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Diesel Engine
Operation Manual
Please read the operation manual carefully
 CONTENTS
CHAPTER I: TO CUSTOMERS .................................................................... 1
1. Diesel engine operation ......................................................................... 1
2. Safety precautions ................................................................................. 1
3. Service guide ......................................................................................... 4

CHAPTER II: DIESEL ENGINE OPERATION MANUAL ........... 5

Part 1. Main technique data and specification for diesel engine .............. 5
1-1 Main technique data and specification ...................................... 5
1-2 Overall engine dimension and installation ................................ 6
1-3 Diesel engine connection dimension ......................................... 8
1-4 Port timing, fuel injection timing, valve clearance .................... 9
1-4.4 Torque specification for main bolts and nuts (see table 1-5)... 10
Part 2. DIESEL ENGINE OPERATION .................................................. 11
2-1 Please pay close attention for safe operation of the diesel 11
engine .............................................................................................. 11
2-2 Fuel choise and Preparation for start diesel engine .................. 14
2-3 Running and stopping of diesel engine ..................................... 16
2-4 Precaution for engine running and after stop ............................ 17
Part 3. TECHNICAL MAINTENCE OF DIESEL ENGINE .................. 17
3-1 Daily checks and maintenance .................................................. 17
3-2 Maintenance for diesel engine .................................................. 17
3-3 Regular checks and maintenance .............................................. 19
Part 4. STROING THE DIESEL ENGINE ............................................. 20
Part 5. DIESEL ENGINE TROUBLE SHOOTING AND REMIDIES
5-1 Engine is not started .................................................................. 20
5-2 Diesel engines stop automatically ............................................. 21
5-3 Diesel engine under power ........................................................ 22
5-4 Diesel engine exhausting black smoke ...................................... 22
5-5 Diesel engine exhausting blue smoke ........................................ 23
5-6 Diesel engine exhausting white smoke ...................................... 23
5-7 Method and location of the inspection when diesel engine failure
to stop runnin .............................................................................. 23

CHAPTER III: Guarantee ............................................................................... 24

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 CHAPTER I: TO CUSTOMERS
Dear user, your name is recorded in our company’s user file.
Following the precautions described in this manual will enable you to use this
engine with compete satisfaction. Failure to observe any of the rules and
precautions, however, may result in a scalding, injury, fire or engine damage and
make the guarantee provided with engine become invalid. Read this manual
carefully and be sure you fully understand it before beginning operation.

1. Diesel engine operation

1.1 A new engine must be properly broker in. For the first 20 hours, run the
engine at low speed and low loads. Do not allow engine to run at high speed and
high loads at se´ l vere condition during the break in period.
1.2 After the break in period, please retighten the nuts and bolts of cylinder head
cover; adjust the valve clearance before run the engine at normal speed.
1.3 Do operate and use the engine upon to the power and speed marked on name
plate. Do not allow engine to run at overload, over speed or low load in long
time.
1.4 After starting the engine, run the engine for 3-5 minutes at low speed,
zero-load, then gradually increase the speed and add the load.
1.5 The worker shoud learn the engine well about the working principle and
structure, check and maintain the engines regularly. Do troubleshoot the problem
in time and not allow run the engine with problem or make the engine work
without work on duty for longtime.
1.6 Use the diesel oil and engine oil specified in this operation manual. Clean
and filter the diesel oil and engine oil before use and keep the oiler clean, change
the engine oil regularly.
1.7 Do maintain the air filter regularly, keep the sponge strainer clean and change
the filter element when necessary.

2. Safety precautions
2.1 Do not allow persons who have no capacity like children, elders, and sick
enter into the work place of diesel engine.
2.2 Do not allow to operate the diesel engine when lose control on self like in bad
heath or drink.

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2.3 Check the fastening including the condition of each installation, connection
and the hold down bolts and fasten them in time.
2.4 Exhaust precautions

● Never inhale the exhaust gases; it contains carbon monoxides, a

colorless, odorless and extremely dangerous gas which can cause
unconsciousness or death.
● Never operate the engine indoors or in a poorly ventilated area,
such as tunnel or cave, etc.
● Exercive extreme care when operating the engine near people or
animals. Keep the exhaust pipe free of external objects.
2.5 Refueling precautions

● Be sure to stop the engine before refueling.

● Do not overfill the fuel tank.
● If fuel is spilled, wipe ii away carefully and wait until the fuel
has dried before starting the engine again.
● Check the fuel the type specified before fill fuel. If add other fuel
like gasoline, it will make fire easily.
● Make sure that there is no fire before refueling and keep the
diesel engine from oil and other inflammable materials to avoid fire.
● After changing oil, make sure that the fuel cap is tightly
secured to prevent fuel leakage.
2.6 Fire precautions

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 ● Never operate the engine while smoking or near an open flame.
● Never use the engine around dry brush, twigs, cloth-rags, or other
flammable materials.
● Keep the engine at least 3 feet (1 meter) away from building or
other structures.
● Keep The engine away from flammables and other hazardous
materials.
2.7 Protective cover

● Always place the protective covers over the rotating parts. If

rotating parts such as the driving pulley, belts, and shafts are exposed,
serious injuries can be coused. To prevent injury, please equip all
rotating parts with protective covers.
● Be care of hot parts. The muffer and other engine parts can become
very hot while the engine running or after the engine has been run.
Always operate the engine in a safe area and keep children away from
running engines.
2.8 Check before operation

● Carefully check fuel pipe and fuel joints for fuel leakage.
Leaked fuel created a dangerous situation.
● Verify that all the nuts and bolts of the engine are tights. A loose nut
or bolts may cause serious engine failure and could lead to serious
injuries.
● Always check the engine oil and refill it if necessary.
● Check the diesel fuel and refill it if necessary. Do not overfill

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 the fuel..
● Wear suitable work cloth operate diesel engine. Accident will happen
for loosed apron, towel or leather belt may be rolled by diesel engine.
2.9 Surroundings

● Operate the engine on a table or level surface of small rocks and loose
gavel.
● Operate the engine on a level surface. If the engine is titled, fuel may
spill form the gas tank.

ATTENTION
Operating the engine at a steep incline may cause the engine to seize up due to
improper lubrication even when the oil level is a maximum.
● Be careful of the fuel spillage when transporting the engine.
● Tighten the fuel cap can close the fuel strainer cock before moving the
engine around.
● Never move the engine while it is in operation.
● If the engine will be transported over a long distance, drain all the fuel
from the fuel tank to prevent fuel leakage.

3. Service guide
3.1 If you have any questions for operate the diesel engine, please contact your
local dealer or us.
3.2 Please note to place the warning mark in the conspicuous position and contact
with local dealer to change new mark when the mark is off or unclear.
3.3 We state here that: Our company will not afford any responsibility for the
problems caused by the unreasonable modification or operation of user.

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 CHAPTER II: DIESEL ENGINE
OPERATION MANUAL

Part 1. Main technique data and specification for diesel engine

1-1 Main technique data and specification

Model 2V88 2V92 2V95F

Type V-twin, 4 stroke, air-cooled, direct injection
Bore x Stroke (mm) 88x75 92x75 95x88
Piston displacement (L) 0.912 0.997 1.247
Compression Ratio 20:1 20:1 20:1
Rated power (kW) 13.8 14.8 14.8 16 18 19
Rated speed (rpm) 3000 3600 3000 3600 3000 3600
Start way Electric start
Lubricating system Forced & splashing
Lube (L) 3 3.8 3.8
Fuel 3000rpm: 250 3000rpm: 250 3000rpm: 250
Consumpition (g/kwh) 3600rpm: 260 3600rpm: 260 3600rpm: 260
Fuel 0#(Summer), -10# (Winter) diesel oil
Lube SAE10W30 (CD grade above)
Overall Dimension
504x546x530 530x580x530 530x580x530
(LxWxH) (mm)
Net Weight (kg) 68 74 7.8
Rotation Direction
(View from Flywheed) Clockwise

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1-2 Overall engine dimension and installation
1-1 The diagram for diesel engine and installation dimension

Figure 1-1 The outline and installation dimension graph of diesel engine

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1-2.2 Installation
(1) There must be a tight stationary foundation for the diesel engine to avoid
vibration or movement when the engine is running.
(2) Make sure that the centering position of the output shaft is properly aligned.
(3) Verify that the dimension of the hole on the belt wheel and keyway shaft match
or correspond with each other. Also make sure that the bolt of the engine shaft is
tightened to the proper torque specification.
(4) When the engine is matched with other belt driven machines, the total desired
belt distance traveled by the driven wheel must equal the total distance traveled by
the driven wheel. If this is not properly calculated and matched, the desired speed
on the driven wheel will be incorrect. A formula used to calculate the necessary
diameters of the various wheels is provided below.
The diameter of driving wheel (belt wheel) can be calculates as follows:

Diameter of engine Diameter of driving machine x speed of drive machine

=
driving wheel Diesel speed (engine speed)

(5) Make sure that the belt has a correct tension to it.
If the belt is too tight, the engine bearing will wear at a high rate leading
to engine failure, If the belt is to loose, the belt will slip at high speeds and high
loads causing high pitch whistling noises.
1-2.3 Crankshaft driving angles must be less than 120˚ (see Fig 1-2)
1-2.4 Gradients
The gradient must be kept within the allowed value shown on Fig 1-3

Output end
Gradient

Permit Gradient
(continuum running) <20˚

Engine Gradient

Permit Gradient
(continuum running) <20˚

FIG. 1-2 FIG. 1-3

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1-2.5 Please contact our dealers about electric circuits involved with this engine.
We recommend the use of accumulator shown in table 1-1.
Table 1-1 unit: AH

2V88, 2V92 45
2V5F 60
1-3 Diesel engine connection dimension
1-3.1 Diesel engine shaft specification
Select the suitable PTO shaft type when diesel engine is fitted with
machines and equipments for reasonable matching. Below seven types of PTO
shaft for users to select (see Fig 1-4) We can design PTO shaft according to special
applications to for users to match with machine better.

Fig 1-4 Diesel engine shaft dimension

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1-3-2 Size of PTO flanges (shown in Fig 1-5)

Detail view in direction a

Fig 1-5 size of PTO flange

1-4 Port timing, fuel injection timing, valve clearance

1-4.1 Port timing (see table 1-2)
Table 1-2 Unit: CA

Model Phase
Item 2V88, 2V92, 2V95F
Intake valve open BTDC 14˚
Intake valve close ATDC 50˚
Exhaust valve open BBDC 54˚
Exhaust valve close ABDC 10˚

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1-4.2 Fuel supply advance angle (see table 1-3)
Table 1-3 Unit: CA

2V88, 2V92, 2V95F

3000r/min 3600r/min
20±1° 22±1°

1-4.2 Valve clearance (cold state) (see table 1-4)

Table 1-4 Unit: mm

Model Phase
Item 2V88, 2V92, 2V95F
Intake valve 0.1
Exhaust valve 0.15

1-4.4 Torque specification for main bolts and nuts (see table 1-5)
Table 1-5 Unit: N.m
Model 2V88, 2V92,
Item NOTE
2V95F
Connecting rod bolt 40 ⁓ 45
Cylinder head nut 70 ⁓ 75
Flywheel nut 68 ⁓ 75
Nozzle retainer nut 20 ⁓ 25 Retighten up
Tighten nut of after test period
30 ⁓ 40
rocket stand
Tighten nut of gear 60 ⁓ 65
case cover
Standard M8 bolt 20 ⁓ 30
Standard M8 bolt 15 ⁓ 20

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 Part 2. DIESEL ENGINE OPERATION
2-1 Please pay close attention for safe operation of the diesel
engine
(1) The fuel used must be filtered by silk fabric or settle for 24 hours before it is
used in the engine. Never add oil to the crankcase when the engine is running.
(2) Keep flammable and combustible goods away from engine white engine is
running. The engine should he placed in a simple ventilated place.
(3) Do not touch the muffer when the engine is running or just after it has
stopped.
(4) The diesel engine should be operated at its rated power and rated speed. If
adnormal operating conditions are detected, stop the engine immediately to
check and fix the problem.
(5) A new engine must be properly broken in. For the first 20 hours, run y the
engine at low speed and low load. Do not allow engine to run at high speed and
high loads during the break in period.

2-2 Fuel choise and Preparation for start diesel engine

2-2.1 Add fuel
Fuel tank can only use light diesel fuel.
Fill fuel tank with diesel fuel, there must be no dirt or water in fuel,
Otherwise, fuel injection pump and the fuel injection nozzle will exit the serious
problems, which will result that engine unit can not work normally.
Adding too much fuel is very dangerous. When adding fuel, pay attention ti
the red display of fuel standard on the fuel tank.
The factory has replaced the engine fuel and engine oil once already
To check the fuel pipeline, make sure the fuel
line is completely drained. If there is air in the
pipeline, drain it out. air
To do this, loosen the, then drain it out the air bleeding
until there are no bubbles left in fuel line and screw
retighten the air bleeding screw.

Note: 1. Smoking is prohibited in the refueling place of the diesel engine or

the storage place of diesel fuel, and sparks cannot enter this area.

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 2. When refueling, it cannot be overflowed. If you accidentally overflow fuel,
you must clean it with a cloth to ensure that the overflowed fuel is dry before
engine unit starts.
3. After refueling, be sure to tighten the lid of fuel tank.
4. Do not refuel when diesel engine is running.
2-2.2 Filling in lube oil
2-2.2.1 Lube oil quality
The qualified lube oil should meet following condition.
ACEA-B2/E2 or higher-grade specification
API-CD/CE/CF-4/CG-4 or higher-grade specification
Lube oil viscosity

Select lube oil viscosity based on ambient temperature when starting at

cold temperature.
It is very important to select the applicable engine oil for keep up the
performance and life of the generating set. If inferior oil is used, or if your engine
oil is not replaced periodically, the risk of piston seizure, piston ring sticking and
accelerated wear of the cylinder liner, bearing and other moving components
increases significantly. So the generating set life will be shortened. We
recommend CC/CD oil classified by API. Choose the applicable viscosity oil
according to the local ambient temperature.
When use inferior engine oil, the interval for changing lube oil will be
shortened to every 150 hours running.
2-2.2.2 Lube oil level of engine

20 hours at first Every 100 hours for

Every 200 hours
next three times

Interval for changing lube oil

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 Opening for filling in lube oil
Put the generator on plain ground, then fill in lube oil through the opening of
oil dipstick. When checking oil level, only screw the dipstick into the
opening.

Upper level limit (H)

Lower level limit (L)

When starting the engine each time, should check oil level. If not being
enough, should add the lube oil to the stipulated level. Draining off lube oil can
be immediately done after engine stopped, because it is difficult to drain off the
oil thoroughly when the engine is in cold state.
After filling fuel, you should tighten the fuel dipstick. Otherwise, rain, dust,
and other dirt may enter diesel engine, which can cause accelerated wear of
internal components. It can cause serious problems.
Note: 1. If engine fuel is insufficient, it will damage the engine.
2. If engine fuel is sufficient, engine fuel will enter the cylinder and
participate in the combustion, which can cause the engine to suddenly
increase speed and emit blue smoke.
2-2.3 Check the air filter

(1) Loosen the bolts, remove the air filter element cover, and remove the
filter element.
Note: 1. Do not use the detergent to clean the filter element.
2. When the output power is reduced or the color of the exhaust smoke is not
goods, replace the filter element.
3. If you do not have a filter element, you cannot start the diesel engine.
Otherwise, it will cause rapid damage to the diesel engine.

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(2) Install the filter element, install the air filter element cover, and loosen the
bolts.

2-2.4 Accumulator
If the accumulator is of liquid-added type, should check the electrolytic level
every month. Hence it is necessary to add the distillatory water to stipulated limit.
It is very important to keep the electrolytic level within stipulated level. When
the level is at lower position, the engine can not be started. If the electrolytic level
is high, the liquid will overflow to corrode the parts nearby.
During the operation, the generator can automatically charge the accumulator.
If the generator is used for stand-by application, should charge the accumulator.
If the accumulator is of valve-controlled lead-acid type, it will be charged
if necessary.

Warning: Do not left two terminals contact with each other, which will
make the circuit short

2-2.5 Connect the battery

As shown in the figure on the right, the
positive pole of the battery is connected to
the terminal of the starter motor; The
negative pole is connected to the position of
any point of the body (it is recommended to
connect the regulator as shown to the bolts).

1
1 COMM This is the wiring diagram of
2 PULL the shutdown electromagnet
2 3
3 HOLD

2-3 Running and stopping of diesel engine

2-3.1 Starting

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(1) Turn the starts switch clockwise to the “Start” position.

(2) If the engine is started, immediately remove your hand away from the key
switch.
(3) If the engine does not start after 5 seconds, wait for a while (about 30 S)
before trying to start the engine again.
Warning: The number of starts within one minute cannot exceed 2
times. If the 3 starts are not successful, and the voltage of the
electromechanical bottle of the fuel supply system should be
checked. Morerver, conduct maintenance according to the
instructions. If it is started forcibly for many times, the starting
motor will be burnt out.
(4) Preheat the engine for three minutes at no load.

2-3-2 Check on the engine while the engine running

(1) Check if there is abnormal noise or vibration.
(2) Check to make sure there is good combustion or over speed running.
(3) Check to see the color of the exhaust gases to see if it is too white or too
black.
If any of these conditions are detected, stop the engine immediately and
contact your nearest dealer for repair information.

2-3-3 Stopping the engine

(1) Let it run for 3 minutes at no load before stopping it.
Sudden stop the engine will cause abnormal temperature increases in the
block of the engine.
(2) Turn the starting swith to the “Off” position.
Under the special conditions (such as a runaway) needs to stop
imminently, the start key is dialed to the stop position, and you can immediately
stop. (If the parking fails, the joint nut of the high-pressure fuel pipe is
immediately loosened, and you can immediately stop.)

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 2-4 Precaution for engine running and after stop
2-4.1 Precaution for engine running
(1) When the oil alarming red lamp is on, stop the engine and check the engine
oil inmediately.
(2) Check the fuel level regularly and refill in the fuel when fuel is insuffcient.
(3) Clean the dirt in the opening of air induct and exhaust of diesel engine
regularly.
(4) The engine is not allowed to run when it exhaust black smoke. If the parts of
engine are normal but there is black smoke in the opening of exhaust, the engine
should be used overload. For this problem, reduce the load. If the fault of engine,
please stop the engine and examine and resolve the problem immediately.
(5) Check whether there is abnormal noise of engine regularly, Stop and examine
the engine immediately.

2-4.2 Precaution after stopping engine

(1) When the parking for a long time, the arrow of the flywheel fan point right
above, which can make the two cylinder valves are closed, so as to prevent dust
from entering the cylinder or corroding the sealing line of the valve.
(2) Check the element of fuel filter is in good condition.
(3) Make sure the fastening of engine base is stable and also the fastening of the
bolts, nuts on engine and tighten them if they are loose.
(4) When the engine will stored for long time, seal the engine with waterless
engine oil.
(5) Clean the dirt from the engine and put the engine in a nice dry noncorrosive
place.

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Part 3. TECHNICAL MAINTENCE OF DIESEL ENGINE
3-1 Daily checks and maintenance
Check the oil level of the engine to see whether it is between the upper and
lower limits.
Check to see whether there any oil leaks within the engine.
Keep the engine clean by cleaning up the dirt and other greasy deposit on the
engine.

3-2 Maintenance for diesel engine

First period maintenance
After running for 150 hours, the diesel engine should be maintained for first
period:
(1) Clean the air filter, make sure the paper core is good and check each tuck.
(2) Check and adjust the valve clearance.
(3) Check the engine oil, change or refill engine oil.
(4) Check the engine oil quality. Change all the engine oil and clean the engine
body and fuel pipeline after the engine running for 200 hours.

Second period maintenance:

It depends on the technique condition of diesel engine the second period
maintenance. Within the period of three guarantees, the second period
maintenance should be conducted with the appointed for below items, excluding
the first period guarantees.
(1) Clean the pipeline of fuel tank, exhaust tube, muffler.
(2) Clean the carbon deposit on the injection nozzle, piston, cylinder, cylinder
head etc.
(3) Check and adjust the fuel injection pressure, clearance for piston rings, fuel
delivery beginning.
(4) Check the tightness of valve and do grind the valve if leakage occurs.
(5) Check the fastening of connection rod, crankshaft, and flywheel etc.
(6) Trail running check.

3-3 Regular checks and maintenance

Regular checks and maintenance are very important for narmal operation
and engine life. The following table indicates what is necessary to be

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performed at specific time intervals. The marks signify that a special tool or
technique is needed for maintenance. Please contact your local dealer for special
maintenance.

Time 1000
After 20 500 hours
Daily 100 hours hours or
Item hours or 6 month
one year
•
(After 50 hour
•
(Tighten the
Check and tighten
the nut and screw ◦ retighten the
stud or cylindet
stud of
cylinder
head) head)
Check and fill
machine oil ◦
Change machine oil ◦ ◦
(Every 100 hours for next there
(First time)
times/Every 200 hours for after)

Clean and change •

(First time for •
(Second time •
oil filter (Change)
clean) and later)
Check oil-leakage ◦
Change the core of
air filter
Period of check and maintenance will
be shorted at duty place ◦
Clean fuel tank Every month
Clean or change fuel
filter
◦
(Clean) ◦
(Change)
Check nozzle •
Check injection
pump •
Check pipeline of ◦
(Change if
fuel necessary)
Adjust valve
clearance of inlet •
(First time) •
and exhaust
Grind holder of
inlet & exhaust valve •
Change piston ring
•
Check battery liquid Every month

Clean the core of air

filter
◦
(Clean) Per month or 500 hours

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 Part 4. STROING THE DIESEL ENGINE

Please follow the instruction below if you plan on storing the engine
for long periods of time to avoid corrosion and damage.
(1) Remove the oil-drain screw, drain off the engine oil and retighten the
oil-drain screw quickly before the engine oil becomes cool when the engine is
stopped.
(2) Drain off the diesel oil of fuel tank.
(3) Take out and clean the lube oil filter.
(4) Remove the fuel injection pump and clean the inner side of cylinder body
with clear diesel oil. Drain off the cleaning oil from the oil-drain screw.
(5) Clean the air filter and inner side. Remove the dirt on the opening of air inlet
and exhaust.
(6) Dehydrate 1.8kg strained lubricating oil (Warm up it to 110-150˚C till no
bubbles). Fill 1Kg dehydrated engine oil into the crankshaft case and turn the
engine to make the lubrication syste filled with engine oil.
(7) Then fill 0.3 kg dehydrated engine oil into the air intake pipe, turn the diesel
engine to make the engine oil onto the piston, cylinder head cover, valve line.
Finally turn the flywheel to the position that both cylinder valves are closed to
make the engine cavity insulated.
(8) Heat the left dehydrated engine oil with 0.2kg industrial Vaseline till they
melt and mix together well.
(9) Clean the outside of diesel engine.
(10) Packed the air cleaner and opening of exhaust with oilpaper to avoid dirt
enter into engine.
(11) Finally brush the mixed oil evenly on the engine parts without paint like
flywheel, fuel pipe etc.
(12) Do not allow brush oil on the parts of rubber and plastic.
(13) The engine should be stored in the well ventilated and dry place and not
allowed to store in the place with chemistry.
The diesel engine can be well stored for six month by above methods.
When it exceeds six month, the engine can be stored again with the instruction.

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 Part 5. DIESEL ENGINE TROUBLE SHOOTING
AND REMIDIES
5-1 Engine is not started
Possible cause Remedy
Preheat the engine oil before fill into the
crankshaft case.
Fill in 2ml engine oil into the opening of
The engine oil become the air-intake pipe and then stard diesel
overly adhesive at low engine and run engine over ten rounds idly to
temperature improve the compression for easy start.
Remove the connection belt of matched
machine and start the engine. Stop the diesel
engine after the engine warm. Install the belt
and start the diesel engine again
Trouble in fuel system Clean the fuel tank filter and fuel pipeline,
and then replace the fuel with new fuel.
The fuel has thickened and Use the correct specific diesel oil.
difficult to flow
Air in fuel system Bleed the air and retighten the connection
parts of fuel pipeline
Poor spray from the Check the position of speed governor handle,
injector or pressure too low clean and maintain fuel injector, injection
pump, and change if necessary.
Problem with fuel injector or incorrect fuel
deliver beginning. Maybe there is leakage
Incomplete combustion
from the washer of cylinder head cover or
insufficient compressor. Maintain the engine
according to the causes.
Insufficient diesel oil in fuel tank. Refill
Fuel delivery is not
diesel oil into fuel tank. Clean the fuel
constant
pipeline or fuel filter if any jam.
Electric solenoid out of Check if the solenoid is electrified and
work normal for open
Insufficient electricity in Charge the battery
battery

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 Insufficient compression
in cylinder, the nut of Tighten the nut of cylinder head in diagonal
cylinder head not be order. Check the washer of cylinder head
tightened, or packing of after test the engine
cylinder head broken or
leaked
The valve clearance of
piston rings is too large Change the piston ring
because water exist
Piston ring gaps may all
Make sure each piston ring gas is off by an
be set up in a line,cause
angle of 120 degrees from each other
air leakage
Piston rings are stuck and Clean rings with fuel or change piston rings
broken
Incorrect valve clearance Adjust the clearance according to instruction

Grind the valve. If the valve thread is too

Leakage of valve deep, deliver the engine back to factory for
repair
The push rod is grasped Open the valve and clean the push rod and
by pipe pipe.

5-2 Diesel engines stop automatically

Possible cause Remedy
Fault in fuel system: no fuel Refill in the diesel oil
Jam in fuel pipeline or fuel filter Maintain or clean it
Air in fuel system Drain off the air
Adhesion of needle valve of fuel Clean and grind the nozzle and
injector change if necessary
Jam in air cleaner Repair or clean it
Load turn heavily suddenly Reduce the load
Check the engine oil level and
Insufficient engine oil or jam in fuel check whether the lube oil pump
pipeline, make components seized work normally, whether the fuel
for lack of engine oil pipelines is unblocked, repair or
change the seized or strained parts

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5-3 Diesel engine under power
Possible cause Remedy
Problem in fuel system: Jam in fuel Check the fuel switch and open it
pipeline and fuel filter. completely. Clean fuel pipeline and
fuel filter.
Poor fuel supply of fuel pump Repair or change the damaged parts
of injection pump.
Fuel injector problem: inaccurate
Adjust the fuel injection pressure
spray pressure
Carbon deposit on spray-hole Clean the spray hole
Adhesion of needle valve Clean or change it
Fitting between the needle valve Change the needle valve or needle
and valve body is too loose valve body
Open the air cleaner to clean or
Jam in air cleaner change the element
Check the engine speed with
Too low speed tachograph and adjust the
speed-limit screw.
Incorrect valve clearance of inlet Adjust the valve clearance refer to
and exhaust instruction
5-4 Diesel engine exhausting black smoke
Possible cause Remedy
Overload Reduce the load. If driven machine is
not properly fitted with proper engine,
change the engine.
Poor spray for fuel injection Repair or clean it
Insufficient air intake or air Clean the air filter, check the cause for
leakage leakage and remedy
Strong wearing resistance Stop and check the engine. If feel strong
inside and problem in the lube resistance, take apart the engine to
oil pipeline repair to avoid serious accident such as
scratch or bearing seized.
Delayed fuel inject, Check and adjust the fuel injection
combustion too much in later timing
phase

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5-5 Diesel engine exhausting smoke
Possible cause Remedy
Check the engine oil level and drain off
Engine oil in cylinder
the needless redundant engine oil.
Piston rings are seized or worn
out, insufficient elasticity or Check and change piston ring, lay the
piston ring gaps are all aligned position of openings of piston ring
to cause engine oil entered into across.
cylinder
Too large clearance between Repair or change
piston and cylinder
Valve and valve guide wear out Change the valve or valve be guided

5-6 Diesel engine exhausting white smoke

Possible cause Remedy
Clean the fuel tank and fuel filter
Water in diesel fuel
and change the diesel oil.

5-7 Method and location of the inspection when diesel engine failure to
stop running
Possible cause Remedy
Check the speed governing
High and low speed fluctuant system is flexible, whether there
is air in the fuel pipeline.
Abnormal sounds Check all the working parts
Engine exhausts black smoke Check the fuel system especially
suddenly the fuel injector.
Metallic knock with regular in Check if the fuel injection timing
cylinder too high and make adjustment
accordingly
The mark of lube oil indicator drops Examine the lubricating system;
suddenly or the lube oil alarming red check whether the coarse filter,
light is on. lube oil pipeline and check lube
oil pump work in order.

23 www.corvexpumps.com
(2) The general sensory phenomena (sound, vibration, oily smell,
etc.)
that do not affect quality and performance.
(3) Problems caused by natural disasters such as typhoons and
floods.
(4) Problems caused by drugs, salt damage, etc.

Do not bear the expenses of the following items

(1) Consumables (air filter element, fuel filter, gaskets, fuses, etc,
and consumables belonging to this category) and grease etc.
(2) It is repaired at a seller or outside the company.
(3) Inspection, eleaning, adjustment and regular inspection and
maintenance.
(4) Inconvenience or loss caused by the inability to use the machine
(such as suspension loss or business loss, etc)
(5) Compensation for expenses outside the conditions stated in the
grantee.

Methods of accepting grantee repairs

When you need to accept grantee repairs, please bring the
engine and grantee, purchase invoice to the store where you purchase
the goods or our service store to apply for and repair, We will not
guarantee repairs without the grantee.

Guarantee service
When the customer purchase the goods, fill in the necessary
items on the goods purchase invoise and guarantee with the store and
sign and seal. It will take effect.

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