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Lovol Phaser/1000 Series 00.

01
The explanation of the supplement

Version Description Date


1 This version includes the July. 2007
following content and the
update information of the
following content:
Unit pump engine. YRZ series
of preheating device.

00.02 Lovol Phaser/1000 Series


Lovol Phaser/1000 Series 00.03
Lovol Phaser/1000 Series 10.01
10 GENERAL INFORMATION

10.02 Lovol Phaser/1000 Series


GENERAL INFORMATION 10

Lovol Phaser/1000 Series 10.03


10 GENERAL INFORMATION

10.04 Lovol Phaser/1000 Series


GENERAL INFORMATION 10

Lovol Phaser/1000 Series 10.05


10 GENERAL INFORMATION

10.06 Lovol Phaser/1000 Series


GENERAL INFORMATION 10

Lovol Phaser/1000 Series 10.07


Lovol Phaser/1000 Series 11.01
BASIC ENGINE DATA 11A

Lovol Phaser/1000 Series 11A.01


11A BASIC ENGINE DATA

11A.02 Lovol Phaser/1000 Series


RECOMMENDED TORQUE TENSIONS 11B

Lovol Phaser/1000 Series 11B.01


11B RECOMMENDED TORQUE TENSIONS

11B.02 Lovol Phaser/1000 Series


RECOMMENDED TORQUE TENSIONS 11B

Lovol Phaser/1000 Series 11B.03


11B RECOMMENDED TORQUE TENSIONS

11B.04 Lovol Phaser/1000 Series


RECOMMENDED TORQUE TENSIONS 11B

Lovol Phaser/1000 Series 11B.05


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.01


12 CYLINDER HEAD ASSEMBLY

12A.02 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.03


12 CYLINDER HEAD ASSEMBLY

12A.04 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.05


12 CYLINDER HEAD ASSEMBLY

12A.06 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.07


12 CYLINDER HEAD ASSEMBLY

12A.08 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.09


12 CYLINDER HEAD ASSEMBLY

12A.10 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.11


12 CYLINDER HEAD ASSEMBLY

12A.12 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.13


12 CYLINDER HEAD ASSEMBLY

12A.14 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.15


12 CYLINDER HEAD ASSEMBLY

12A.16 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.17


12 CYLINDER HEAD ASSEMBLY

12A.18 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.19


12 CYLINDER HEAD ASSEMBLY

12A.20 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.21


12 CYLINDER HEAD ASSEMBLY

12A.22 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.23


12 CYLINDER HEAD ASSEMBLY

12A.24 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.25


12 CYLINDER HEAD ASSEMBLY

12A.26 Lovol Phaser/1000 Series


CYLINDER HEAD ASSEMBLY 12

Lovol Phaser/1000 Series 12A.27


12 CYLINDER HEAD ASSEMBLY

12A.28 Lovol Phaser/1000 Series


13 PISTON AND CONNECTING ROD ASSEMBLIES

Lovol Phaser/1000 Series 13A.01


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.02 Lovol Phaser/1000 Series


13 PISTON AND CONNECTING ROD ASSEMBLIES

Lovol Phaser/1000 Series 13A.03


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.04 Lovol Phaser/1000 Series


13 PISTON AND CONNECTING ROD ASSEMBLIES

Lovol Phaser/1000 Series 13A.05


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.06 Lovol Phaser/1000 Series


13 PISTON AND CONNECTING ROD ASSEMBLIES

Lovol Phaser/1000 Series 13A.07


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.08 Lovol Phaser/1000 Series


13 PISTON AND CONNECTING ROD ASSEMBLIES

Lovol Phaser/1000 Series 13A.09


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.10 Lovol Phaser/1000 Series


PISTON AND CONNECTING ROD ASSEMBLIES 13

Lovol Phaser/1000 Series 13A.11


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.12 Lovol Phaser/1000 Series


PISTON AND CONNECTING ROD ASSEMBLIES 13

Lovol Phaser/1000 Series 13A.13


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.14 Lovol Phaser/1000 Series


PISTON AND CONNECTING ROD ASSEMBLIES 13

Lovol Phaser/1000 Series 13A.15


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.16 Lovol Phaser/1000 Series


PISTON AND CONNECTING ROD ASSEMBLIES 13

Lovol Phaser/1000 Series 13A.17


13 PISTON AND CONNECTING ROD ASSEMBLIES

13A.18 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.01


14 CRANKSHAFT ASSEMBLY

14A.02 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.03


14 CRANKSHAFT ASSEMBLY

14A.04 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.05


14 CRANKSHAFT ASSEMBLY

14A.06 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.07


14 CRANKSHAFT ASSEMBLY

14A.08 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.09


14 CRANKSHAFT ASSEMBLY

14A.10 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.11


14 CRANKSHAFT ASSEMBLY

14A.12 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.13


14 CRANKSHAFT ASSEMBLY

14A.14 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.15


14 CRANKSHAFT ASSEMBLY

14A.16 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.17


14 CRANKSHAFT ASSEMBLY

14A.18 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.19


14 CRANKSHAFT ASSEMBLY

14A.20 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.21


14 CRANKSHAFT ASSEMBLY

Signal panel (available for 4 cylinder wit To fit


unit pump engine) 1. Put the front end of the crankshaft downward
vertically and sturdily.
To remove and to fit 2. Tap the location pins into the pinhole at the
seventh crank of the crankshaft slightly and
To remove leave the location pins 3cm out of the hole; the
1. Put the front end of the crankshaft downward head of the location pin shall not be deformed.
vertically and sturdily. 3. Align the center hole of the signal panel to the
2. Remove the locking screws of the signal panel. flange of the seventh crank; and align the
3. At the symmetrical position near the center, location pinhole of the signal panel to the
slightly tap the signal panel from below to up at location pin and then push the signal panel fully
the symmetrical position with 2 copper rods but onto the position.
carefully not tap the tooth in outer rim of the 4. Tap the signal panel along the rim with the
signal panel until the signal panel loose. copper rod and ensure the side of the signal
Carefully not damage the flange at the seventh panel sticks to the seventh crank closely.
crank. 5. Fit the locking screws of the signal panel.
4. Remove the signal panel.

14A.22 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.23


14 CRANKSHAFT ASSEMBLY

14A.24 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.25


14 CRANKSHAFT ASSEMBLY

14A.26 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.27


14 CRANKSHAFT ASSEMBLY

14A.28 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.29


14 CRANKSHAFT ASSEMBLY

14A.30 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.31


14 CRANKSHAFT ASSEMBLY

14A.32 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.33


14 CRANKSHAFT ASSEMBLY

14A.34 Lovol Phaser/1000 Series


CRANKSHAFT ASSEMBLY 14

Lovol Phaser/1000 Series 14A.35


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.01


15 TIMING CASE AND DRIVE ASSEMBLY

15A.02 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.03


15 TIMING CASE AND DRIVE ASSEMBLY

15A.04 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.05


15 TIMING CASE AND DRIVE ASSEMBLY

15A.06 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.07


15 TIMING CASE AND DRIVE ASSEMBLY

15A.08 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.09


15 TIMING CASE AND DRIVE ASSEMBLY

15A.10 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.11


15 TIMING CASE AND DRIVE ASSEMBLY

15A.12 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.13


15 TIMING CASE AND DRIVE ASSEMBLY

15A.14 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.15


15 TIMING CASE AND DRIVE ASSEMBLY

15A.16 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.17


15 TIMING CASE AND DRIVE ASSEMBLY

15A.18 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.19


15 TIMING CASE AND DRIVE ASSEMBLY

15A.20 Lovol Phaser/1000 Series


TIMING CASE AND DRIVE ASSEMBLY 15

Lovol Phaser/1000 Series 15A.21


15 TIMING CASE AND DRIVE ASSEMBLY

15A.22 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series 16A.01


CYLINDER BLOCK ASSEMBLY 16

16A.02 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series 16A.03


CYLINDER BLOCK ASSEMBLY 16

16A.04 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series 16A.05


CYLINDER BLOCK ASSEMBLY 16

16A.06 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series 16A.07


CYLINDER BLOCK ASSEMBLY 16

16A.08 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series 16A.09


CYLINDER BLOCK ASSEMBLY 16

16A.10 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series


16A.11
CYLINDER BLOCK ASSEMBLY 16

16A.12 Lovol Phaser/1000 Series


CYLINDER BLOCK ASSEMBLY 16

Lovol Phaser/1000 Series


16A.13
CYLINDER BLOCK ASSEMBLY 16

16A.14 Lovol Phaser/1000 Series


Lovol Phaser/1000 Series 17.01
ENGINE TIMING 17A

Lovol Phaser/1000 Series


17A.01
17A ENGINE TIMING

17A.02 Lovol Phaser/1000 Series


ENGINE TIMING 17A

Lovol Phaser/1000 Series


17A.03
17A ENGINE TIMING

17A.04 Lovol Phaser/1000 Series


ENGINE TIMING 17A

Lovol Phaser/1000 Series


17A.05
17A ENGINE TIMING

17A.06 Lovol Phaser/1000 Series


ENGINE TIMING 17A

Lovol Phaser/1000 Series


17A.07
17A ENGINE TIMING

17A.08 Lovol Phaser/1000 Series


ENGINE TIMING 17B

Lovol Phaser/1000 Series


17B.01
17B ENGINE TIMING

17B.02 Lovol Phaser/1000 Series


ENGINE TIMING 17B

Lovol Phaser/1000 Series


17B.03
17B ENGINE TIMING

17B.04 Lovol Phaser/1000 Series


ENGINE TIMING 17B

Lovol Phaser/1000 Series


17B.05
ENGINE TIMING 17C

Lovol Phaser/1000 Series


17C.01
17C ENGINE TIMING

17C.02 Lovol Phaser/1000 Series


ENGINE TIMING 17C

Lovol Phaser/1000 Series


17C.03
17C ENGINE TIMING

17C.04 Lovol Phaser/1000 Series


ENGINE TIMING 17C

Lovol Phaser/1000 Series


17C.05
ENGINE TIMING 17D

Four cylinder unit pump


General Description.………………………………………………………………………17D.02
Engine timing
17D-01 Adjust the number 1 piston to the TDP during the compression stroke…… refer to 17A.04
17D-02 Check the valve timing…………………………………………… refer to 17A.04
17D-03 Check the fuel injecting pump timing……………………………………………. 17D.03

Lovol Phaser/1000 Series


17D.01
17D ENGINE TIMING

General Description:
On Phaser series engines, electronic control unit pump is satisfy the emission standard defined in EURO III..
used and is modified and improved in combustion system to

17D.02 Lovol Phaser/1000 Series


ENGINE TIMING 17D

Engine timing

Check the fuel injecting pump timing 17D-03

Electronic control unit identifies the rotational speed compression stroke, rotate the flywheel along
and working phase with rotational speed sensor, so as the rotational direction of crankshaft and check
to ensure the correctness of the injecting timing of fuel the rotation angel of key slot of Cam of injection
system which means ensuring injecting fuel at a pump according to related requirement when
suitable time. The phases of the system consist Cam number 1 cylinder (engine piston) is on the
phase and crankshaft phase, see diagram “installation TDC of compression stroke.
phase scheme” for the detail. The design of phase is 3. Method 2: when number 1 cylinder (engine
based on the TDC of compression stroke of number 1 piston) is on the TDC of compression stroke,
cylinder during its TDC. check the Cam lift value of injection pump
1. Check the crankshaft phase: whether the angel according to related requirement ( it can be
from the multiple holes of signal panel to the checked with processing pump).
probe of rotational speed sensor is 65° along the Technical requirement
1. This diagram shows the state at compression top dead center of
rotation direction of crankshaft when number number 1 cylinder (the cone surface end of camshaft as the
1(engine piston) cylinder is on the TDC of number 1 cylinder).
2. The angel between the installation axial line of the pump (the
compression stroke. direction of piston moving) and the vertical direction is 15º.
2. Check the Cam phase: Method 1: when number
3. The position of the signal sensor of the camshaft is determined
by the user (it can be allocated along the axle direction); the
1 cylinder (engine piston) is on the TDC of installation hole of the sensor
4. When the number 1 cylinder piston is at the compression top
Pump Cam Phase dead center, the angle between the camshaft key groove and the
vertical direction is 42.4 ± 0.2º (in the view of pump gear).
5. When the number 1 cylinder piston is at the compression top
dead center, the angle between the cam signal panel multihole
and the camshaft rotational speed sensor is 117º (in the direction
of rotation).
6. The angle between the cam signal panel multihole and the
normal hole is 15º.
7. The size of the signal groove of the cam signal panel is as above
diagram.
8. The thickness of the cam signal panel is 5m; the jumping
distance of the signal panel shall not be above 0.05m when
rotating in high-speed.
9. The tolerance of unlabelled angel tolerance adopt GB/T1804-n
grade.

Lovol Phaser/1000 Series


17D.03
17D ENGINE TIMING

Technical requirement
1. When the number 1 cylinder piston is at the
compression top dead center, the angle between
the camshaft multihole position and the camshaft
sensor is 65.
2. The angle between the crankshaft signal panel
multihole and the normal hole is 15º.
3. The size of the crankshaft signal hole is φ6 with the
hole-depth of 6m.
4. The crankshaft signal sensor is installed right above
the flywheel shell (or determined by the user and
allocated along the axle direction), the connection
between the installation hole and the sensor monitor
shall be tangent with the moving direction of the
flywheel signal hole (this direction is the signal
sensitive direction).
5. The radial jumping range of the flywheel signal
panel shall be less than 0.1m.
6. The tolerance of unlabelled angel tolerance adopt
GB/T1804-n grade.

Crankshaft phase

17D.04 Lovol Phaser/1000 Series


ENGINE TIMING 17E

Six cylinder unit pump


General Description.………………………………………………………………………17D.02
Engine timing
17E-01 Adjust the number 1 piston to the TDP during the compression stroke .refer to 17A.04
17E-02 Check the valve timing………………………………………………. refer to 17A.04
17E-03 Check the fuel injecting pump timing…………………………………………. 17E.03

Engine timing

Lovol Phaser/1000 Series 17E.01


17E ENGINE TIMING

Check the fuel injecting pump timing 17E-03

Check the fuel injecting pump timing


Electronic control unit identifies the rotational speed of compression stroke.
and working phase with rotational speed sensor, so as 2. Check the Cam phase: Method 1: when number
to ensure the correctness of the injecting timing of fuel 1 cylinder (engine piston) is on the TDC of
system which means ensuring injecting fuel at a compression stroke, rotate the flywheel along
suitable time. The phases of the system consist of the rotational direction of crankshaft and check
Cam phase and crankshaft phase, see diagram “Cam the rotation angel of key slot of Cam of injection
phase and crankshaft phase” for the detail. The design pump according to related requirement when
of phase is based on the TDP of compressor of number 1 cylinder (engine piston) is on the
number 1 cylinder during its TDC. TDC of compression stroke.
1. Check the crankshaft phase: whether the angel Method 2: when number 1 cylinder (engine
from the slot on the rim of flywheel groove to piston) is on the TDC of compression stroke, check
the probe of rotational speed sensor is 108° the Cam lift value of injection pump according to
along the rotation direction of crankshaft when related requirement ( it can be checked with
number 1(engine piston) cylinder is on the TDC processing pump).

Technical requirement
1. During the mechanical installation, ensure
the No.1 cylinder lift to be 6.93mm ±
0.05mm which corresponds to the No.1
cylinder compression top dead center;
2. Above relevant sizes of crankshaft and cam
signal is the mechanical angle; the signal
angel may be diversity due to the installation
of the sensor and the affection of the output
specification.
3. This diagram can be the design reference of
the engine flywheel, which request the
center of the electromagnetic sensor align to
the center of the thirty sixth groove of the
flywheel when the engine is on the top dead
center of the No.1 cylinder.

17E.02 Lovol Phaser/1000 Series


ENGINE TIMING 17E

Pump cam phase and crankshaft phase

Lovol Phaser/1000 Series 17E.03


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.01


18 ASPIRATION SYSTEM

18.02 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.03


18 ASPIRATION SYSTEM

18.04 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.05


18 ASPIRATION SYSTEM

18.06 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.07


18 ASPIRATION SYSTEM

18.08 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.09


18 ASPIRATION SYSTEM

18.10 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.11


18 ASPIRATION SYSTEM

18.12 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

Lovol Phaser/1000 Series 18.13


18 ASPIRATION SYSTEM

18.14 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

EGR Inlet System 18A.07


To remove and to fit 1. Fit the bracket of the EGR cooler on the body.
To remove (when changing EGR valve or EGR Put the EGR cooler on the bracket and fasten the
cooler) nut connecting the EGR cooler and the bracket
1. Disconnect the inlet and outlet hose of the EGR and the EGR tubes on both sides.
cooler. Carefully not splash water onto EGR 2. Connect the inlet and outlet hoses of the EGR
valve and electrical elements. cooler.
2. Loose the nut on the inlet and outlet of the EGR 3. Insert the EGR valve into the hole of the inlet
cooler, then loose the nut on the bracket of the bend. Fasten the nut connecting the EGR valve
EGR cooler and finally remove the EGR cooler and inlet bend. Connect the wiring harness of
and its bracket. the EGR valve.
3. Put the inlet and outlet of the EGR cooler Notice:
downward and drain the remaining water in the The exhaust inlet of the EGR valve must be
EGR cooler. downward and must be the lowest point of the valve.
4. Disconnect the wiring harness on the EGR The valve must be installed in the range of ±85°
valve. Loose the nut connecting the EGR valve referring to vertical direction, as the following
and inlet bend. Remove the EGR valve. diagram:
To fit

Incorrect installation method:

The arrangement illustration of EGRvalve:

Lovol Phaser/1000 Series 18.15


18 ASPIRATION SYSTEM

Fault diagnosis

1. General Description

Dark EGR fault indicator shows that EGR system is working normal. And flashing EGR fault indicator means fault
exists in EGR system. EGR fault indicator shows the codes for the types of EGR system fault by a series of short
and long signal combination.“0”presents a short signal. “1” presents a long signal. The fault code and the text of
the fault name of the EGR system also show in the bottom of the “Data Log” window of the calibration software.

Fault type Fault item label Fault code Fault indicator


Normal EGR system 0000 0000 Dark
Engine’s rotational speed signal is not within the Engine's rotational 0001 0000 0-1-1
measuring range (too high or too low). speed signal
Throttle’s position sensor signal is not within the Throttle’s position 0000 1000 0-1-0
measuring range. sensor
Water temperature sensor signal is not within the Water temperature 0000 0010 0-0-1
measuring range. sensor
The connecting cable of water temperature sensor Water temperature 0100 0000 0-0-1
is broken or the sensor is not installed. sensor
The lift position sensor signal of the EGR valve is Lift position sensor 0010 0000 1-1-0

18.16 Lovol Phaser/1000 Series


ASPIRATION SYSTEM 18

not within the measuring range. signal of the EGR valve

Lovol Phaser/1000 Series 18.17


ASPIRATION SYSTEM 18

2. Fault elimination

Before determining the fault:

 Ensure the correct installation of each part of the EGR system (ECU, EGR valve, throttle position sensor and
water temperature sensor) and the correct installation for acquiring the rotational speed signal and engine
pole pair.
 Ensure no open circuit, bonding, false welding and ensure the correct connecting of each part.

Connect the diagnosis plug and the calibration software of the EGR system and turn on the main power.

 If the lamp in the front of the “ECU Monitor” option in the main interface of the calibration software is dark,
check no open circuit along the ECU cable and diagnose the connector.

 When the lamp in the front of the “ECU Monitor” option is lit, click the “Data” option in the main interface
of the calibration software and the “Data log” window will appear, depicted as the diagram.

Click the “Data Logger active” option, observe the fault code display area at the bottom of the window and
confirm the fault type according the shown fault code and above fault description.
1. Fault code “0000 0000” means normal state of EGR system.
2. Fault code “0001 0000” means a fault in the rotational speed signal of the engine. First determine the wiring
of the ECU and engine and check no wrong connection; second, click the “Engine” option in the main
interface of the calibration software and the “Crank to generator speed” window appears; change the setting

Lovol Phaser/1000 Series 18.17


of “generator speed” to adjust the shown value in the “Engine Speed” option of “Data log” into a reasonable
range.

3. Fault code “0000 1000” means a fault in the throttle signal of the engine.Click the “TPS Setup” option in the
main interface of the calibration software and the “TPS Setup” window appears; change the setting of “TPS Setup”
to adjust the shown value in the “TPS Norm” option of “Data log” into a reasonable range.

4. Fault code “0010 0000” means a fault in the water temperature signal of the engine and checks no open circuit
in the water temperature sensor or the water temperature sensor is not installed.
5. Fault code “0010 0000” means the lift position sensor signal of the EGR valve is not within the measuring
range. This fault can only be resolved by resetting the ECU; that is after a period of warming up, the EGR valve
can automatically complete the initial setup.

ECU, EGR valve, throttle position sensor and water temperature sensor are all sealing devices and can not be
repaired. Any problems occurring, they have to be replaced.
LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.01


19 LUBRICATION SYSTEM

19A.02 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.03


19 LUBRICATION SYSTEM

19A.04 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.05


19 LUBRICATION SYSTEM

19A.06 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.07


19 LUBRICATION SYSTEM

19A.08 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.09


19 LUBRICATION SYSTEM

19A.10 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.11


19 LUBRICATION SYSTEM

19A.12 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.13


19 LUBRICATION SYSTEM

19A.14 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.15


19 LUBRICATION SYSTEM

19A.16 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.17


19 LUBRICATION SYSTEM

19A.18 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.19


19 LUBRICATION SYSTEM

19A.20 Lovol Phaser/1000 Series


LUBRICATION SYSTEM 19

Lovol Phaser/1000 Series 19A.21


19 LUBRICATION SYSTEM

19A.22 Lovol Phaser/1000 Series


FUEL SYSTEM 20

Lovol Phaser/1000 Series 20A.01


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.01


20A FUEL SYSTEM

20A.02 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.03


20A FUEL SYSTEM

20A.04 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.05


20A FUEL SYSTEM

20A.06 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.07


20A FUEL SYSTEM

20A.08 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.09


20A FUEL SYSTEM

20A.10 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.11


20A FUEL SYSTEM

20A.12 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.13


20A FUEL SYSTEM

20A.14 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.15


20A FUEL SYSTEM

20A.16 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.17


20A FUEL SYSTEM

20A.18 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.19


20A FUEL SYSTEM

20A.20 Lovol Phaser/1000 Series


FUEL SYSTEM 20A

Lovol Phaser/1000 Series 20A.21


20A FUEL SYSTEM

20A.22 Lovol Phaser/1000 Series


FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.01


20B FUEL SYSTEM

20B.02 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.03


20B FUEL SYSTEM

20B.04 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.05


20B FUEL SYSTEM

Fuel injection pump 5. Carefully rotate clockwise the crankshaft until the
piston just contacting the piston position monitor.
To remove and to fit 20B-05 6. Loose the location screw and remove the gear cover
on the timing gear box.
To remove 7. Then loose the gear cover screw of fuel pump and remove
the nut connecting the injection pump and the gear. (B1)
Special tools

Piston location monitor

1. Remove rocker arm


2. Loose the fixing screw on atomiser
3. Rotate the crankshaft clockwise at front end until
the push rod of number 1 cylinder intake valve.
Remark: when the checking angel of engine is less
than 100, a self-made washer (A2) must be installed in
the piston position monitor (A1). See data and size for
the detail.
4. Remove the atomiser and the housing from number
1 cylinder and then place the piston position monitor
PD 221(A1) to its position. Fit the atomiser clamp
onto the monitor and gradually tighten the location
screw uniformly.
Caution: ensure the piston just contacting the piston
position monitor to avoid damaging the piston; at the
same time, the monitor will bend and result in the
incorrect position of the piston.

20B.06 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.07


20B FUEL SYSTEM

To fit uniformly to 12 N.m (9lbf)1.2kg.f.m


1. Install the fuel injection pump on the gear of injection5. Install rocker arm, see 20B-08.
pump and ensure the correct installation of the keys. 6. Dispel the air in the fuel system, see 20B-08.
2. According to the requirement of relevant torque, install7. Check the fuel injection pump timing according to 17B-
the fuel injection pump on the timing injection pump 03.
and install the bracket of injection pump, lubricant pipe8. Run the engine and check the leakage. To run the engine
and low and high pressure pipes. to its normal operation temperature, check the idle speed
3. Install the gear coven on the timing gear chamber. is normal, see 20B-06.
4. Loose the location screws and remove the piston9. If a new fuel injection pump has been installed, check
position monitor from number 1 cylinder and the the maximum load-free speed, see 20B-6.
specific washer(if exist).Gradually tighten the atomiser

20B.08 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.09


20B FUEL SYSTEM

20B.10 Lovol Phaser/1000 Series


FUEL SYSTEM 20B

Lovol Phaser/1000 Series 20B.11


FUEL SYSTEM 20C

Lovol Phaser/1000 Series 20C.01


20C FUEL SYSTEM

20C.02 Lovol Phaser/1000 Series


FUEL SYSTEM 20C

Lovol Phaser/1000 Series 20C.03


20C FUEL SYSTEM

20C.04 Lovol Phaser/1000 Series


FUEL SYSTEM 20C

Lovol Phaser/1000 Series 20C.05


20C FUEL SYSTEM

20C.06 Lovol Phaser/1000 Series


FUEL SYSTEM 20D

Engine installed with unit pump 20D


General Description…………………………………………………………..20D.02
Fuel pump
20D-03 Installation…………………………………………………..……..20D.03
Fuel injection pump
20D-04 To remove and to fit………………………………………...……..20D.04
Common fault modes and remedy flow………………………………....……20D.07
Maintenance and servicing…………………………………………..……..…20D.08
Possible reasons and remedy of common faults……………………..…..……20D.07

Lovol Phaser/1000 Series 20D.01


20D FUEL SYSTEM

General Description
The matching condition of unit pump engine: 4-
cylinder engine matches Wit unit pump and 6-cylinder It adopts axial positioning on flange surface between
engine matches Hengyang unit pump. Now the Wit gear chambers (flange surface attaching to the surface
unit pump is taken as an example to illustrate. of gear chamber), radial positioning at bearing cover,
The assemble mode of Wit 4-cylinder pump unit is the four bolts on flange surface tightened and assistant
similar with the P7100 mechanical pump. supporting at rail bracket.

20D.02 Lovol Phaser/1000 Series


FUEL SYSTEM 20D

Fuel pump

To remove and to fit 20D-03


The installation of the fuel pump shall be carried out 25 N.m ~ 30N.m ) after the oil delivery pump
in specific conditions to ensure the cleanness of the installed into pump box, then install the oil inlet and
assembly. When installing, first link one end of the oulst connector of the oil delivery pump, see lower
cross groove of the cross transmission sleeve of the right diagram.
fuel pump to the single-line shape rabbet of camshaft Notice: If incorrect connection occurs the engine can
and the another end to the single-line shape rabbet of not start. After installation, it is not permitted oil
fuel pump. Pay attention to the installation of O ring seepage and oil leakage at sealing sits and each oil
on fuel pump, see the left lower diagram. Rotate the pipe connector.
fixing bolt(Q1841025TF2 with an tightening torque of

Fuel injection pump

Lovol Phaser/1000 Series 20D.03


20D FUEL SYSTEM

To fit 20D-04

1. Connect the WP2000 pump assembly with the


engine。
First connect the bracket and the pump as the lower
left diagram. The tightening torque is 25-30N.m and
appropriate amount of medium-intensity thread
locking fixation adhesive.
Plaster appropriate grease on the guiding flange
sealing ring and align the guiding flange to the
installation hole on the cover of the engine gear Install rear supporting bracket. 
chamber; then push the WP2000 pump assembly into The positioning installation of the flange
the hole( don't damage the aprons when installing and 2. Harness installation (see 23D.01)
change the aprons if trimming phenomenon founded, 3. Check the installation quality by engine barring;
or oil leakage may occur), as the lower right diagram seizure is not permitted.
shows. Notices:
Connect the four flange bolts and tighten them in the 1. Electronic Unit unipump is a kind of precision
order of 1-2-3-4 as right diagram with a pre-tightening product; the operator must be familiar with its
torque of 10-155N.m and final torque of 50-55N.m; structure and the function of each parts in it
the performance grade of the bolts shall be greater before installing; it must not be dismantled or
than or equal to 8.8. installed by untrained non-professional staff.
Connect oil pump bracket and engine. 2. The assembly of WP2000 pump assembly shall
Connect high-pressure oil pipe between the WP2000 be carried out in a clean working site so as to
pump assembly and the injector with an tightening ensure the cleanness of the assembly. Before
torque of 25-30N.m; installing and dismantling the injection pump,
Install fuel entering and returning oil pipe and engine the outside of the pump must be cleaned up.
oil entering and returning oil pipe. Generally, it is not permitted to dismantle and
Connect the oil pump gear and other relevant parts to change the critical parts of the pump unit.
the WP2000 pump assembly, and the installation shall Cleanness and the installation space are also to
meet the requirement of phase relation diagram. be paid attention when changing and
After the whole installation, no residual installation dismantling oil delivery pump, oil returning
stress shall exist to affecting the utilization of the valve, temperature sensor and oil pipe and etc
pump. When installing oil delivery pump, one end of
the cross groove of the cross connecting sleeve
of the oil delivery pump shall connect the
single-line shape head of the camshaft and the
other end shall connect the single-line shape
  head of the oil delivery pump; at the same time,
pay attention to the installation of O ring on the
installation face of oil delivery pump.
3. After the installation of WP2000 pump
assembly or changing the pump unit, high-

20D.04 Lovol Phaser/1000 Series


FUEL SYSTEM 20D

pressure oil pipe and fuel entering and returning pump assembly, no oil seepage, leakage shall
oil pipe, it shall conduct exhausting treatment occur at each sealing site and each joint of oil
before starting engine. At complete vehicle, the pipe during working. Treat it if any problem
exhaust may be carried out with hand pump ; found.
and at engine test bench, the exhaust may be 6. After starting, No abnormal sound is permitted
carried out by pulling with dynamometer or to be heard in WP2000 pump assembly.
loosing the nut of high-pressure oil pipe.
4. When dismantling and installing EUP, a mark
must be done on each cylinder to prevent
incorrect installation. The dismantlement of
EUP can not be carried out without special
inspection instruments.
5. After completing the installation of WP2000

Common fault modes and the remedy flow


1. Remedy flow for engine not starting

Lovol Phaser/1000 Series 20D.05


20D FUEL SYSTEM

2. Remedy flow for engine smoking

3. Remedy flow for insufficient power output of engine

20D.06 Lovol Phaser/1000 Series


FUEL SYSTEM 20D

4. Remedy flow for system leakage

Lovol Phaser/1000 Series 20D.07


20D FUEL SYSTEM

5. Remedy flow for the failure indicator lit

20D.08 Lovol Phaser/1000 Series


FUEL SYSTEM 20D

6. Remedy flow for abnormal sound of engine

Lovol Phaser/1000 Series 20D.09


20D FUEL SYSTEM

Maintenance and servicing


1. Basic requirements 5) The electromagnetic plug shall be reliably
1) After trial run and running-in, the WP2000 linked to avoid short circuit. If the faults of
pumps assembly shall be checked and no oil leakage, crack, short circuit and etc
oil leakage phenomenon shall be seen at occur, the electromagnet shall be replaced
each sealing site. with a new one and the pertightening
2) Together with the daily maintenance of the torque of the rear cover of the
engine, the sealing of the WP2000 pumps electromagnet shall be 40~45 N·m.
assembly and the fastening of the bolts 6) The harness shall be changed timely if the
shall be checked. electric connection fault, insulting layer
3) Together with the second order servicing damage and fracture due to over bending
requirement, check the installation bolts, and extruding are found.
electromagnetic bolts and wiring screws to 7) The sensors shall be changed if the faults of
see whether they loose. error signal or no signal in sensors occur.
2. Notices for maintenance  Specific notices
1) During the installation and dismantlement 1) The parts of the WP2000 pump assembly can
of the WP2000 pump assembly, pay not be dismantled or changed by non-
attention to avoid knocking with other parts professional personnel authorized by
and foreign material entering WP2000 manufacturer, so as to avoid the changes in its
pump assemble. properties.
2) Before the installation of WP2000 pump 2) When removing the WP2000 pump unit from
unit, appropriate amount of grease (ZF-1) pump chamber, the installation bolts shall be
shall be plastered onto the sealing ring loosen for 5-7 teeth and then rotate the
uniformly. camshaft to push the pump unit out.
3) The WP2000 pump assembly can not be 3) The ECU controller has been conducted by
dismantled or installed by non-professional waterproof treatment. If the fault in ECU
personnel. occurs, it is forbidden to open the ECU
4) When installing WP2000 pump unit, the 2 controller and it shall be sent to a authorized
installing bolts shall be tightened service site.
uniformly.

Possible reasons and remedy of common faults


Possible reasons and remedy on the WP2000 pump fuel injection system for the common fault
20D FUEL SYSTEM

happenedFault
in the engine or the finished vehicle.
Possible reason Remedy

Oil leakage at the 1) Fixing bolt loose 1) Tighten it according to regulation (torque:
contact interface 2) Black O ring damage 40-45 N.m)
between the WP2000 2) Change the sealing ring.
pump unit and pump box
Oil leakage at the 1) Oil pipe connector loose 1) Tighten it according to regulation (torque:
connection between 2) Oil pipe connectordamage 25~30 N.m)
WP2000 pump assembly 3 ) WP2000 pump assembly 2) Change oil pipe
and high pressure oil connector damage 3 ) Change the WP2000 pump assembly and
pipe pump unit
1 ) incorrect installation of the 1) Check and reinstall the WP2000 pump
parts of the WP2000 unit assembly assembly
Abnormal sound in
2)Camshaft and roller damage 2)Check and change the failure parts
WP2000 pump
3 ) foreign substance in the pump 3 ) Remove the foreign substance and check
box no damage in the parts.
1)Air remains in the fuel cavity 1 ) loose the nut of the oil pipe connector to
2)Oil pipe damage or air leakage exhaust air.
at connector 2)Check the oil pipe and the connector
3 ) Oil pump failure result in 3)check and change the oil delivery pump
adequate oil supply 4)check and change the oil filter
4)Oil filter blocked or inadequate 5)check and change the oil returning valve
oil filter flow result in adequate oil 6)check and change the ECU
supply 7 ) Check and eliminate faults and check no
5 ) fuel returning valve failure damage in relevant parts
result in adequate oil absorbing 8)check and change the sensor or remove the
6)ECU controller damage foreign substance
7)short circuit or breaking circuit 9 ) Wash, examine and repair or change the
in harness injector.
Starting difficult or not
8)Sensor failure or metal foreign 10)Adjust the fuel injection advance angle of
starting of engine
substance in monitor the electric control system
9 ) Bad injection or too low 11 ) Check the power supply circuit of ECU
injection pressure controller
10 ) incorrect fuel injection 12) Adjust the installation space of camshaft
advance angle rotational speed sensor
11 ) Abnormal power supply in 13 ) Turn the fault diagnosis switch off and
ECU controller reset it.
12 ) Problem in the installation 14)check and change the harness
space of camshaft rotational speed 15)Tighten, wash or change it
sensor 16)Check other parts of the engine.
13 ) Fault diagnosis switch turned
on before starting
14)Harness contact failure

Lovol Phaser/1000 Series 20D.09


20D FUEL SYSTEM

15 ) the plug of electromagnetic


valve becomes loose, dirty and
rotted.
16)Other reason
1 ) Faults in Cam or crankshaft 1 ) Check and repair or change the rotational
rotational speed sensor speed sensor
2 ) Bad or damaged harness 2)Check and repair or change the harness
contact 3)Change the ECU controller
Stop running of engine
3)ECU controller damage 4)Change the failure parts
4)multiple pumps unit or injector 5)Check other relevant parts of the engine
damage
5)other reasons
1)bad atomization of injector and 1)Check and repair or change WP2000pump
black smoking unit or injector
2 ) Crankshaft rotational speed 2 ) Clear up the iron clips or change the
sensor damage or absorbing iron crankshaft
Engine smoking clips 3 ) Change the timing by adjusting the
3 ) Timing error; Block or blue position of the flywheel
smoking. 4)Change the ECU controller
4)ECU controller failure 5)Check other relevant parts of the engine
5)Other reasons in engine
1 ) Damaged oil pipe or air 1)Check the oil pipe and the connector
leakage in connector 2)Check and change the oil delivery pump.
2 ) Oil delivery pump failure 3)Check and change the oil filter
resulting in adequate oil supply 4 ) Check and change the WP2000 pump
3 ) Oil filter blocked or adequate assembly
oil filter flow result in adequate oil 5 ) Clear up the iron clips or change the
supply crankshaft
4 ) WP2000 pump assembly 6 ) Check and repair or change the sensor of
Insufficient power of failure or low performance gas pedal
engine 5 ) Crankshaft rotational speed 7)Check and repair or change the failure pats
sensor absorbing iron clips or 8)Check the plug of booster pressure sensor
damage or change it
6)Bag contact in the sensor of gas 9)Check other relevant parts of the engine
pedal
7)failure in injector
8 ) Bag contact or damage in the
plug of booster pressure sensor
9)Other reasons in engine
COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.01


21 COOLING SYSTEM

21A.02 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.03


21 COOLING SYSTEM

21A.04 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.05


21 COOLING SYSTEM

21A.06 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.07


21 COOLING SYSTEM

21A.08 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.09


21 COOLING SYSTEM

21A.10 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.11


21 COOLING SYSTEM

21A.12 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.13


21 COOLING SYSTEM

21A.14 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.15


21 COOLING SYSTEM

21A.16 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.17


21 COOLING SYSTEM

21A.18 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.19


21 COOLING SYSTEM

21A.20 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.21


21 COOLING SYSTEM

21A.22 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.23


21 COOLING SYSTEM

21A.24 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.25


21 COOLING SYSTEM

21A.26 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.27


21 COOLING SYSTEM

21A.28 Lovol Phaser/1000 Series


COOLING SYSTEM 21

Lovol Phaser/1000 Series 21A.29


21 COOLING SYSTEM

21A.30 Lovol Phaser/1000 Series


FLYWHEEL AND FLYWHEEL HOUSING 22

Lovol Phaser/1000 Series 22A.01


22A FLYWHEEL AND FLYWHEEL HOUSING

22A.02 Lovol Phaser/1000 Series


FLYWHEEL AND FLYWHEEL HOUSING 22

Lovol Phaser/1000 Series 22A.03


22A FLYWHEEL AND FLYWHEEL HOUSING

22A.04 Lovol Phaser/1000 Series


FLYWHEEL AND FLYWHEEL HOUSING 22

Lovol Phaser/1000 Series 22A.05


Lovol Phaser/1000 Series 23.01
ELECTRICAL EQUIPMENT 23A

Lovol Phaser/1000 Series 23A.01


23A ELECTRICAL EQUIPMENT

23A.02 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23A

Lovol Phaser/1000 Series 23A.03


23A ELECTRICAL EQUIPMENT

23A.04 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23A

Lovol Phaser/1000 Series 23A.05


23A ELECTRICAL EQUIPMENT

23A.06 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23A

Lovol Phaser/1000 Series 23A.07


ELECTRICAL EQUIPMENT 23B

Lovol Phaser/1000 Series 23B.01


23B ELECTRICAL EQUIPMENT

General Description

The direct driving starters of Lovol engines are mainly out the one-way clutch to mesh the flywheel through
composed of DC series excitation motor, driving one- fork: the power of the battery is sent to the motor at
way clutches mechanism and electromagnetic switch. the same time----the gear of the one-way clutch begins
The organic composition and working together among to rotate---produce electromagnetic torch to start the
these 3 parts can realize the starting process of engine engine.
smoothly. The detailed working process is as follows: After the engine starting, the fork is reset under the
Turn on the starting ignition switch-----the starting action of spring force at the moment of cutting off the
relay gets power----electromagnetic switch is electromagnetic switch, which pushes the gear of one-
electrified----produce electromagnetic tension----push way clutch out and stops the engine.

23B.02 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23B

Lovol Phaser/1000 Series 23B.03


23B ELECTRICAL EQUIPMENT

accumulation of dust and oil dirt has narrowed the


confined space and the move of isolator becomes
Analysis and elimination of the faults more and more difficult. On the other hand, the
During daily using, the starter may present various damage to starter shaft caused by foreign material
faults due to its working conditions, high temperature, (clips of clutch) and other impurities may also
hot-moist changes, oil contaminant and erosion and decrease the space between the isolator and the shaft,
etc. Here we just discus it from the viewpoint of user which would result in the slow reset of isolator.
and try to find the main reason of these faults; thus we Actually, the accumulation of oil dirt and the damage
can take relative measures to lower the fault rate and from foreign material usually occurs together.
lesson the time for maintenance and prolong the In order to avoid this kind of fault, periodical
working life of the engine. cleanness and maintenance are necessary and the
Fault 1 the starter clutch does not reset. interval usually is 3 months. It mainly includes: rip
out the oil dirt on the surface and clear up the foreign
This is a common fault and the occurrence rate may material in the flywheel shell, especially on the fault
increase significantly after the vehicle or the engine of clutch. After changing clutch disc, pay attention to
has run for a while. clear up the foreign material.
Why this fault may happen? It is necessary to analyze
it from the whole startup system. First, the Fault 2 mis-engagement of starter
inducements of the faults can be divided into internal
cause, which happen in the starter itself, and external When calculating the damage rater of the ring
cause, which happen in starting circuit. gear of the flywheel, many internal engines users may
External cause 1: incorrect selection of the starting find that the damage of ring gear usually be the
relay or the quality problem. Because its contacts may milling of the gears on the opposite side of the starter
result in large electric arc at each connection and drive pinion and usually occurs regularly in the
disconnection, thus the surfaces of the contacts may relative fixed regions (this is associated with the
be oxidized after working for a while. On the acting of number of the cylinders of the engine).When this kind
current, the welding occurs at the moment of of fault occurs, the possibility of the starter drive
attracting, which results in a perpetual closing circuit pinion engaging into the ring gear becomes
of the starter. If such fault happens, immediately cut increasingly small and whistle caused by the milling
off the starter circuit, or else may result in serious of high-speed rotation of pinion and ring gear can be
result. heard at each starting. Thus the starting failure may be
External cause 2: Because of long-term using and the caused.
approximate closed space in the flywheel shell, the Internal cause: this is one of common fault in
dust of clutch is filled; and grease is usually applied compulsory joggle starter. The engagement
onto the surfaces of the isolator and the output axis to mechanism of this kind of starter is: before the pinions
ensure good sliding fit and this kind of grease must be of the starter engaging with the ring gear, if
resistant to high-temperature, temperature-change interference phenomenon occurs and the pinions can
cycle and abrasion. At the same time, the starter not move due to the limitation of the ring gear, but
armature is to rotate in the electromagnetic field there is an engagement spring designed at the front
produced by stator assemble and output end of sliding ring of the one-way clutch (a similar
electromagnetic torques; thus the armature shaft and spring is also designed at the rotation support point of
the parts contacted with it must have magnetism; after the shifting fork of some starter). This spring is
multiple electrifying, the shaft bears residual pressed to deform by the action of internal movable
magnetism which can absorb dust. The long-term piston of the electromagnetic switch on electrifying

23B.04 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23B

state and the deformation can ensure the conduction of If the starter dose not rotate or rotates slowly and
internal main contact; then the motor of the starter powerlessly, and can not starts the engine, the
begins to rotate due to the conduction and the one-way sequence of the judgment of fault usually is:
clutch also begins to rotate at the same time. When the battery, starter electromagnetic switch , system
pinion is just aligned to the groove of the ring gear, circuit and the inner of the starter.
the pinion is hit into the ring gear with the energy
preserved during the deformation of the spring, (1) battery failure:
But above work mechanism is just an ideal state; The common failures in battery include 3 situations:
because the distance between the installation surface no power in the battery; loose connecting bolt on
of the starter installed in the engine and the end terminal post of the battery , too much oxidation on
surface of the flywheel ring gear is affected by the the surface of terminal post and broken the connecting
errors due to the design and installation of the relative wire; inadequate battery capacity.
parts, the scattering difference of this distance may be
up to 3mm or larger. Thus, when interference occurs, When checking the fault, first turn the ceiling lamp

the difference of spring force, the difference of on or press the horn; if the lamp doest be lit, the

rotational speed on each starter turning on main circuit possible reasons may be one the previous two.Now,

and the difference of the time of connecting of the we should check whether the surface of the battery

main contacts and other factors result in the pinions at terminal post accumulates too much oxidation, the

a high-speed rotation state before entering the ring bolt of the terminal post becomes loose and the

gear. The pinions at high–speed rotation can not enter connection of the battery is broken. If there is too

into gear ring, thus the gear ring may be milled. And much oxidation on the surface, firstly wash it with

when this milling becoming more and more serious, water and then remove the connecting bolts and

the distance between the pinions of the starter and ring remove the connecting wire to clean up the oxidation.

gear becomes longer and longer, which further The bolts of terminal post also should be cleaned up

deteriorate the milling fault due to early connection. and then be tightened. Check no faults in the

External cause: it is the same as the cause connection and the terminal post of the battery. That

described in fault 1: since the output axis of the starter means the fault is result from no power in the battery.

is contaminated, the isolator returns slowly or can not The ceiling lamp is lit and the barn sounds, but the

reset, and that may result in slow output. So the lamp become dark when the machine is started; that

electromagnetic force of the switch still can overcome means the battery capacity is insufficient or the power

the resistance and switch the main contact on. Thus is adequate. The fault of battery can also be judged by

the gear begins to rotate before contacting the motor measuring the voltage with multimeter.

of flywheel motor. And the final result is the milling


(2) The faults of the electromagnetic switch and the
phenomenon.
system circuit of the starter
So, the cleanness and maintenance of the output
axis of the starter also can avoid the occurring of
If the battery is normal, but no response occur in the
milling. Of course, the milling damaged flywheel
starter when press the start button, then the
gears have to be changed or treated by angel
electromagnetic switch of the start shall be checked.
changing.
The method is to disconnect the cable on the terminal
post of the battery and then touch the “1” terminal
Fault 3 the starter does not rotate or rotates
post with the positive electrode; if no response, the
powerlessly
fault is at the electromagnetic switch; now, multimeter
can be used to measure the electromagnetic switch:

Lovol Phaser/1000 Series 23B.05


23B ELECTRICAL EQUIPMENT

the resistance to ground of No.1 terminal post is sliding bearings are selected and used to support each
2.55Ω, and the resistance to lower motor’s terminal bearing journal of the starter. Heavy electric appliance
post of No.1 terminal post is 1.0Ω and the resistance system has larger load, so the bearing with bush plus
to ground of upper terminal post is infinity. If the lubricant is often selected and used, but not powder
electromagnetic switch responding, the fault is at the metallurgy bearing.
system circuit. Now, press the starting button and The causes of bush wear are as follows:
measure the resistance between the positive electrode 1. foreign substances enter into the space between the
and No.1 terminal post; the result shall not show bush and the bearing and the grinding action of
disconnecting. Or else, check no damage in the relay rotation bearing to the bush during the starter running
and check no rupture in the ignition switch and wears the bush.
relevant wiring. 2. Too large impact or long-tern driving of the starter
results in the force produced by the action between
(3) Inside the starter: driving gear to flywheel ring gear is applied to the
bearing and then it exerts pressure in the opposite
If no fault found in the electromagnetic switch, then direction of engaging and rubs the bush.
check no fault inside the starter. Use the positive
electrode of the battery to short connect the terminal 3. Water contained in the lubricant at the cover in
post of the stator winding on the starter; if the starter the driving end is evaporated due to over high
not rotating or rotating slowly and powerlessly, the temperature in the starter cabin; then the lubricant
fault may exist in the electric brush, stator, rotor and becomes dry, which results in the deteriorated state of
the magnets of rotor and stator; if the engine rotating, friction contact. In order to avoid the starter fault due
then indicates the fault in the connecting circuit to bush wear, it is recommended periodically
between the battery positive electrode and the top of dismantling the starter from the engine and checking
the starter. its cleanness, then adding lubricant which comply
with the design requirement of starter and ensuring
good lubrication state.
Fault 4 the wear of the bush on the cover on the
driver end of the starter If wear has occurred, firstly check the bearing
journal and then change it with an appropriate bush
and lubricate it with regulated lubricant.
Due to the limitation of the structure size, the

23B.06 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23B

Lovol Phaser/1000 Series 23B.07


ELECTRICAL EQUIPMENT 23B

23B.08 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23C

Lovol Phaser/1000 Series 23C.01


23C ELECTRICAL EQUIPMENT

23C.02 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23C

Lovol Phaser/1000 Series 23C.03


23C ELECTRICAL EQUIPMENT

23C.04 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23C

YRZ series preheating device


General Description
XYZ series preheating equipment adopts
microcomputer controller and the controller
controls the preheating process of the preheating
plug, the oil supply of electromagnetic valve and
the ignition time of preheating plug according to
the system voltage and temperature signal, and
then it shall cut off the power and stop the operation
after completing the procedure. The voltages of
the product consist of 2V and 24V; connect the
preheating equipment according to above diagram
and

Pay attention to the following points:


1. The guide wiring of the preheating plug circuit shall meet2. The serial fuse must meet the requirement defined in the
the requirement of the diagram. small table.

voltage Single-plug fuse Double-plug fuse


12V 60A 120A
24V 30A 60A

Lovol Phaser/1000 Series 23C.05


23C ELECTRICAL EQUIPMENT

The fault and maintenance of flame preheating device

Fault Cause Remedy


Indicator failure Changing the lamp
Circuit failure or
The indicator is not lit Check the circuit
connector failure
when the switch is
Short circuit in the
pushed to preheating
loop of external relay
mod. Changing the relay
or too great current of
the loop
Check the circuit or
Electromagnetic valve
change the
not open
electromagnetic valve
The indicator works Fuse of power supply
normal when the circuit of preheating Changing the fuse
switch is pushed to plug broken
preheating mode, but it Wire broken in Changing preheating
can not start. preheating plug plug
External relay failure Change external relay
Df electrical controller Change the electric
damage control box
The indicator works One preheating plug
Changing preheating
normal when the damaged for double
plug
switch is pushed to plug starting system
preheating mode, but it Carbon accumulation
Clear up carbon
is difficult to start. in preheating plug
The battery voltage is
close to critical
voltage; the voltage is
When the switch is higher than the critical
pushed to preheating voltage when the
Chang the battery or
mode, the indicator is switch is just pushed
charge it
lit for a while and then to preheating mode;
turned out. and it may be lower
than the critical
voltage when the
battery discharging.

23C.06 Lovol Phaser/1000 Series


ELECTRICAL EQUIPMENT 23C

Lovol Phaser/1000 Series 23C.07


ELECTRICAL EQUIPMENT 23D

The electric elements of the fuel-supply system of unit pump 23D


General Description.........................................................................23D.01
The electric elements of the fuel-supply system of unit pump
ECU electronic control unit ……………………………………. …23D.01
The installment and dismantle of ECU…………………………….23D.01
Speed sensor of Cam and speed sensor of crankshaft………………23D.04
Water temperature sensor and fuel temperature sensor …………. …23D.05
Inlet temperature and pressure sensor……………………………….23D.06
Harness……………………………………………………….... …..23D.07

Lovol Phaser/1000 Series 23D.01


23D ELECTRICAL EQUIPMENT

General Description
The electric elements of the fuel-supply system of unit example. Refer to Hengyang 6 cylinder unit pump and
pump (Take the wit 4 cylinder unit pump as the the electric elements of EGR system)
ECU electronic control unit
ECU is installed on the gantry frame of the vehicle. of 18-22 N.m. Must not bump and drop during
Keep the insert clean during installation and installation. Installation interface of ECU is depicted
dismantle; tight the four installation nuts with a torque as the following diagram.

The suspension position of ECU is vertical to the


harness adaptor aside and the harness connector shall
not be upward. In order to conduct the fitting of the
harness plug, space of ≥120 shall be preserved at the
side of the plug and space of ≥100 be preserved at
both sides of harness installation interface; the
distance between side of the harness plug to the
installation face of the ECU on the engine shall be
≥30.
If electric control unit damaged, the whole unit must
be changed and sent to Wit service for maintenance
and treatment. It is prohibited to open the control shell
and repair it by yourself.

23D.02 Lovol Phaser/1000 Series


The installation and dismantlement of ECU

To fit To remove
Power off

Install shock absorbing bushing according to


pairing relation Reset the handle on the plug
or the bolt and then draw
them out.

Fix ECU with bolt, the four bolts shall be tightened with
uniform torque.

Install oil entering and returning pipe


(optional)

Remove oil entering


and returning pipe

Adjust the plug of the insert to its original


position and insert it into the socket
according to later method Loose the four fixing bolts and
remove the ECU control unit

Place the plug of the 81-pin and 40-pin inserts


onto the socket of the 121-pin insert of the ECU,
and press it lightly to its position. Remove shock absorbing
bush

Power on
23D ELECTRICAL EQUIPMENT

Cam rotation speed sensor and crankshaft rotation speed sensor


To fit To remove
Power off

Ensure the measurement space


within 1.0±0.2mm Press the clamp at the plug
of the harness and pull out
the plug between the
harness and the sensor.

Insert the sensor (with sealing ring)


into the installation hole, and tighten
it with a torque of 4N.m.

Remove the fixing bolt and the


sensor (keep the corresponding
pad)

Insert the plug between the harness and the


sensor until it clamped

Power on

Notice: sensor within the range of 1.0±0.2mm.


1. Keep the monitor surface of 3. Must ensure the dependable connection of the
crankshaft/camshaft position sensor parallel to the sensor plug.
tangent direction of the outer circle of the signal hole. 4. The tightening torque of the fixing bolt of the
2. Strictly ensure the measurement space of the sensor is 8-10N.m

23D.04 Lovol Phaser/1000 Series


Water temperature sensor and fuel temperature sensor

To fit To remove
Power off

Install the sensor Push the lug on the harness


into the installation plug out and plug off the plug
hole tightly. between the harness and the
sensor.

Insert the plug between the


harness and the sensor (until
the lug clipped) Rotate the temperature
sensor along the opposite
direction of the thread.

Power on

Notices:
1. Do not exert excessive force when installing the 2. Don’t bump on the exposure part to avoid
sensor to avoid damaging the sensor itself. damaging the sensor itself.

Lovol Phaser/1000 Series 23D.05


Entering air temperature and pressure sensor

To fit To Remove
Power off

Insert the sensor (with sealing Press down the lug on the plug of harness
ring) into the installation hole, and then remove the plug between the
tighten the fixing bolt. harness and sensor.

Insert the plug between the


harness and sensor (until it click Remove the fixing bolt and sensor.
with the lug)

Power on

Harness
To fit
1. Turn off the power.
2. Carefully keep each electric interface clean. On engine, insert each plug of sensor into its corresponding
plughole according to the mark on the harness. Connect the harness of pump EUP. Use clip to fix harness.
Connect the harness to the ECU. Finally connect the harness to the electric throttle pedal and other harness in
cab.
3. If the second operation involves electric parts, it must be done according to the installation requirement of
electric parts.
The connection between harness and EUP
The 8 control wires are divided into 4 groups with 2 wires as 1 group; connect the 4 groups to electromagnets
respectively; the red wire of each group will connect the control wire of each cylinder electromagnetic valve. The
wiring relation is indicated as follows:

The connection between harness and power


The harness connects to the power through the power connector of the 81-pin plug.
The connection between harness and computor
When computer is needed to monitor the process, connect the communication ports of the harness into the
RS232 ports of the computer to carry out communication.
The connection between harness and ECU
The first step, pull the plug of the insert to its longest position, depicted as follows.

The longest position


The longest position
of the plug
of the plug

The second step: place the plug of the insert on the housing of corresponding connector in the ECU with the
plug facing outwards. Then press the plug downward lightly and confirm the connection; and then insert it to the
bottom, depicted as follows.

Push the plug into the Push the plug into the
bottom of connector. bottom
Notice: the harness of 6 cylinder Hengyang unit pump engine is different to the plug needed to connected to
ECU; its connection method is as follows.
The first step, pull the handle of the insert to position indicated in the diagram, depicted as follows.

The second step: Place the plug of the insert on the housing of the socket of the ECU and press it lightly. Then
draw the handle of the plug of the insert to the position indicated in the diagram, and the handle shall be clipped by
the pin on the plug of the insert.
Notice:
The harness shall be fixed after correct installation to prevent the scraping damage caused by mechanical
shock. At the same time, it shall be installed away from high-temperature area and the highest environmental
temperature shall not be above the regulated maximum working temperature.

To remove
1. Turn off the power.
2. According to above passage, cut off the connection between the harness and ECU. Cut off the connection of
the harness to the electric throttle pedal and other harness in cab. On the engine, pull the plug of each sensor
off, disconnect the harness with the pump EUP and disconnect the clip used to fix the harness, and then
dismantle the harness.
3. If the second operation involves electric parts, it must be done according to the dismantlement and
installation requirement of electric parts. Notice: when disconnecting the plug, you must pinch the clip
groove of the plug and draw it out alone the opposite direction of inserting plug; the cable can not be pulled
out directly.
Lovol Phaser/1000 Series 24.01
AUXILIARY EQUIPMENT 24A

Lovol Phaser/1000 Series 24A.01


24A AUXILIARY EQUIPMENT

24A.02 Lovol Phaser/1000 Series


AUXILIARY EQUIPMENT 24A

Lovol Phaser/1000 Series 24A.03


24A AUXILIARY EQUIPMENT

24A.04 Lovol Phaser/1000 Series


AUXILIARY EQUIPMENT 24A

Lovol Phaser/1000 Series 24A.05


AUXILIARY EQUIPMENT 24B

Lovol Phaser/1000 Series 24B.01


24B AUXILIARY EQUIPMENT

24B.02 Lovol Phaser/1000 Series


AUXILIARY EQUIPMENT 24B

Lovol Phaser/1000 Series 24B.03


24B AUXILIARY EQUIPMENT

24B.04 Lovol Phaser/1000 Series


AUXILIARY EQUIPMENT 24C

Lovol Phaser/1000 Series 24C.01


24B AUXILIARY EQUIPMENT

24B.02 Lovol Phaser/1000 Series


24C AUXILIARY EQUIPMENT

24C.01 Lovol Phaser/1000 Series


LIST OF SPECIAL TOOLS 25

Lovol Phaser/1000 Series 25A.01


25 LIST OF SPECIAL TOOLS

25A.02 Lovol Phaser/1000 Series


LIST OF SPECIAL TOOLS 25

Lovol Phaser/1000 Series 25A.03


25 LIST OF SPECIAL TOOLS

25A.04 Lovol Phaser/1000 Series


LIST OF SPECIAL TOOLS 25

Lovol Phaser/1000 Series 25A.05


25 LIST OF SPECIAL TOOLS

25A.06 Lovol Phaser/1000 Series


LIST OF SPECIAL TOOLS 25

Lovol Phaser/1000 Series 25A.07

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