump to the service station not flexible 4 The fuel distributed to each cylinder is 4 Send the oil pump to the service station not even 5 One of the nozzles is bad 5 Check and replace the bad nozzle 9 6 Stopping the engine suddenly 6 The solenoid plug of fuel pump is not 6 Ch
3. freezing solution to the cooling water in winter otherwise the frozen water may damage the cooling water system A Anti rusting solution Be sure to use the superior quality anti rusting solution But do not use it in winter because it may freeze when the air temperature is low Its standard mixing ratio is 6 B Anti freezing solution Be sure to use the superior quality anti freezing solution However it s not necessary to use it with anti rusting solution simultaneously This kind of solution can be added to cooling water in all seasons Its mixing ratio is 30 55 OPERATION NOTE E if the mixing ratio of anti freezing solution is too low cooling water will freeze in low temperature which causes damage or rust to the water pipe WE if the mixing ratio of it is too high the engine performance will be decreased Use the commercial available anti freezing solution with the mixing ratio recommended by manufacturer meanwhile it must be replaced every year 11 3 2 Preparation before starting 3 2 1 Add the lubricating oil 1 The amount of the lubricating oil added should flush with height of the lubricating oil level in the oil sump Put the engine on a level surface at first then check the oil level 2 The lubricating oil level in the oil sump should between the lower and upper marked line of the oil stick OPERATION NOTE W The lubricating oil level in the oil sump should between the lower and upper mark
4. r min 10 The engine oil filter is too dirty 10 Clean or replace the element Lube oil fuel consumption ratio at full speed and full load 11 11 Check and replace 12 The engine oil manomenter is broken 12 Replace Exhaust smoke FSU Rotation direction in the face of flywheel Counterclockwise 2 The engine oil pressure is over high 12V DC electric start 1 The adjustment of the pressure limited 1 Check and adjust Pressure and splash valve is not right and the engine oil can t Overall dimension LXWXH mm 594 451X623 return Net weight kg 2 The air temperature is over low and 2 Use the specified fuel type its the oil viscosity is too large viscosity will fall automatically after warming up Starting system A iN Lubricating system 3 The lubrication at the camshaft neck is 3 Eliminate the dirt that restricts the eng not good ine oil and clean the oil passage of the cylinder head 2 2 Specifications and Data of Key Parts 9 8 The engine temperature is over high The cause of the fault Elimination method 1 The water temperature of exhausted is over high 1 The water in the reservoir is not 1 Add water and eliminate the air enough 2 The dirt clings to the surface of the 2 Clean the dirt with the compressed air radiator pieces and copper pipes 3 The scale deposit in the cooling sys 3 Clean the scale deposit tem is too thick to cool the system down 4 There is water leakage in t
5. required the solenoid valve won t be opened and the engine won t start even sudden stop will happen OPERATING NOTICE E After starting the starter switch key shouldn t be pulled out but placed at ON position If placed at the OFF position the battery won t be charged OPERATING NOTICE E After starting the handling lever should be put at idle or middle low speed position for running several minutes Then check the all meters whether are normal or not whether there is abnormal sound of engine If either of them is abnormal stop the engine to check and remedy it right away 3 Check the injecting pressure and the atomization quality of the fuel Injector Check the injecting pressure and the atomization quality of the fuel Injector every 100 hours Refer to the figure 7 3 If you find there is oil leakage atomization quality is bad and needle valve of the nozzle is blocked please remove and clean the injector or replace the injecting nozzle If you find the oil pressure isn t up to specified value you can adjust the pressure regulating spring by adding the steel shims Refer to figure 7 4 for the structure of the fuel injector OPERATION NOTICE 4 1 4 When the ambient temperature is below 5 C it may be difficult to start the engine Warm up the intake gas fuel cooling water lube oil or use some solvent to make engine start easy Fuel nozzle is a couple of exact assembly don t replace the any of the par
6. 1 Safety Marks E Be sure to read and follow the instructions on the manual and safety marks E Operating the engine without proper training or instruction is not allowed E CAUTION Many accidents are resulted from false operating For your safety please obey to the following instructions OPERATING NOTICE Covers important safe information Be sure to pay special attention to and follow it otherwise the engine performance will decrease or the engine fault and parts damage will result 1 2 Safety Caution Be sure to pay attention to the following safety cautions while running the engine CAUTION To avoid being scalded with vapor E Do not open the radiator cap while the engine is running otherwise the vapor scald will result Be sure to open the radiator cap with cloth covered it after the engine temperature decreased and tighten the radiator cap while the engine is running CAUTION To provide well ventilation for the battery E To keep the battery at well ventilated place and far away from the fire otherwise hydrogen explosive will result CAUTION To avoid fire resulted from improper operating E Use the recommended grade diesel oil Other fuels such as gasoline and kerosene will cause engine rough running fuel injection system fault even the fire or explosive Be sure to use the recommended fuel described in this manual E Refuel in a well ventilated area with the engine stopped Keep flames and sparks away If the fu
7. 1 The air cleaner is too dirty and the 1 Clean and replace fuel is restricted 2 The throttle doesn t work normally 2 Regulate the throttle 3 Fuel pipe is clogged 3 Check and clean 4 There is leakage or there is some air 4 Tighten it again eliminate the air in t in the fuel system he system M10 1 25 37 547 5 5 The speed regulation spring is slack 5 Regulate the max speed limited screw M12X1 25 60 10 6 The timing of the supplying fuel is not 6 Regulate it as specified Note Turbocharger type main bearing bolt M12 x 1 25 correct tightening torque 85 5N m 7 There are some faults in the injector 7 Check the pressure of oil injection and atomization condition 8 The air cleaner is too dirty 8 Clean and replace the element 9 Mix air phase or valve clearance isn t 9 Check and regulate it correct 10 The compression pressure of the cylinder is not enough There is air leakage at the valve Abrade the surface or replace the valve and valve base ring 2 There is air leakage at the cylinder 2 Replace the cylinder cushion cushion 8 The cylinder piston ring or piston is 3 Replace the relative parts and abrade worn out the cylinder surface 4 There is air leakage when install the 4 Replace the seal gasket or adiabatic injector line of the nozzle The bolt of the cylinder is loosened Tighten the bolt again as required 34 7 Glow plug thread M10x1 25 1242 Othe
8. Sound When Running the Engine ee 38 9 12 The Engine Oil Level rises ic cies ticssictcte css masivtansisianteieseniednehanh nine eanitatnatainastis 39 10 Storage 46st ead ae ea ae Ri 40 10 1 Storage Rete EES ESSE SEES COSSEOSSOSSSESSSOSOSSSSOOSSSSOSOSS SSO OSSOSOOSOSOSIOOOSOSOOSS 40 FRADPENIK eii eni EE E E E 41 The Outineof the Tiltttyoe engine sc eee eee 41 Electio Wining Diagrami Senaren en E E ES 42 11 APPENDIX The outline of the tilt position engine SZE To the oil pump MAX height position The center of the exhaust export The center line of the crankcase The center of the inlet 3 The center line of the engine To oil pipe MAX height 4 Supercharger NOTE According to actral requirement the dimension and dimension can be deduced further 41 10 STORAGE 10 1 Storage 10 1 1 The diesel and spare parts and tools leaved from the factory should be wrapped in the water proof plastic cover The bottom bracket should be mounted at the casing box bottom And the casing box should closed and clenched firmly 10 1 2 The casing box should be put the dry and ventilated room Forbid putting it the open air and putting it with the chemical such as pesticide and chemical fertilizer 10 1 3 The effective period of the oil seal is one year Check the corrosion of the diesel after one year Store the engine after coating it with oil seal if necessary 40 1 SAFETY INFORMATION 1
9. User Manual of Diesel Engine Electric Wiring Diagram 1 The alternator 2 The voltage regulator 3 The CHG indication lamp 4 The hot insulation indication lamp 5 The Current meter 10A 6 The generator 15A 7 The starter motor 42 8 The grow plug 9 The current sensor 10 The warm up timer 11 The grow plug resistance 12 The grow plug relay 13 The water temperature sensor 14 The battery Contents 1 Safety Wit On revatio eeinetan iaeiiai i iias 1 1 1 Safety Mark ccc cece it ie ie eit cist tie cites ices iesieisitistn 4 1 2 Safety c ile ii a ee ee ee 1 2 Product Instructions eee eee eeens eeinetan 4 2 1 Main Specifications and Data ct tt tt eit 4 2 2 Specifications and Data of Key Parts c eet et et ttt et titties 5 23 Man Adjusting Data Table see sisne nm peteciectontgneiaieetaen item yotsetnionacuns 6 24 Tightening Torque of Main Bolts and NutS veces 7 2 5 Operation Control Device Ge essi steininn aa EE 8 3 Preparation before Operation a r a E E A E E E 10 3 1 Prepare the Fuel Lubricating Oil and Cooling Water oeeeveseseserenenennn 10 3 2 Preparation before Starting lt i ie etree eee ee eee rans 12 4 Operation Instruction ee et tt tt ete ete 15 4 1 Starting PEATE abla cing ie betas aceon oye at i anna ea ete E S E el dean fete he lean bye 31 dhenie 15 4 2 Running padded saad Mee E EE E EE E telnet ae N EE E EE E EN E N 16 4 3 Check Engine during the Running eeeeeee
10. battery electrolyte E The electrolyte contains diluted sulphuric acid which can cause blindness 2 The gap between piston and cylinder 2 Clean or replace the oil hole is too large and the oil hole in the piston and burn if eyes or skin contacted with it If electrolyte splash into your eyes circle groove is clogged flush thoroughly with water immediately and call a physician 3 The piston ring is clogged circuit groove 3 Clean repair or replace or the installation position of the 4 There isoil leakage in the front seal and 4 Check and replace the relative parts A WARNING rear seal of the crankcase CAUTION To avoid short circuit to prevent from fire 5 The engine oil temperature and 5 Decrease the temperature check and l l pressure is excessive regulate the pressure limited valve M Do not confuse the earth terminals while checking electric system otherwise the fire will result from short circuit 6 There is oil leakage in the air valve seal 6 Replace the air valve seal 9 11 There is abnormal sound when running the engine The cause of the fault Elimination method 1 The gap between piston and cylinder 1 Replace the piston ring piston and is too large bore the cylinder if necessary A WARNING CAUTION To avoid being caught into the rotary parts Be sure to carry out maintenance with the engine stopped E Do not remove the cover of rotary parts 2 The gap between piston pin and small 2 Repalc
11. ction carefully 8 1 The adjustment of valve clearance The valve clearance refers to the cam surface the clearance of inlet valve should be 0 25 mm in cold condition and that of the exhaust valve should be 0 30 mm In hot condition the clearance of inlet valve should be 0 30 mm and that of the exhaust valve should be 0 35mm If the clearance is improper make it reach to the standard by adjusting the shim thickness 8 1 1 The measurement of the clearance Measure the clearance using the ruler as shown in the figure 8 1 1 Measure the clearance in cold condition 2 The rabbet in the cam should be toward up 8 1 2 The selection of the adjusting shim clearance T T A A T the thickness of the shim replaced T the thickness of the shim measured A the metrical value A the standard value 8 1 3 The replacement of the adjusting shim Press the valve tappet down using the special tools and get out the shim used for the measurement then replace the shims that need to install to primary position T Fig 8 1 Check the valve clearance 29 7 Check the air cleaner If the dust is drawn into the air cleaner and clings to air cleaner parts it will affect the output of the engine sooner or later When the combustion chamber draws the dust in it will accelerate the worn of the moving parts and cause the engine not to run normally When you run the engine in the dusty place the service interval should be shortened as possibl
12. e 30 spot NO 1 cylinder In other word it s the injection pump bolt fan mark 2 Loosen the mounting nuts in the fuel injection pump and the bolts in the supporting plate of the fuel injector rear end until the fuel injection pump can revolve Then keep the fuel injection pump toward the inner surface to the bottom 3 Install the lever type micrometer calipers in the front end of the fuel injection pump and let the pointer needle point at naught 4 Crank the crankcase to make NO 1 cylinder of the engine stay at upper dead center of the compression stroke 5 Turn the injection pump toward outside surface slowly until the reading of the meter is 0 97 0 03mm 6 Check the meter again Crank the crankcase to position 1 watch the reading of meter whether reset to naught position Then crank the crankcase until it reaches the upper dead center check the meter reading whether is 0 97 0 03mm If the reading is right the adjustment is completed If the reading isn t right repeat the above adjusting steps 7 Tighten loosened nuts and bolts above mentioned 30 OPERATION NOTE Using the improper type lubricating oil will burn out the inner part of the engine even cause the engine to wear rapidly And the service life of the engine will be also shortened 3 1 3 Cooling water Be sure to adopt tap water as cooling water OPERATION NOTE E Be sure to add anti rusting or anti freeze solution to the cooling water E Add anti
13. e as you can paper air cleaner element Loosen the wing nuts in center of air cleaner remove the air cleaner cap then get out the paper element inside the air cleaner Blow and clean the inner surface of the parts using the compressured air below 0 2 Mpa Clean the dirt and dust clinging to the surface If the elements are dirty or broken always replace them with new elements Reinstall the paper element after cleaning the dirt and dust clinging to the air cleaner and chassis h 7 3 The technical maintenance after the engine works 1000 hours Repeat those items as technical maintenance after working 500 hours then perform the following maintenance items 1 Check the tightness degree of the bolt in the connecting rod and main bearing 2 Check the seal of the inlet and exhaust valve If necessary machining the surface of the valve seat over again 3 Check the starter motor and generator If necessary add the lubricating oil and run the engine at idle speed after reinstalling it Add grease to the bearing before putting the engine to use 4 Check each part of the diesel engine 5 Reinstall the parts removed in the maintenance course to primary position eliminating the potential fault 28 The fuel line of the engine fuel system is as shown in figure 3 2 2 followed To eliminate the air in the low pressure fuel line loosen the connector of the intake pipe in the VE dispensing pump at first then expel the ai
14. e the worn parts keep the end bush of connecting rod is too large specified gap 3 The gap between main bush and the 3 Replace main bush connecting rod A CAUTION connecting rod bush is too large bush keep the radial gap specified E g a PE E Do not rebuild product without permission 4 The gap between the piston ring and 4 Replace the piston ring and replace WE Do not release the control the high speed limiting screw and oil level piston ring circuit groove is too large the piston if necessary limiting bolt otherwise the engine life will be shortened Any rebuilding or disassembling of the engine will decrease safety even cause severe accident If necessary contact your local agents for replacing the genuine parts or technical support 5 The gap between pressure surface 5 Replace the thrust piece and keep the and thrust piece is too large specified gap 6 The piston bumps into the air valve 6 Check the clearance height 7 The abrasion of the gears is serious 7 Judge whether replace the gear or not and the gap between the gears is according to the abrasion degree excessively large There is a clash bump when reducing the speed suddenly 8 The timing of oil supply is too early 8 Check and regulate the timing of oil supply 9 The oil injector assembly is snapped 9 Clean or replace the nozzle assembly 38 3 9 9 Engine oil pressure is abnormal 2 PRODUCT INSTRUCTION Sr The cause of the fault Elimination method 1 T
15. eck the circuit electrified 7 The denticulate belt is broken 7 Replace and test 8 The crankcase can t crank 8 Replace and test a The piston sticks to the cylinder a Send it to the service station b The oil pressure is too low and the lube b Send it to the service station and oil is not enough to cause the crankshaft check the lubricating system sticking to cylinder 9 7 The engine can t stop when the solenoid is cut off The cause of the fault Elimination method 1 There is some fault about the solenoid 1 Replace the solenoid and clean the element 2 The seal surface of the solenoid loses 2 Send the oil pump to the service station its seal function 3 The switch of the solenoid doesn t work 3 Replace or repair 35 9 3 Fuel consumption is too large 2 4 Tightening Torque of Main Bolts and Nuts Thread Tightening Bol Cylinder head bolt M12 x 1 25 90 10 4 injection timing is abnormal 4 regulate the injecting timing Main bearing bolt M10 X 1 25 Oil sump bolt i a a 8 w 8 6 isan nozzle assembly doesn t Me 55415 20 9 4 The power is not enough Flywheel bolt M10x1 25 5545 6 The cause of the fault Elimination method 1 Fuel leakage 1 replace or tighten securely 2 idle speed is too high 2 regulate idle speed 3 the max rotation speed is too high 3 check the max speed set bolt of the at the no load injector pump The cause of the fault Elimination method
16. ed line of the oil stick If the lubricating oil is not enough it will damage the engine easily However if excessive the lubricating oil will spill over from the air opening hole 3 2 2 Refill the fuel tank 1 Add the fuel to the fuel tank Add the fuel without containing dirt and water To prevent the fuel from overfilling during the running course the amount of the refilled fuel should be 90 of the fuel tank capacity Make certain whether the type of the fuel refilled is right or not If improper fuel is added it will cause the fire If the fuel is overfilled wipe it up at once 2 Eliminate the air in the fuel system When refill the fuel at first time or refuel the tank normally as required you should eliminate the air in the fuel line which begins from the fuel tank though water oil separator or fuel filter or primary oil delivery pump to the fuel injection pump If the air mixes with the fuel in the fuel line the fuel injection pump won t provide the high pressure fuel for the fuel injector and the engine can t start also This product adopts the VE distributor pump and the lubricating and cooling of the VE distributor pump relies on the fuel So if the fuel is cut off it will result in damage of VE distributor pump 12 8 THE ADJUSTMENT OF THE TECHNICAL DATA KM376 series engines are different from the general use diesels in the structure In order to ensure maintenance quality please read this additional se
17. eeeesereerererrereerennierneere 18 AAS top te Engine steer a a a S edathetees 19 5 Break in Period and Trial Run ccc cece eet ett te tenet 20 6 The Storage for a Long time 0 21 7 The Method of the Maintenance and Service eee ee eee ee 22 7 4 Daily Technical Maintenance 06eeeeveveveseseseenenenereneeeennn nn 22 7 2 Pernodically Check and Service eerssssesriosnrctiss nki istit Eh 22 8 The Adjustment of the Technical Data 0eeeeeererereessenene 29 8 1 The Adjustment of Valve clearance oe issn 29 8 2 The Adjustment of the Injection Timing eee tee 30 8 3 The Adjustment of the Fuel Injector eetere 31 8 4 The Adjustment of the Injection PUMP eee 31 8 5 The Adjustment of the V Belt eetere 31 9 The Engine Fault and the Elimination Method 32 9 1 Starting hard or can t start ccc eee ei ecient 32 9 2 The Exhaust Gas is Excessive and Its Color is Abnormal 33 9 3 Fuel Consumption is Too Large etiseri ii 34 9 4 The Power b Not Enough nee cer erent ene ee reese tennant eee tee 34 9 5 The Running is Not Stable acter costae etce ese te pie ee 35 9 6 Stopping the Engine Suddenly eee 35 9 7 The Engine Can t Stop When the solenoid is Cut Off 35 9 8 The Engine Temperature is Over High eeestis ieten 36 9 9 Engine Oil Pressure is ADNOnmal isissssiisisissisurersisssidiissstsressisioniskoitinsssssauntsssss 36 9 10 Engine Oil Consumption is Over Large osc teins 38 9 11 There is Abnormal
18. el filter is restricted 2 Replace the fuel filter 3 the assembly in injector nozzle 3 clean repair doesn t work normally 2 the exhaust gas is black smoke 1 Fuel injector is clogged by the carbon cumu 1 Check repair or replace lated and the needle valve is blocked up 2 The load is too large 2 Reduce the load to the specified range 3 Fuel injection is too late part of fuel a Replace the cable or tight connection is burnt in the exhausting course 4 The clearance is not accurate and 4 Check the valve clearance and seal it s seal is not effective surface of valve 5 The distribution of the fuel to each 5 Regulate the fuel distribution of each cylinder isn t even cylinder 6 The inlet pipe and air cleaner is 6 Remove the air cleaner and clean it clogged so the air is restricted 3 the exhaust gas is white smoke 1 Injection pressure is too low atomi 1 Check regulate repair or replace zation isn t good and there is oil leakage the nozzle assembly 2 The temperature of the cooling water 2 Increase the temperature of is too low cooling water 3 The cylinder is penetrated by water 3 Check the cylinder head shim 4 The exhaust gas is blue smoke 1 The piston ring is worn excessively or 1 Clean or replace the piston ring engine oil enters into the combustion chamber in cause of the spring of the carbon clogged is not enough 2 The engine oil level is too high 2 Drain out
19. el spilled immediately clean up the overflowed fuel with rag E Keep the engine far away from gasoline kerosene match and other explosive or flammable materials otherwise will result fire A WARNING CAUTION To avoid inhale the poisonous exhaust E The exhaust contains poisonous content Do not run the engine at poor ventilated places such as confined rooms tunnels tents and cabins Be sure run the engine at well ventilated place A WARNING CAUTION To avoid being caught into the moving parts E When the engine is running keep your hands body and clothes away from rotary parts such as cooling fan V type belt and starter axle A CAUTION CAUTION To avoid touching the hot parts to prevent from scald E Be careful not to be scaled with hot engine body when the engine just stopped Keep hands body and clothes far away from muffler exhaust pipe and radiator etc parts E Do not operate the engine after drinking alcoholic beverage 9 12 The engine oil level rises The cause of the fault Elimination method 1 Repalce the cylinder head gasket 2 Check and repair or replace 1 There is water leakage at the cylinder head gasket 2 There is water leakage in the cylinder head or engine body 39 9 10 Engine oil consumption is over large Safety information about inspection and maintenance The cause of the fault Elimination method i ie a ain S 00 OWARE deiseplage neengine ol Drang CAUTION To avoid touching the
20. er needn t be drained out Drain out the water by opening the draining water valve in the engine lower body At the same time open the radiator cap to drain the water 2 Clean the dirt dust and oil clinging to engine body 3 Periodically check and replace the engine oil 4 To prevent the fuel vapor changing into moisture in the fuel tank you can drain out the all of the fuel in the tank or refuel the fuel tank fully 5 Remove the negative terminal of the battery at the ground cable In order to makeup the wastage that caused by discharging of battery itself Charge the battery every month in the storage course 6 Add the lubricating oil to the acceleration coils and system 7 Coat the muffler air cleaner electric parts with the plastic cover to prevent the water moisture and dust entering into those parts The places in which the engine stores should be dry and free of dust OPERATION NOTICE When reuse the engine after storing for a long time make the preparations as using a new engine at first 21
21. he engine oil lack of pressure or the pressure is too low 2 1 Main Specifications and Data 1 The engine oil in the oil sump is not 1 Refill the engine oil up to the specified enough level KM376QC KM376G KM376AG 2 The engine oil becomes thin 2 Choose the specified fuel type Type Palak In line 4 stroke Tilt 4 stroke 3 The oil pipe is broken pipe connector 3 Replace or tighten it water cooled tercooled water cooled is loosened and there is oil leakage in the Combustion chamber type Swirl type oil pipe Bore X cycle mm 76X73 76X77 4 The gap of the engine oil pump is too large 4 Replace it Cylinder no 3 5 The plunger of pressure limited valve 5 Replace it Piston displacement L 0 993 1 048 isn t quick and the spring is broken or Compression ratio 21 5 6 The drive pin of engine oil pump is broken 6 Replace it Rated power kW 18 7 20 6 19 5 23 7 The fit clearance between the main 7 Check adjust or replace Rated speed r min 15 minutes power 5000 3000 3600 3000 3600 bearing and connecting rod is too large 8 The plug of the oil pipe is loosened 8 Check the plug Max torque speed N m r min 54 lt 3200 56 lt 3000 62 5 lt 3000 Min fuel consumption at max throttle g kW h 312 300 300 i lair filter i i 312 30 9 Te engine oil air filter is clogged by 9 Check and clean air filter Max steady speed at zero load r min 5800 150 the dirt 900 50 lt 0 8 Idle speed
22. he operation reliability of each connection Remedy the fault as soon as find it 3 2 6 Check the connection of the bolt mounted to ground and the driven machinery If loosened tighten it securely at once 3 2 7 Before connecting the battery make sure that the connection of the negative lapping iron and the electrical diagram is right and electric capacity of the battery is sufficient 14 6 Check the battery electrolyte When check the electric circuit you must close the battery switch disconnect the ground terminal If there is a shortcut in the circuit it may result in fire Please recharge the battery in a good ventilated place Keep all fire sources away because the hydrogen produced in the battery causes fire easily The electrolyte contains a mount of sulfuric acid It could cause burnt injury even blind if the eyes and skin contact with it Please wear the glasses and rubber gloves when you handle the battery electrolyte If you touch the electrolyte without precaution use a large quantity of water to wash it and see the physician as soon as you can Check the electrolyte level every month If the level is lower than the lower limit mark refill the distilled water to the upper limit mark Upper limit mark Lower limit mark OPERATION NOTICE 1 If you continue to use the battery when the electrolyte is not enough you will cause the damage of the battery Periodically check the electrolyte capacity If
23. he pump or 4 Disassemble check and repair the shaft of pump is broken the impeller Governor Mechanical full length Modi S series P series tread coupling Working pressure 249Kpa can t rotate Working speed 2500r min Lube oil pump 5 The fan belt is broken or too loosened 5 Replace the belt or adjust the belt l Centrifugal tension Cooling water 6 The cooling water line pipe or engine 6 Clean the water line 55L min cooler is clogged 7 The thermoregulator is damaged 7 Replace it Lube oil filter Screw in type 8 The diesel runs under over load 8 Reduce the load Specifications and Data 2 The engine oil temperature is over high Silicon rectifying parallel excitation Generator 1 The engine oil is insufficient or 1 Add the engine oil as specified excessive Rated current 40A 45A in cold area 2 The engine cooler is clogged by dirt 2 Clean it 3 The quality of the engine oil is bad 3 Replace the engine oil as specified 4 The amount of air flee is excessive in 4 Check the air flee for the piston ring Glow plug raw 5 The cooling water temperature is over 5 Reduce the temperature as described high above Working temperature Above 750 C 6 The diesel runs under over load 6 Reduce the load Thermoregulator Paraffin type 7 The engine oil temperature meter doen t work 7 Replace it ae Paper element with fuel water Diesel oil filter separator and portable pump 36 5
24. hoose the appropriate brand for the light diesel oil according to actual ambient temperature Light diesel oil brand Temperature 20 10 0 10 20 30 40 C 2 Fuel usage The fuel with water or dust contaminated will cause the rough running of the engine Be sure to use the clean container for storing the fuel meanwhile the container must be stored at a clean and dry place Then suck out the upper level clean fuel with a pump as below figure E The improper fuel cannot make the engine achieve the best performance and even cause the fault of the part E Only use the upper level clean fuel Do not use the lower deposited fuel 3 1 2 Lubricating oil 1 Do use L ECD grade oil the quality index is 15W 30 or 15W 40 2 The usage of lubricating oil A Carefully store and use the lubricating oil Avoid any dust and impurity in the oil B Do not mix two different type lubricating oil otherwise the lubrication performance will be decreased 10 8 3 The adjustment of the fuel injector The test and regulation of the injector should be done on the fuel injector test bed Its purpose is regulating the oil pressure and watching the atomization quality and eliminating the fault 1 Pump the oil by using the hand pump unit the injection pressure is 14 0 5Mpa check the Injection condition and atomization quality whether accords with injection requirement If there is oil leakage or dropping in the injector you should rem
25. lean please replace it at once Ue Filter element Fig 7 2 24 4 2 2 When the engine is running normally inspect the engine oil pressure and temperature cooling water temperature and the working condition of the charging indicator frequently Be careful to observe the color of exhaust gas and listen to the working sound during the operation 4 2 3 In the normal run course shouldn t increase or decrease the rotary speed and load suddenly A WARNING If you find one of the phenomena that the engine oil pressure is over low and the temperature of cooling water is over high It s over the specified range in the chart 2 4 dense smoke exhausting from the engine and there is knock sound in the normal run course stop the engine as soon as possible and check the reason of these symptoms Otherwise the fault will lead to damage of the engine 4 2 4 Provide the adequate heat preservation measure for running the engine in the winter to prevent the temperature of the cooling water and engine oil is over low However Provide the adequate cooling measure for running the engine in the summer to prevent the temperature of the cooled water and engine oil is over high A WARNING Never keep the engine running under overload for long time Otherwise it will result in fault and shortening the service life 17 4 3 Check engine during the running Make sure there is no abnormal case during the running referring to following items
26. moving parts as radiator fan belt drive shaft and so on When check and service the engine near these parts be sure that the engine is stopped Before running it make sure that there isn t anything left on these moving parts E When the engine is running or stopped not for a long time your hands body and clothes should not contact with the muffler exhaust pipe and radiator 4 1 Starting 4 1 1 Start the engine under no load When starting the engine on the vehicle let the vehicle to stop before 4 1 2 Set the throttle lever at the half open position when you start the engine 4 1 3 Insert the key to the engine switch hole then turn it to the ON position clockwise At this time the grow plug indicator lamp is on After it last about 7 seconds it goes out soon The next step turn the key to the START position clockwise let the starter motor to start the engine Finally release the key and it will return to ON position automatically This is completing the engine start OPERATING NOTICE Don t use the start switch over 15 seconds each time If you can t start the engine wait for 1 minute then restart the engine Otherwise the long time running with electricity overheats the engine to cause fault 15 OPERATING NOTICE When put the key at the ON position 12V DC voltage will open the solenoid valve in the VE pump If the electrical bottle voltage is lower than 8V or the cable isn t connected as
27. ne in winter you need to make antifreezing preparative 19 5 BREAK IN PERIOD AND TRIAL RUN 5 1 A new engine needs a break in period and a trial run course And this course should not be less than 45 hours or 2800 km 5 2 During the break in period don t let the engine stay at the high speed state with the fuel valve open fully And you should increase the engine load slowly at the same time inspect the engine s running data measured by the all kinds of meters OPERATION NOTICE To make your engine run reliably and use for a long time provide a new engine with a break in period During the break in period you should inspect all kinds of meters whether work normally After the break in period please replace the engine oil in the oil sump 5 3 After break in and trial run course replace the engine oil in the oil sump Clean the engine oil filter and fuel filter Check the tightening torques of the cylinder head bolt and the others connecting bolts These torques should meet the requirement as specified 20 6 THE STORAGE FOR A LONG TIME OPERATION NOTICE If you don t drain out the cooling reserved in the engine it will be frozen which will damage the parts In order to reuse the engine normally the following measurements should be carried out when you store the engine for a long time 1 When stored for a long time in winter the water in the engine should be drained out If antifreeze is used the wat
28. nection or other driven machinery 6 Keep the engine clean Clean the oil and dust using dry rags or rags with detergent Keep the electric appliance connected to the engine dry and clean especialy 7 Eliminate the fault and abnormal symptoms that have been found 7 2 Periodically check and service In order to keep the engine at good running state the daily check is necessary The following table specifies the rules about when and how to check and repair the engine Check the engine usage load fuel used lube oil quality and operation state when make the periodically maintenance The following table describes the common cases about the maintenance OPERATION NOTICE According to use condition set down periodically maintenance schedule Perform the rules to check the engine without missing as the schedule specified In case of missing the necessary item it will affect the durability of engine parts As to the parts marked with specially the owner should have the proper tools and be mechanically proficient Otherwise please send your products to your dealers and consult with them 22 4 4 Stop the engine 4 4 1 If the engine needs to be stopped decrease the engine speed to the idle state gradually Let the engine stop only when the temperature of the cooling water is below 70 C 4 4 2 When you need to stop the engine only turn the starter switch key to OFF position refer to 4 1 1 4 4 3 After you stop the engi
29. ove the fuel injecting assembly to clean or repair it until make injection up to requirement 2 The adjustment of injection pump Pump the oil by using the hand pump When the reading of the fuel injection starting pressure can t reach 13Mpa you can remove the injection assembly by increasing the thickness of the adjustment shims to improve the injection pressure until the pressure reading is up to standard If the reading is over 13Mpa you should reduce the thickness of the adjustment shims 8 4 The adjustment of the injection pump Injection pump has been tested and adjusted before leaving from the factory If you need to readjust it you should perform the adjustment on the test bed according to relative regulations 8 5 The adjustment of the V belt As shown in the figure make the tension check in the arrowhead direction As to new products put a 100N force on the it and loosen the belt until looseness degree reaches 4 5 mm Under the normal condition put on a 100N force until the looseness degree is 6 7mm If you put on a 100N force but the looseness is no less than 9mm replace the V belt Crankshaft 31 8 2 The adjustment of the injection timing In order to obtain the most economical fuel consumption ratio and better running performance the injecting ahead angle should be set properly The adjustment method of KM376QC KM376ZQC ahead angle should be as followed 1 Crank the crankshaft to make crankshaft lies on th
30. r bolts and nuts Thread of fuel injector body M20 1 25 o T e J r te f s ee a el a 2 5 Operation Control Device The operation control device connected to warm up unit electric starter and fuel pump solenoid valve respectively The electric wiring of the control device is as below figure 2 1 The electric wiring of the starting motor is as below figure2 2 Recommended voltage is DC 12V Recommended current is less than 90A The electric wiring of the glow plug is as below figure 2 3 The resistance of the glow plug is 0 4 0 6Ohm The function and operation of the electric starting switch is as below Rotary 3 position switch The key can be pulled out when the switch is on OFF position Meanwhile the current is cut off at this position When the switch is on ON position 1 the warm up indicating lamp of glow plug will keep light for 7 8 seconds and then goes out automatically 2 The solenoid of fuel injection pump is acted When the switch is on START position release The operation procedure the key and let it automatically return back to ON Of the switch is position The solenoid of fuel injection pump is OFF ON START ON acted however the glow plug is still unconnected 9 2 The exhaust gas is excessive and its color is abnormal The cause of the fault Elimination method 1 The smoke exhausted is too thick 1 the injecting timing is improper 1 Adjust the injecting timing 2 the fu
31. r from the fuel Inspect the connector of the VE pump return pipe If there is a lot of fuel overflowed and no air bubble occur It indicates that there is no air in the low pressure fuel line primary oil delivery pump diesel fuel filter Oil return tube solenoid valve fuel injector fuel tank oil water separator VE distributor pump 3 2 3 Eliminate the air in the high pressure fuel line The high pressure fuel line begins from VE dispensing pump through high pressure fuel pipe to the fuel Injector Method of the treatment loosen the connector where the high pressure fuel pipe connects with fuel injector then start the starter motor and let it run at low speed until the fuel overflows around the connector finally tighten it If there is still some air in the high pressure fuel pipe the engine won t start 13 3 2 4 Add the cooling water 1 The water in the radiator water tank should be sufficient Expel the air from the water line when adding the water At the same time check the water tank and connector of pipes for leakage and remedy if in time 2 After adding water tighten the radiator water tank cap Otherwise it will cause scald for the hot water 3 If there is some air in the water line it will cause the restriction of cooling water even engine damage because of the excessive high temperature in the engine 3 2 5 Check the all operation control systems and t
32. reduced or not If the exported cooling water decreases stop to check the engine C Check the cooled water whether injected or leaked If there is an abnormal case stop to check the engine right away If continue to run the engine lacking of the cooled water it will cause the engine over hot to burn out the inside parts Check and Service items 5 Check the oil pressure lamp whether is on and the oil pressure sign is red If the oil pressure sign is red stop to check the engine If continue to run the engine at the no oil state it will result in burning out the inside parts Check the clearance of the exhaust and inlet valve Check the battery voltage and density of the electrolyte Check the connection condition of every contact spot Clean the dirt on the surface of air compressor Clean the dirt from impeller and engine inner surface Check the tightness of the bolt In the cylinder a O O D oO q ab lt _ ue O Sent gt fon Q eb iC 3 Boa O ab Ee O Replace engine oil in the sump Clean or replace cleaner element Check atomization quality Clean or replace fuel cleaner element Check the VE pump Replace the cooling water Clean the thermoregulator Check the tension of fan bolt Clean the air cleaner element Clean dust from the inlet pipe Check the phase of gas mixed Check the inner rotator 6 Check the charging indication lamp is on If the charging indica
33. the electrolyte level is below the standard specified please refill the electrolyte in time In hot summer the electrolyte tends to be vaporized So check it ahead of the specified time 2 If the engine can t start using the accelerating return use the gravity meter to measure the density When charged fully the density should be above the 1 27 g ml 20 hours If the density is below to 1 24 g ml it indicates that the battery needs to be charged If the density doesn t increase after charging please replace the battery 27 4 Check and adjust the valve clearance Check the valve clearance every 100 running hours method check valve clearance by removing the cylinder head according to the method described in figure 8 1 of section 8 1 If you want replace the adjusting shim use the professional tools for the engine Then get out the shims according to figure 7 5 and replace the shims you need to install Max height Nice 3 Tappet Fig 7 5 5 Check the tightness of the bolt in the cylinder Check the tightness of the bolt in the cylinder by using the torque wrench every 100 hours Check the bolts in sequence as described in figure 7 6 The tightening 10 torque should be 90 N m Front side 26 4 OPERATION INSTRUCTION A WARNING E Provide the engine with good ventilation condition for its running When running the engine your hands body clothes shouldn t close to or contact with such
34. the excessive engine oil 3 The installation of the air ring is 3 Make the surface marked converse in up and down direction with T toward up 4 Replace the valve seal 4 Valve seal is damaged 33 9 THE ENGINE FAULT AND THE ELIMINATION METHOD Elimination method 1 Battery electric amount isn t enough 1 Charge the battery tighten the connec or the connection is loosened tion and repair the terminal if necessary 2 The contact of between the carbon 2 Repair or replace the carbon brush brush and rectifier is poor 3 The gear of the starter engine can t 3 Revolve the flying wheel until the small re be embedded into flying wheel circle gulating gear levels with the denticulate circuit 4 The electric battle cable is too long 4 Replace the electrical battle cable too thick voltage decrease is too large 1 The fuel in the tank is used up a The cable is cut and the connection is loosened b The winding of the solenoid is damaged c The solenoid element is snapped d There is fault in the starter switch 3 There is some air in the injector pump 4 Fuel filter element is clogged 5 The plunger of the injection pump is 5 Replace the parts of the injector broken or snapped pump distributor 6 The transmission bolt in the plane 6 Replace the transmission bolt in the cam of the injector pump is broken plane cam of the injector pump 7 The inner oil ring of the injector 7 Replace the parts of the injec
35. tion lamp is on it indicates that you can t charge the battery Lubricating Air inlet pipe amp Air cleaner Inlet and exhaust air Bolts and cylinder cap Electric 7 If there is burn or funk or smoke please add the lubricating oil in time You must stop the engine when add the lubricating oil If there is an abnormal case but you can t determine the reason stop the engine and send to the dealer s shop to Note O Indicates that it s a necessary item or content 18 23 7 THE METHOD OF THE MAINTENANCE AND SERVICE In order to make the engine work normally and reliably proper technical maintenance should be given to the diesel engine And the technical maintenance includes following kinds the daily technical maintenance the periodical maintenance and the maintenance after working 1000 hours 7 1 Daily technical maintenance 1 Check the lubricating oil level in the oil sump whether is between the upper mark line and lower mark line of the oil dipstick and near the upper mark line If it is a new engine or an old engine stored for a long time add the lubricating oil up to the upper mark line and run it at low speed for 5 10 minutes before stopping it Then measure the height of the oil level with the oil dipstick 2 Check the water amount in the radiator 3 Check the reliability and degree of tightness of cables connection 4 Check the leakage of water oil and gas 5 Check the degree of tightness of the supporting con
36. tor pump is snapped pump distributor B the warm up system doesn t work normally 1 The grow plug relay doesn t work normally 1 check and repair or replace 2 Warm up timer doesn t work normally 2 check and repair or replace C Water temperature sensor doesn t work normally C check and repair or replace The cause of the fault 1 Starting speed is low D Injector doesn t inject fuel or atomization quality is too bad 1 Nozzle is snapped 1 Replace the nozzle assembly 2 The atomization quality of nozzle is too bad 2 Replace the nozzle assembly 3 Pressure regulating spring is broken 3 Replace pressure regulating spring 4 There is oil leakage at the 4 Replace the fuel injector assembly high pressure oil seal 32 1 The solenoid of fuel injection pump 4 Starter motor 7 Glow plug relay 2 Warm up indicating lamp 5 Glow plug 8 Warm up timer 3 Voltmeter 10A 6 Glow plug resistance 9 Battery Figure 2 1 The electric wiring diagram of control device 1 Housing ground 2 Terminal 50 3 Terminal 30 1 To the solenoid of fuel injection pump 2 To warm up indicating lamp 3 To voltmeter 10A Figure2 3 Electric wiring of glow plug 9 3 PREPARATION BEFORE OPERATION 3 1 Prepare the Fuel Lubricating Oil and Cooling Water 3 1 1 Fuel 1 To keep the engine in best working condition be sure to use the recommend ed fuel light diesel oil JIS K2204 GB252 87 However be sure to c
37. ts solely when clean them Don t damage the surface of the injector lower body two terminal surfaces of the middle gasket and main surface of the nozzle Otherwise oil leakage will occur affecting the quality of atomization 4 2 Running E 4 2 1 After starting the engine keep it at idle state about 5 minutes then change it into medium speed small load running state Increase the load and rotary speed gradually along with the temperature of the cooling water and engine oil becoming higher and higher Regulation shim of injection pressure OPERATING NOTICE 2 Pressure regulation spring E After starting the engine shouldn t increase the rotary speed to high speed or run the engine under the large load suddenly Otherwise it will cause the damage of them even shorten the parts service lives 3 Needle valve 4 Needle valve body Fig 7 4 16 25 1 Replace the engine oil and clean the lubricating oil filter element Replace the engine oil every 100 hours Clean or replace the lubricating oil filter element Refer to figure 7 1 bypass valve 2 cooling water 3 bypass valve 4 To main oil passage The oil pump troops bypass passage to the pump Fig 7 1 2 Clean and replace the diesel oil filter element Clean the diesel oil filter element every 100 hours and drain out the water in the sedimentation cup refer to figure 7 2 If you find the element is broken or can t be c
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