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Perkins Repair Manual
Perkins Repair Manual
01
The explanation of the supplement
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
Engine timing
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.
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
Engine timing
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.
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.
2. Fault elimination
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
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
20B.02 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B
20B.04 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B
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
20B.06 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B
20B.08 Lovol
Phaser/1000 Series
FUEL SYSTEM 20B
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.
Fuel pump
To fit 20D-04
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
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
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.
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.
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
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.
To fit To remove
Power off
Fix ECU with bolt, the four bolts shall be tightened with
uniform torque.
Power on
23D ELECTRICAL EQUIPMENT
Power on
To fit To remove
Power off
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.
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.
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 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