Manual de Mantenimiento TB504 Motor

D/4B/QC Diesel Engines
MAINTENANCE MANUAL
THE PEOPLE’S REPUBLIC OF CHINA

LOVOL INTERNATIONAL HEAVY INDUSTRY CO.,LTD
1
Engine maintenance manual
(QUANCHAI D series, 4B series, QC490T, QC495T, QC498T engine)
Foreword
The manual provides the information about diagnosis, maintenance procedures, adjustment and
other information of two institutions and five systems of engine with four cylinders not used for
road of Anhui QUANCHAI Engine Co., Ltd., which can be used by maintenance technician. If
necessary, please use with parts atlas.
If you want to obtain the related information on the relating products type, part drawing number
and special tools stated in the manual, please call or write to our company. All the information,
illustrations and production instructions collected in the manual should be compiled according to
the present conditions.
In order to promote the quality of the machine, improve the using performance and safety
performance, our company will design and change the parts timely; therefore, this instruction has
differences about contents and illustrations, etc. from the entity. If there are changes for the
contents of this instruction, it will not be prior noticed, please understand.
Without approval of Shandong LOVOL Heavy Industry International Trading Co., Ltd, no parts of the
manual can be copied and stored in a retrieval system or transmitted in any form and means
(including but not limited to, electronic, copying and recording). Above statement is applicable for
all the characters, diagrams and tables.
Contents
Part I Overview .......................................................................................................................................................... 1
Chapter 1 Safety Precautions ............................................................................................................................. 1
Chapter 2 Technical parameters ......................................................................................................................... 3
1. Main technical parameters ..................................................................................................................... 3
2. Filling capacity ...................................................................................................................................... 6
3. Main performance parameters of diesel engine ..................................................................................... 7
4. Engine parameters ............................................................................................................................... 15
5. Torque value ........................................................................................................................................ 16
6. External dimension parameter ............................................................................................................. 17
7. Some exposed parts of engine ............................................................................................................. 20
Chapter 3 Fuel and engine oil .......................................................................................................................... 22
1. Use and precautions of fuel ................................................................................................................. 22
2. Engine lubricating oil ........................................................................................................................... 24
3. Engine coolant ..................................................................................................................................... 25
Chapter 4 Nameplate Positions ........................................................................................................................ 26
1. Engine nameplate................................................................................................................................. 26
2. Nameplate of fuel injection pump ....................................................................................................... 27
3. Generator name plate ........................................................................................................................... 28
4. Start nameplate .................................................................................................................................... 29
5. Air compressor nameplate ................................................................................................................... 30
Chapter 5 Product Characteristics and Accessories ......................................................................................... 31
1. Product standard configuration ............................................................................................................ 31
2. Optional configuration ......................................................................................................................... 31
Part 2 Disassembly and assembly and adjustment ................................................................................................... 32
Chapter 1 Disassembly and assembly of valve mechanism ............................................................................. 32
1. Maintenance equipments and tools ...................................................................................................... 32
2. Torque requirement and data size ........................................................................................................ 32
3. Disassembly of valve mechanism ........................................................................................................ 42
4. Installation of valve mechanism .......................................................................................................... 48
Chapter 2 Disassembly and assembly of crank-link mechanism ..................................................................... 58
3. Disassembly of crank-link mechanism ................................................................................................ 66
4. Installation of crank-link mechanism................................................................................................... 73
Chapter 3 Cooling System ............................................................................................................................... 81
3. Disassembly and adjustment of cooling system .................................................................................. 83
4. Assembly and adjustment of cooling system ....................................................................................... 93
Chapter 4 Lubrication System ......................................................................................................................... 95
2.1 Torque requirement ............................................................................................................................ 95
1
2.2 Data size............................................................................................................................................. 96
3. Disassembly and assembly of lubrication part..................................................................................... 97
4. Disassembly and assembly of lubrication part..................................................................................... 99
Chapter 5 Starting System ............................................................................................................................. 100
1. Maintenance equipments and tools .................................................................................................... 100
2. Torque requirement ............................................................................................................................ 100
3. Disassembly of starting system.......................................................................................................... 101
4. Installation of starter system .............................................................................................................. 101
Chapter 6 Oil Feeding System ....................................................................................................................... 102
1. Maintenance equipments and tools .................................................................................................... 102
2. Torque requirement and data size ...................................................................................................... 102
3. Disassembly of oil feeding system .................................................................................................... 103
4. Oil feeding system assembly ............................................................................................................. 105
Chapter 7 Subsidiary Parts Disassembly Assembly And Adjustment ............................................................ 107
1. Data and Dimensions ......................................................................................................................... 107
2. Gear room disassembly and assembly ............................................................................................... 108
3. Structure chart of fuel injection pump ............................................................................................... 109
4. Fuel injector ....................................................................................................................................... 114
5. Flame heater plug .............................................................................................................................. 119
Part 3 Inspection, Adjustment, Diagnosis and Troubleshooting ............................................................................ 120
Chapter 1 Dynamic inspection....................................................................................................................... 120
1. Overview ........................................................................................................................................... 120
2. Inspect the engine oil level ................................................................................................................ 121
3. Inspect the level and status of coolant ............................................................................................... 122
4. Inspect the fan and the belt ................................................................................................................ 123
5. Inspect the fuel system....................................................................................................................... 124
6. Inspect the inlet and outlet system ..................................................................................................... 125
7. Inspect the electrical system .............................................................................................................. 126
8. Idling test of engine ........................................................................................................................... 127
Chapter 2 Operating Principle ....................................................................................................................... 128
1. Valve mechanism ............................................................................................................................... 128
2. Crankshaft and connecting rod mechanism ....................................................................................... 130
3. Lubrication system............................................................................................................................. 132
4. Fuel supply system ............................................................................................................................ 133
5. Cooling system .................................................................................................................................. 134
6. Electric system ................................................................................................................................... 136
Chapter 3 check and adjustment .................................................................................................................... 141
1. Valve lash clearance ........................................................................................................................... 141
2. Cylinder pressure ............................................................................................................................... 143
3. Fuel injection pump timing check ..................................................................................................... 144
4. Fuel injection pump calibration ......................................................................................................... 145
5. Fuel injector atomization ................................................................................................................... 146
6. Oil pressure check.............................................................................................................................. 147
7. Check and adjustment of the starter pinion place .............................................................................. 148
Chapter 4 Diagnosis and Troubleshooting ..................................................................................................... 149
2
1. White smoke ...................................................................................................................................... 149
2. Blue smoke ........................................................................................................................................ 149
3. Black smoke or gray smoke ............................................................................................................... 150
4. Low compression in cylinders ........................................................................................................... 150
5. Air intake system restriction .............................................................................................................. 152
6. Black smoke in exhaust ..................................................................................................................... 152
7. Unusual noise of the diesel engine..................................................................................................... 153
8. Engine is not running properly or frequently shut off........................................................................ 154
9. Low power output .............................................................................................................................. 155
10. Oil and water mix ............................................................................................................................ 156
11. Engine running overspend ............................................................................................................... 156
12. Engine speed surges ......................................................................................................................... 157
13. Engine is overheat............................................................................................................................ 157
14. Coolant temperature is out of normal .............................................................................................. 159
15. Zero or low lubricating oil pressure ................................................................................................. 160
16. Lubrication oil pressure high ........................................................................................................... 160
17. Lubricating oil temperature high ..................................................................................................... 161
18. Lubricating oil consumption excessive ............................................................................................ 161
19. Starting motor low speed ................................................................................................................. 162
20. Engine will not start or difficult to start ........................................................................................... 162
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Part I Overview
Chapter 1 Safety Precautions
This is a safety symbol. Safety symbols are found on

the tractor or in this manual. They highlight hazards
that may result personal injury.
The tips for operating procedure and safety

precautions must be strictly followed.
1. Scalding symbol
To avoid scalding, stand away from the hot surfaces of
the engine while it is running.
2. No-touching symbol
Do not touch the engine body while the engine is

running.
Do not maintain the engine until it shuts down and
cools for at least half an hour to ambient temperature.
Other symbols are described in the tractor

maintenance manual or operation instructions.
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3. Engine hoisting equipment
Correct equipment and method shall be used for

hoisting the engine. Recommended hoisting
equipment is as illustrated. Attach the chains to both
of the lifting eyes of the engine. Never use a single
lifting eye.
Before hoisting the engine, check that the lifting eyes

are tightened to 44N.m without damage and looseness.
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Chapter 2 Technical parameters
1. Main technical parameters
Note:
It will not be noticed if there are any changes for the products design and technical indicators.
D series engine
Model Unit QUANCHAI
Model —— QC4102T50 QC4102T55 QC4105T55 QC4105T60 QC4108T65 QC4108T70 QC4108T75
Type —— Upright, four-stroke, water-cooled
Number of
—— 4
cylinders
Cylinder bore ×
mm 102×118 105×118 108×118
stroke
Rated power kW 36.8 40.4 40.4 44 48 51.5 55
Rated rotation
r/min 2400
speed
Maximum torque N·m 212-217 227-233 240-245 235-250 260-270 260-270
Rotating speed at
maximum torque (r/min) 1600-1800
point
Fuel consumption
under rated
≤248
operating
conditions
(g/kW
Engine oil h)
consumption
under rated ≤1.6
operating
conditions
Lubrication mode —— Mandatory and splash lubrication
Startup mode —— Electrical starting
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4B series engine
Model Unit QUANCHAI
Model —— 4B4-35M22 4B2-40M22
Type —— Upright, four-stroke, water-cooled
Number of cylinders —— 4
Cylinder bore × stroke mm 85×100 90×100
Rated power kW 25.7 29.4
Rated rotation speed r/min 2350 2400
N·m/(r/m
Maximum torque/rotation speed ≥124/1750±100 ≥145/1650±100
in)
Fuel consumption under rated

≤245 ≤245
operating conditions
(g/kW h)
Engine oil consumption under
≤1.63 ≤1.63
rated operating conditions
Lubrication mode —— Pressure lubrication
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QC490T/QC495T/QC498T series engine
Model Unit QUANCHAI
Model —— QC490T40 QC495T45 QC495T50 QC498T50
Four-stroke, water-cooled, upright, direct injection combustion

Type ——
chamber
Number of cylinders —— 4
Cylinder bore × stroke mm 90×105 95×105 98×105
Rated power kW 29.4/2400 33.1/2400 36.8/2400 36.8/2400
Cylinder sleeve form —— Wet type Dry type
Rated rotation speed r/min 2400
Maximum torque N·m 155 170 175 190
Rotating speed at maximum

(r/min) 1800
torque point
The fuel consumption rate

with the rated working
≤248
condition under the total
power
The minimum fuel

consumption rate with (g/kW h)
≤238
external characteristic under
the total power
Engine oil consumption

under rated operating ≤1.6
conditions
Lubrication mode —— Pressure lubrication
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2. Filling capacity
QUANCHAI Engines
Model Unit
4102T/4105T/4108T 4B4-35M22/4B2-40M22 QC490T/QC495T/QC498T
Water volume of
6L 4.5 5
diesel engine
L
Engine oil sump 13L 5.5 8
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3. Main performance parameters of diesel engine
D series engine
50 55 55 60
Rated power of tractor (Ps) 65 horsepower 70 horsepower 75 horsepower
horsepower horsepower horsepower horsepower
Model QC4102T50 QC4102T55 QC4105T55 QC4105T60 QC4108T65 QC4108T70 QC4108T75
Type Four-stroke, water-cooled, upright, direct injection combustion chamber
Way of air inlet Naturally aspirated
Number of cylinders × cylinder bore × piston

4×102×118 4×105×118 4×108×118
stroke mm
Total displacement L 3.857 4.087 4.324
Cylinder distance mm 124
Ignition order 1-3-4-2
Net quality of engine kg 430
Size of engine (length/width/height) mm 932×626×760
Cylinder sleeve form Dry cylinder sleeve
Compression ratio 17:1
Rated air inlet volume of engine m3/h ≥236 ≥250 ≥265
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50 55 55 60
Air inlet resistance limits KPa System (including pipelines) inlet resistance≤5 (air filter alarm pressure is 6)
Standard heat dissipating capacity of engine KW ≤33 ≤35 ≤38 ≤40 ≤43
Total power /rotating speed (KW/rmin) 12h

41-43/2400 44-46/2400 47-49/2400 51-54/2400 55-57/2400 55-57/2400
power of rated point
Power/rotating speed (KW/rmin) 12h power of

36.8/2400 40.4/2400 40.4/2400 44/2400 48/2400 51.5/2400 55/2400
nameplate rated point
Torque value at maximum torque point N•m 212-217 227-233 240-245 235-250 260-270 260-270
Rotating speed at maximum torque point r/min 1650±100 1680±100
Torque value at 1000r/min (N•m) ≥154 ≥161 ≥175 ≥182 ≥190 ≥190
The fuel consumption rate with the rated working

≤248
condition under the total power g/(KW•h)
The minimum fuel consumption rate with external

≤238
characteristic under the total power g/(KW•h)
Engine oil consumption rate (12h working

≤1.6
condition of power) (g/KW.h)
Low idling speed r/min 700±30
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50 55 55 60
Steady state speed governing rate% ≤6
The maximum light-proof smoke value within the

≤2.0
full speed scope of engine m-1
(Rated rotating speed) exhaust back pressure KPa ≤10
Cold start adaptability to adapt temperature ℃ -5
Whether the emission standard/type certification

Stage II of Chinese non-road
is passed
Vibration (GB/T7184) Above Grade C4
Noise limit (sound power level) dB(A) ≤110
The highest altitude that is allowed to run

2000
constantly (m)
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4B series engine
Seri
al Rated power of tractor (Ps) 35 horsepower 40 horsepower
No.
1 Model 4B4-35M22 4B2-40M22
2 Type Four-stroke, water-cooled, upright
3 Way of air inlet Naturally aspirated
4 Fuel injection system Direct injection
Number of cylinders × cylinder bore × piston

5 4×85×100 4×90×100
stroke mm
6 Total displacement L 2.272 2.544
7 Cylinder distance mm 109
8 Ignition order 1-3-4-2
9 Net quality of engine kg About 285
10 Size of engine (length/width/height) mm As shown in the outline drawing
11 Cylinder sleeve form Wet sleeve
12 Compression ratio 18.5:1 18:1
13 Rated air inlet volume of engine m3/h ≥150 ≥180
System (including pipelines) inlet resistance≤5 (air

14 Air inlet resistance limits KPa
filter alarm pressure is 6)
Standard heat dissipating capacity of engine

15 ≤22
KW
Total power /rotating speed (KW/rmin) 12h

16 26.5/2350 32.4/2400
power of rated point
Power/rotating speed (KW/rmin) 12h power of

17 25.7/2350 29.4/2400
nameplate rated point
Equipower segment:Total power/scope of

18 25.7~26.5/2200~2350 29.4~32.4/2200~2400
rotating speed (KW/r/min)
19 Torque value at maximum torque point N•m 124~132 145~155
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Seri
al Rated power of tractor (Ps) 35 horsepower 40 horsepower
No.
20 Rotating speed at maximum torque point r/min 1650±100 1680±100
21 Torque value at 1000r/min (N•m) ≥94
The fuel consumption rate with the rated

22 working condition under the total power ≤248
g/(KW•h)
The minimum fuel consumption rate with

23 external characteristic under the total power ≤238
g/(KW•h)
Engine oil consumption rate (12h working

24 ≤1.63
condition of power) (g/KW.h)
25 Low idling speed r/min 800~850
26 Steady state speed governing rate% ≤8
The maximum light-proof smoke value within

27 ≤2.0
the full speed scope of engine m-1
(Rated rotating speed) exhaust back pressure

28 ≤10
KPa
29 Cold start adaptability to adapt temperature ℃ -5
Whether the emission standard/type

30 Stage II of Chinese non-road
certification is passed
31 Vibration (GB/T7184) Above Grade C4
32 Noise limit (sound power level) dB(A) ≤107
The highest altitude that is allowed to run

33 2000
constantly (m)
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QC490T/QC495T/QC498T engine
Serial
Rated power of tractor (Ps) 40 45 50 50
No.
1 Model QC490T40 QC495T45 QC495T50 QC498T50
Four-stroke, water-cooled, upright, direct injection combustion

2 Type
chamber
3 Way of air inlet Naturally aspirated
4 Ignition order 1-3-4-2
Number of cylinders × cylinder

5 4/90/105 4/95/105 4/98/105
bore mm × piston stroke mm
6 Cylinder distance 112
7 Total displacement L 2.672 2.977 3.168
8 Cylinder sleeve form Wet type Dry type
9 Compression ratio 18:1
Net quality of the whole engine

10 280 300 300 370
(Only for reference) kg
Size of diesel engine

11 880×612×749
(length/width/height) mm
Air inlet volume at the rated speed

≥185 ≥206 ≥219
of diesel engine Kg/h
12
Air outet volume at the rated
≥216 ≥243 ≥270
speed of diesel engine Kg/h
13 Air inlet resistance limits KPa ≤5
Standard Maximum power

≤26 ≤29 ≤31
heat point
14 dissipating
capacity of Maximum torque
engine kW ≤24 ≤27 ≤29
point
Total power/rotating speed at rated

15 point (kW)/(r/min) 32~34/2400 35~37/2400 37~38/2400 38~40/2400
(12h power)
16 Power/rotating speed of nameplate 29.4/2400 33.1/2400 36.8/2400 36.8/2400
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Serial
Rated power of tractor (Ps) 40 45 50 50
No.
rated point (KW)/(r/min)
(12h power)
Torque value at the maximum

17 torque point under total power 155~160 170~175 175~180 190~195
working condition N•m
Rotating speed at maximum

18 1600~1800
torque point r/min
19 Torque value at 1000r/min (N•m) ≥115 ≥129 ≥140 ≥140
The fuel consumption rate with

20 the rated working condition under ≤248
the total power g/(KW•h)
The minimum fuel consumption

21 rate with external characteristic ≤238
under the total power g/(KW•h)
Engine oil consumption rate

22 (12h power working condition) ≤1.6
(g/KW.h)
23 Low idling speed r/min 750±30
Steady state speed governing

24 ≤8%
rate%
Maximum light-proof smoke

25 ≤2.0
value of engine m-1
26 Exhaust back pressure KPa ≤10
Whether the emission

27 standard/type certification is Stage II of Chinese non-road/pass and obtain the certificate
passed
28 Vibration (GB/T7184) Above Grade C4
Noise limit (sound power level)

29 ≤108 ≤109
dB(A)
The highest altitude that is

30 2000
allowed to run constantly (m)
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4. Engine parameters
4102T/4105T/4108 4B4-35M22/4B2-4 QC490T/QC495T/

Project name Unit
T 0M22 QC498T
The radiator cover opening

KPa 40-50 43-53 43-53
pressure values
Engine oil temperature at the

℃ 93 93 93
825th turn

℃ 105 105 105
2200th turn

KPa 100 100 100
825th turn

KPa 250-480 250-480 250-450
2200th turn
The maximum explosion

KPa 10000 2400 2400
pressure of cylinder
Maximum differential pressure

KPa 500 350 350
among cylinders
Minimum idle speed of engine r/min 700 800 800
Maximum idle speed of engine r/min 2540 2650 2650
Fuel injection pump bolts

N.m 70 70 70
assembly torque
Intake valve lash adjustment mm 0.3-0.35 0.3 0.3
Exhaust valve lash adjustment mm 0.35-0.4 0.35 0.3
Belt tension N 98 98 98
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5. Torque value
Serial
Description Unit 4102T/4105T/4108T 4B4-35M22/4B2-40M22 QC490T/QC495T/QC498T
No.
Cylinder
1 N.m 200-220 145~155 120-140
cover bolts
Rocker arm
2 shaft support N.m 21-25
long bolts
Cylinder head
3 N.m 21-25
cover nut
Connecting
4 N.m 100-120 60~70 100~110
rod bolt
Main bearing
5 N.m 180-200 140~160
cap bolts
Water pump
connected to
6 N.m 25
the engine
body
Engine oil
pump
7 assembly in N.m 25
the engine
body
Starter is
connected
8 N.m 80
with flywheel
housing
Fuel injection
pump is
9 connected N.m 70
with gear
chamber
Fuel injection
10 N.m 29-39 40~60
nozzle nut
Fired heater
assembly on
11 N.m 60~70
the air inlet
pipe
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6. External dimension parameter
D series engine
QUANCHAI
Model Unit
4102T 4105T 4108T
Power Ps 36.8 40.4 40.4 44 48 51.5 55
Length 932
External
Width mm 626
dimensions
Height 760
Width of oil sump mm 291
Height from water

pump to crankshaft mm 302
center
Fan diameter mm 450
Quality kg 430
4B series engine
QUANCHAI
Model Unit
4B4-35M22 4B2-40M22
Power Ps 35 40
Exter Length 820.5

nal
dime Width mm 568
nsion
s Height 641
Width of oil sump mm 270
Height from water pump to

mm 260
crankshaft center
Fan diameter mm 380
Quality kg 285
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QC490T/QC495T/QC498T Engine
QUANCHAI
Model Unit
QC490T40 QC495T45 QC495T48 QC498T50
Power Ps 40 45 48 50
Length 828
External
Width mm 630
dimensions
Height 710
Height from water pump to

241
crankshaft center
Fan diameter 420
Quality kg 300 370
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7. Some exposed parts of engine
7.1 Left side of engine
1-Fan 2-Thermostat cover 3-Cylinder cover 4-Filler cap 5-High-pressure oil pipe 6-Fuel injector
7-Flame heater plug 8-Cylinder cover 9-Air intake pipe 10-Air inlet pipe 11-Air pump 12-High-pressure
oil pump -Connecting plate -Engine body -Oil sump -Oil filter -Diesel filter -Flywheel housing
19-Flywheel
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7.2 Right side of engine
20-Breather 21-Exhaust pipe 22-Starter motor 23-Generator 24-Gear chamber 25-Gear chamber
26-Water pump 27-Belt of alternator 28-Belt tensioner 29-Water pump belt 30-Crankshaft pulley
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Chapter 3 Fuel and engine oil
1. Use and precautions of fuel
1.1 Storage of fuel
The fuel is avoided to be stored for too long time, if

the diesel in the fuel tank or transport tank revolves
slowly, the fuel regulator should be added in order to
prevent water concentration.
You should contact with the supplier of LOVOL to

obtain the suitable use and maintenance suggestions.
Please purchase high-quality clean fuel from dealers

with good reputation.
Suitable fuel storage is very important, you can use

clean warehouse and oil tank to store them, and
regularly discharge water and precipitate from the
bottom.
The fuel is stored at the convenient place; please keep

them away the building.
Note:
In order to reduce fuel gelatinization and control wax
separation, in cold weather, fuel regulator can be
added or it can be stored in bulk.
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1.2 Precautions for fuel use
The biodiesel conforming to DIN51606 or diesel with

equivalent performance are allowed.
The diesel cannot be mixed with oil or other type of

lubricants.
Before the diesel is injected into the fuel tank, be

certain that the diesel is deposited (generally above 48
hours), and then filtered to remove foreign bodies, and
prevent severe wear of the precise parts (plunger and
barrel assembly, delivery valve assembly, and needle
valve assembly) the fuel system resulted from the
foreign bodies.
In case of lack of low condensation point light diesel

in a cold area and in a cold season, it is possible to use
the exhaust gas or circulating water for preheating and
heat insulation of the fuel tank and fuel delivery pipe
and improving fluidity of the diesel, so as to use a
high condensation point light diesel.
Also we recommend you use following oil of

equivalent international brands:
ASTM D-975 2-D (≥ +5℃)

ASTM D-975 1-D (≤ +5℃)
1.3 Refuel
You should refuel according to the oil level indicator

of fuel tank.
The specific refueling position should be shown in TE,
TB and TA Tractor Maintenance Manuals.
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2. Engine lubricating oil

Lubricating oil:
You should choose CD or above grade engine oil and
the viscidity grade can be selected according to the
environment temperature as shown in the following
table.
Other equivalent international brand is suggested to
use:
SAE 15W-40 (API CD) (≥ -5℃)
SAE 10W-40 (API CD) (≤ -5℃)

It is better to choose the engine oil with more
viscosity.
The above recommended engine oil is used to extend
the service cycle. Contact with the supplier of LOVOL
specifically.
Appropriate
Serial Engine oil
environment Remarks
No. brand
temperature
1 15W/40 Above -5℃
2 10W/30 -5℃~-20℃
3 5W/30 Below -20℃
Notice:
1. It is necessary to choose appropriate engine oil
brand according to environment temperature, and
change it regularly as regulated.
2. Different types of engine oils cannot be mixed to
use in order to prevent chemical reaction that can
make engine oil deteriorated and lose efficacy.
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3. Engine coolant
The cooling water should be the clean soft water,

such as river water, rainwater, snow water, tap water,
etc. Because the soft water contains few mineral
substances, after heating, there are few incrustations,
which is not easy to cool down and the system is easy
to be blocked so that affects heat dissipation. If the
hard water is used because the soft water is hard to
obtain, such as well water, spring water or other hard
water with much mineral substances should be
softened. The easiest handling method is to first boil
the water and then precipitate, finally use after
removing impurities.
If the diesel engine is used in cold weather, you
should firstly look around the environment
temperature; add an appropriate amount of
anti-freezing solution which can be mixed by alcohol
and glycerin or use ethanediol in cooling water.
We recommend you to use following coolant for

engine:
ASTM D3306
SAE J1034
SAE 814c
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Chapter 4 Nameplate Positions
1. Engine nameplate
Diesel engine nameplate information mainly include

the manufacturer, type, rated power/rated rotating
speed, type approval number, diesel engine number,
production date, supply number and net weight of
diesel engine.
Notice:
In order to ensure the engine fittings report
accurately, when the clients report the demands, the
nameplate information should be provided together
to the company.
Engine nameplate position

Nameplate should be located on the top and side of
cylinder head cover or air inlet pipe.
QC495T\QC498T
QC490T
4B series
D series
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2. Nameplate of fuel injection pump
Fuel injection pump nameplate information
Fuel injection pump nameplate information includes

figure number, model, order number, factory number
and manufacturer.
Position of fuel injection pump
A- Nameplate of fuel injection pump
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3. Generator name plate
Alternator nameplate information includes power,

voltage, figure number, telephone number and
manufacturer.
Generator nameplate position
A- Generator name plate
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4. Start nameplate
Starter nameplate information includes model,

voltage, power, supply number, production date and
manufacturer.
Start nameplate position
A- Nameplate of starter motor
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5. Air compressor nameplate
Air compressor nameplate includes model, figure

number, production date and manufacturer.
Air compressor nameplate position

The air compressor nameplate is located at the
middle part of air compressor.
A- Air compressor nameplate
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Chapter 5 Product Characteristics and Accessories
1. Product standard configuration
Engine introduction:
Diesel engine:
4-cylinder
Straight and water-cooled
Four-stroke high-speed diesel engine
Application of the diesel engine

Dry cylinder sleeve
Wet sleeve
Naturally aspirated
Direct injection mode
Configuration includes:
Starter motor
Generator
Flame heater plug.
2. Optional configuration
Air compressor assembly can be selected according to

the requirements of complete engine.
A- Air compressor
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Part 2 Disassembly and assembly and adjustment
Chapter 1 Disassembly and assembly of valve mechanism
1. Maintenance equipments and tools
Note:
Special tools
Torque wrench
2. Torque requirement and data size
2.1 Torque requirement
Measurem QC490T/QC495T/
Item D series engine 4B series engine Remarks
ent Unit QC498T
Cylinder cover fixed

N.m 200-220 145-155 120-140
bolts
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2.2 Data size
This information is provided to guide engine overhauling personnel and data presented herein is used for
factories.
Cylinder cover-D series

Exhaust valve------------------------------------------------------------------------------------------------------------- 90°
Intake valve--------------------------------------------------------------------------------------------------------------- 90°
The original installation hole diameter of valve shaft guide-------------------------------------------------- 14mm
Leakage test pressure-------------------------------------------------------------------------------------------------- 600Ka
Thickness of cylinder cover------------------------------------------------------------------------------------------- 95mm
The minimum allowable thickness of cylinder cover after processing------------------------------------- 94.9mm
Cylinder cover- 4B series

Exhaust valve------------------------------------------------------------------------------------------------------------- 90°
Intake valve--------------------------------------------------------------------------------------------------------------- 90°
Leakage test pressure-------------------------------------------------------------------------------------------------- 400KPa
Cylinder cover-QC490T/QC495T/QC498T
Exhaust valve------------------------------------------------------------------------------------------------------------- 90°
Intake valve--------------------------------------------------------------------------------------------------------------- 120°
Leakage test pressure-------------------------------------------------------------------------------------------------- 400KPa
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Intake valve- D series

Valve rod diameter----------------------------------------------------------------------------------------------------- 9mm
Valve shaft guide clearance------------------------------------------------------------------------------------------ 0.1mm
The maximum clearance of valve shaft guide------------------------------------------------------------------- 0.13mm
Valve head diameter--------------------------------------------------------------------------------------------------- 45mm
Valve cone angle-------------------------------------------------------------------------------------------------------- 90°
Full length---------------------------------------------------------------------------------------------------------------- 128mm
Sealing mode------------------------------------------------------------------------------------------------------------ valve seal
Intake valve- 4B series

Valve cone angle-------------------------------------------------------------------------------------------------------- 90°
Full length---------------------------------------------------------------------------------------------------------------- 117.5mm
Intake valve-QC490T/QC495T/QC498T
Valve cone angle-------------------------------------------------------------------------------------------------------- 120°
Full length---------------------------------------------------------------------------------------------------------------- 125mm
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Exhaust valve- D series

Valve cone angle-------------------------------------------------------------------------------------------------------- 90°
Full length---------------------------------------------------------------------------------------------------------------- 128mm
Exhaust valve- 4B series

Valve cone angle-------------------------------------------------------------------------------------------------------- 90°
Full length---------------------------------------------------------------------------------------------------------------- 117.5mm
Exhaust valve-QC490T/QC495T/QC498T
Valve cone angle-------------------------------------------------------------------------------------------------------- 90°
Full length---------------------------------------------------------------------------------------------------------------- 125mm
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Valve shaft guide- D series

Inner diameter---------------------------------------------------------------------------------------------------------- 9mm
Outer diameter--------------------------------------------------------------------------------------------------------- 14mm
Seal joints of valve shaft guide and cylinder cover------------------------------------------------------------- H7/u7
The bottom length of valve spring extruding groove---------------------------------------------------------- 48.7mm
Valve shaft guide- 4B series

Seal joints of valve shaft guide and cylinder cover------------------------------------------------------------- H7/u6
The bottom length of valve spring extruding groove---------------------------------------------------------- 39.7mm
Valve shaft guide -QC490T/QC495T/QC498T

Seal joints of valve shaft guide and cylinder cover------------------------------------------------------------ H8/h7
The bottom length of valve spring extruding groove--------------------------------------------------------- 44.5mm
Dual-valve spring * outside- D series

Installation length----------------------------------------------------------------------------------------------------- 48.7mm
Loading of installation length--------------------------------------------------------------------------------------- 175N
Valid number of winding--------------------------------------------------------------------------------------------- 5
Direction of spring rotation----------------------------------------------------------------------------------------- Right-hand
Dual-valve spring * outside- 4B series

Valid number of winding--------------------------------------------------------------------------------------------- 4.25
Number of suspension coils----------------------------------------------------------------------------------------- 6.25
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Dual-valve spring * outside-QC490T/QC495T/QC498T

Dual-valve spring * inside- D series

Dual-valve spring * inside- 4B series

Dual-valve spring * inside-QC490T/QC495T/QC498T

Number of suspension coils----------------------------------------------------------------------------------------- 8
Tappet- D series
Tappet diameter------------------------------------------------------------------------------------------------------- 28mm
Tappet hole diameter on cylinder--------------------------------------------------------------------------------- 28mm
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Tappet clearance on cylinder--------------------------------------------------------------------------------------- (0.04-0.076)mm

Tappet rod- 4B series
Tappet rod diameter-------------------------------------------------------------------------------------------------- 8mm
Tappet rod hole diameter on cylinder---------------------------------------------------------------------------- 14 mm
Tappet rod clearance on cylinder---------------------------------------------------------------------------------- (0.016~0.052)mm
Tappet rod-QC490T/QC495T/QC498T
Tappet rod diameter-------------------------------------------------------------------------------------------------- 8mm
Tappet hole diameter on cylinder--------------------------------------------------------------------------------- 15 mm
Tappet clearance on cylinder--------------------------------------------------------------------------------------- (0~0.027)mm
Rocker arm shaft- D series

Outer diameter-------------------------------------------------------------------------------------------------------- 20mm
Rocker arm shaft- 4B series

Rocker arm shaft-QC490T/QC495T/QC498T

Rocker arm and bushing- D series

Original installation hole diameter of bushing----------------------------------------------------------------- 24mm
Outer diameter of bushing----------------------------------------------------------------------------------------- 24mm
The interference assembly of rocker arm in bushing-------------------------------------------------------- H7/s7
The inner diameter of bushing after reaming----------------------------------------------------------------- 20F7
The clearance between rocker arm bushing and rocker arm shaft--------------------------------------- (0.02-0.066)mm
The maximum allowable clearance between rocker arm bushing and rocker arm shaft----------- 0.15 mm
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Rocker arm and bushing- 4B series

Original installation hole diameter of bushing---------------------------------------------------------------- 22mm
Rocker arm and bushing-QC490T/QC495T/QC498T

Original installation hole diameter of bushing---------------------------------------------------------------- 22mm
Camshaft- D series
Journal 1 diameter--------------------------------------------------------------------------------------------------- 57mm
All journal clearances------------------------------------------------------------------------------------------------ (0.05-0.099)mm
Camshaft- 4B series
All journal clearances------------------------------------------------------------------------------------------------ (0.05-0.075) mm
Camshaft-QC490T/QC495T/QC498T
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All journal clearances------------------------------------------------------------------------------------------------ (0.025-0.085)mm

Cam lift- D series
Intake valve------------------------------------------------------------------------------------------------------------ 7.8mm
Exhaust valve---------------------------------------------------------------------------------------------------------- 7.8mm
The maximum allowable ovality and wearing capacity of journal---------------------------------------- 0.22mm
Cam lift- 4B series

Intake valve------------------------------------------------------------------------------------------------------------ 6.25mm
Exhaust valve---------------------------------------------------------------------------------------------------------- 6.25mm
Cam lift-QC490T/QC495T/QC498T
Intake valve------------------------------------------------------------------------------------------------------------- 6.55mm
Exhaust valve---------------------------------------------------------------------------------------------------------- 6.55mm
Axial clearance- D series

Production limit------------------------------------------------------------------------------------------------------- (0.07-0.22)mm
Maintenance limit---------------------------------------------------------------------------------------------------- 0.32mm
Axial clearance- 4B series

Axial clearance-QC490T/QC495T/QC498T
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Camshaft gear wheel- D series

Number of teeth------------------------------------------------------------------------------------------------------ 52 teeth
Aperture---------------------------------------------------------------------------------------------------------------- 30mm
Outer diameter of camshaft hub--------------------------------------------------------------------------------- 140.24mm
Fit clearance of gear on hub--------------------------------------------------------------------------------------- H7/K6
Camshaft gear wheel 4B series

Aperture---------------------------------------------------------------------------------------------------------------- 34mm
Outer diameter of camshaft hub--------------------------------------------------------------------------------- 123.19mm
Fit clearance of gear on hub--------------------------------------------------------------------------------------- H7/js7
Camshaft gear wheel-QC490T/QC495T/QC498T

Aperture---------------------------------------------------------------------------------------------------------------- 30mm
Outer diameter of camshaft gear hub--------------------------------------------------------------------------- 131.59mm
Fit clearance of gear on hub--------------------------------------------------------------------------------------- H7/js6
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3. Disassembly of valve mechanism
3.1 Disassembly of cylinder head cover
Disassemble the nut A and sealing gasket B of cylinder

head cover and take down the cylinder head cover C.
A- Cylinder cover nut C

A
B-Combined sealing washer
C-Cylinder head cover
B
3.2 Disassembly of valve rocker arm assembly
1. See Section 3.1 in this chapter for disassembly of

cylinder head cover.
2. Disassemble rocker arm bracket bolt IA and rocker
arm bracket bolt IIB, and disassemble rocker arm C
B
bracket assembly C. A
3. Take out the tappet.
A- Rocker arm bracket bolt Ⅰ
B-Rocker arm bracket bolt Ⅱ

C-Rocker arm bracket assembly
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3.3 Disassembly of valve rocker arm

2. See Section 3.2 of this chapter for disassembly of
valve rocker arm assembly.
3. Disassemble screw B, nut I and bolt J, then
dissemble ring K on both ends of valve rocker arm
assembly.
4. Disassemble adjustment screw G and adjustment
nut H, take down rocker arm bracket C, rocker arm
bracket D, rocker arm shaft spring E and valve rocker
arm F on the rocker arm shaft successively.
A- Rocker arm shaft

B-Screw
C-Rocker arm bracket I (oil hole available)
D-Rocker arm bracket II (oil hole available)
E-Rocker arm shaft spring
F-Valve rocker arm
G-Valve clearance adjusting screw
H-Valve clearance adjusting nut
I-Nut
J-Bolt
K-Collar
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3.4 Disassembly of inlet and exhaust manifold
1. Disassemble the bolt, and take down exhaust pipe

A and exhaust pipe gasket B.
2. Disassemble the bolt, and take down inlet pipe F
and inlet pipe gasket E.
3. Disassemble the bolt, and take down lug C, inlet
pipe D and inlet pipe gasket G.
A- Exhaust pipe
B-Exhaust pipe gasket
C-Lug
D-Air intake pipe
E-Air inlet pipe pad
F- Air inlet pipe
G- Air inlet pipe pad
3.5 Disassembly of oil injector assembly
Disassemble the high-pressure oil pipe, oil injector

follower bolt, oil injector follower and oil injector
respectively according to the order.
A- High-pressure oil pipe assembly

B-Oil injector follower
C-Oil injector follower bolt
D-Fuel injector
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3.6 Disassembly of cylinder cover

inlet and exhaust manifold.
oil injector assembly.
5. Disassemble the cylinder cover bolt A, and take
down cylinder head gasket B and cylinder cover
assembly.
Notice:
The bolts should be gradually unscrewed according to
the diagonal order when disassembly to prevent
deformation of cylinder cover.
The joint surface of the cylinder cover should not be
damaged when storage.
A- Cylinder cover bolts

B-Cylinder cover gasket
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3.7 Disassembly of inlet and exhaust valve
Tools:
Valve spring compressor

cylinder cover assembly.
2. You should use the valve spring compressor to
disassemble locking plate B, and take out upper valve
spring bracket A, outer valve spring C, inner valve
spring D, valve oil seal E, valve shaft guide F, intake
valve G, exhaust valve J, intake valve retainer H and
exhaust valve retainer I successively.
Notice:
You should mark properly at the valve end upon
disassembly of it to ensure it to be installed to the
original location when reuse.
A- Upper bracket of valve spring

B-Valve locking clamp
C-Outer valve spring
D-Inner valve spring
E-Valve oil seal
F- Valve shaft guide
G- Intake valve
H-Intake valve retaine
I-Exhaust valve retainer
J-Exhaust valve
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3.8 Disassembly of camshaft
1. See Chapter 3 in this Part for disassembly of the

cooling system
3. See Section 2 of Chapter 7 in this Part for
disassembly of gear chamber cover and camshaft
timing gear.
4. See Section 3 of Chapter 2 in this Part for
disassembly of flywheel and flywheel housing.
Notice:
Special puller device should be used for disassembly
of timing gear.
A- Bolt
B-Camshaft timing gear
4. You should invert the engine to disassemble

camshaft D on engine side, and use the special tool to
take out camshaft bushing A, B and C.
Notice:
Oil should be discharged prior to the inversion of
engine.
The rear bowl plug of camshaft is a disposable part
and must be replaced.
A- Camshaft rear bushing

B-Camshaft middle bushing
C-Camshaft front bushing
D-Camshaft
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4. Installation of valve mechanism
4.1 Installation of cylinder head cover
1. Install the cylinder head cover gasket and cylinder

head cover C.
Notice:
The cylinder cover and sealing gasket surfaces should
be cleaned prior to installation.
2. Install sealing gasket B and fasten the nut A.
A- Cylinder cover nut

B-Combined sealing washer
C-Cylinder head cover
Tightening torque -----------------------------21~25N.m
4.2 Installation of valve rocker arm assembly
1. Install tappet rod.

Notice:
The tappet rod sphere should be put into the tappet
groove.
2. Install valve rocker arm assembly C and fasten bolt
A and B.
Notice:
Unscrew the valve clearance adjusting screws prior to
installation to prevent damages to valve rocker arm.
The adjusting screw should be put into the tappet rod
groove.
A- Rocker arm bracket bolt Ⅰ
B-Rocker arm bracket bolt Ⅱ

C-Rocker arm bracket assembly
Tightening torque -----------------21~25N.m
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4.3 Installation of valve rocker arm
1. Install ring K on one end of rocker arm shaft A,

install front rocker arm bracket C, and valve rocker
arm F, rocker arm bracket D, valve rocker arm F, and
valve arm bracket spring E successively, and install
ring K on the other end after completion of the four
groups above.
Notice:
If the clearance of rocker arm on rocker arm shaft
exceeds 0.13mm, you should replace rocker arm
bushing or rocker arm shaft.
The lubrication hole of new bushing should be aligned
with the rocker arm. After reaming, the clearance
between it and rocker arm should be 0.03/0.09mm.
2 .Install tightening bolt J and nut I of rocker arm

shaft.
A-Rocker arm shaft
B-Screw
C-Rocker arm bracket Ⅰ (oil hole available)
D-Rocker arm bracket Ⅱ (oil hole available)

E-Rocker arm shaft spring
F-Valve rocker arm
G-Valve clearance adjusting screw
H-Valve clearance adjusting nut
I-Nut
J-Bolt
K-Collar
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4.4 Disassembly of inlet and exhaust manifold Tightening torque ---------------------58~71N.M
1. Install exhaust pipe basket B, exhaust manifold A

and lug C and use bolts to fasten them.
2. Install inlet pipe basket G, inlet manifold D and lug
C and use bolts to fasten them.
3. Install inlet pipe F and inlet pipe basket E and use
bolts to fasten them.
Notice:
Binding agents are not allowed for installation of inlet
and exhaust manifold.
A- Exhaust pipe
B-Exhaust pipe gasket
C-Lug
D-Air intake pipe
E-Air inlet pipe pad
F- Air inlet pipe
G- Air inlet pipe pad
4.5 Installation of oil injector assembly
1. Install oil injector D and connect oil return pipe of

oil injector.
2. Install oil injector follower B and fasten bolt C.
3. Install high-pressure oil pipe A, and tighten all
high-pressure oil pipe connectors.
Notice:
Check whether the oil injector is normal prior to
assembly; see Section 4 of Chapter 7 in this Part for
specific check standards.

B-Oil injector follower
C-Oil injector follower bolt
D-Fuel injector
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4.6 Installation of cylinder cover
Notice:
Clean the cylinder cover prior to assembly to ensure it
clean.
Replace the bowl plug prior to assembly to ensure
sealing effects.
1. Install cylinder gasket B, install cylinder cover
according to the position of engine locating bushing
and fasten cylinder cover bolt A.
Notice:
Ensure that locating pin has been inserted into the
cylinder prior to installation to prevent damages to
cylinder cover gasket. Binding agents are not allowed
for installation of cylinder cover gasket.
The surface indicated “TOP” will face upwards upon
installation of cylinder gasket.
Clean the undersurface and top-surface of cylinder
cover prior to assembly and ensure it free of chips in
the cylinder bore.
Tighten the cylinder cover in diagonal order, ensure
even stresses of cylinder cover and gasket, and
correct locating to prevent deformation.
A-Cylinder cover bolts
B-Cylinder cover gasket
Tightening torque -------------------200-220N.m
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4.7 Installation of inlet and exhaust valve
1. Install valve shaft guide F, intake valve retainer H

and exhaust valve retainer I.
2. Install valve oil seal E, intake valve G, exhaust valve
J, inner valve spring D, outer valve spring C, upper
valve spring support A and valve locking clamp B
successively.
3. Install the rest intake valves successively according
to the above requirements.
Note:
Use valve spring compressor when installing valve
locking clamp to avoid damages to the parts.
A- Upper bracket of valve spring

B-Valve locking clamp
C-Outer valve spring
D-Inner valve spring
E-Valve oil seal
F- Valve shaft guide
G- Intake valve
H-Intake valve retaine
I-Exhaust valve retainer
J-Exhaust valve
Special tools:
1-Valve spring compressor
2-Stud connector
3-Locating screw connector
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4.8 Installation of camshaft
Notice:
Use white silk fabric to clean bearing holes and check
whether there is any a scratch, dusts or oil dirt in the
camshaft bushing prior to installation.
Do not crush and damage inner holes of camshaft
bushing because it will not be processed after
assembly.
1. After pressing of camshaft bushing, the oil hole of
bushing and the cylinder oil passage hole should be
aligned.
2. The camshaft bushing should be paralleled to the
front end of cylinder.
Notice:
Fitness data of camshaft bushing hole should be
(0-0.03) mm.
A- Camshaft rear bushing

B-Camshaft middle bushing
C-Camshaft front bushing
D-Camshaft
3. Installation of the camshaft timing gear.

Notice:
All timing gears should be marked with alignment
prior to installation.
A- Bolt
B-Camshaft timing gear
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4.9 Valve seat alignment
Special tools:
Intake valve seat cutter
Exhaust valve seat cutter
Guide rod used for valve seat cutter fitness
Handle bushing used for valve seat cutter fitness
Notice:
The new valve shaft guide must be installed prior to
any actions are made to the valve seat.
1. Install the guide rod into the valve shaft guide and
fasten the guide rod.
2. Select appropriate cutter, adjust the blade of the
cutter to the diameter of valve seat, install the cutter
to the guide rod and install handle.
Note:
The cutter is not allowed to fall below the valve seat,
otherwise it may damage the cutter edge.
3. Clockwise rotate the cutter carefully to perform the

minimum cutting to ensure intact valve seat.
4. After reaming of valve seat, disassemble the cutter
and guide rod, remove cutting chips at valve seat and
around the guide rod.
5. Install the valve and slightly grind the valve and
valve seat.
6. Check whether the valve depth is within the limit.
Note:
In case of correction not available due to severe
damage or wear to the valve seat, valve seat insert
can be installed or valve retainer can be replaced.
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4.10 Clearance check of valve shaft guide
Check whether the valve shaft guide is worn:

New valve shaft guide must be installed if its
clearance exceeds the limit after installation of the
new valve.
The following steps are recommended to check valve
shaft guide clearance:
1. Put a new valve in the new valve shaft guide.
2. Put a dial indicator (with magnetic base) on the
cylinder cover surface.
3. Lift the valve by 15mm, use gauge to contact the
edge of valve head, take the valve away from the D
gauge in radical direction, and zero set the dial A
indicator when the valve maintained is in the B
position. E
4. Let the valve cross over the axis of cylinder cover

and towards the gauge, and record readings of the
gauge. A new valve shaft guide must be installed if
the measuring results are equal to or exceed the
following data.
The maximum allowable clearance when the valve is C
lifted by 15mm:
nlet valve guide: 0.24mm
Exhaust valve guide: 0.32mm
A- Dial indicator
B-Gauge
C-Valve head
D-Valve shaft guide
E-The maximum clearance of valve rod and guide hole
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4.11 Adjustment of the valve lash
Special tools:
Feeler gauge
A- Feeler gauge
Operating sequence of four-cylinder engine should be:

1-3-4-2
Regulating sequences:
Double exhaust valve without intake
How to locate the Top Dead Center (TDC) on cylinder
1:
There is two pointers on the crankshaft pulley and
gear chamber, you should align the pointers to see
whether cylinder 1 moves, it will be TDC on the
exhaust valve if one of them slightly moves; it will be
TDC on compressor if both of them don’t move, and
you adjust the valve at this moment. Adjust according
to the “double exhaust valve without intake” rule and
in 1-3-4-2 order.
Namely:
Adjust the intake and exhaust valve of cylinder 1
Adjust the exhaust valve of cylinder 3
Do not adjust cylinder 4
Adjust the intake valve of cylinder 2
Rotate the flywheel one lap after adjustment, adjust
the exhaust valve of cylinder 2, intake valve of
cylinder 3 and intake and exhaust valve of cylinder 4.
Specifications:
Intake valve (cold state) 0.30mm
Exhaust valve (cold state) 0.35mm
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Chapter 2 Disassembly and assembly of crank-link mechanism
Special tools:
Open spanner, 17mm sleeve spanner, 21mm sleeve spanner, digital display torque spanner and adjustable torque
spanner
Measureme QC490T/QC495T/QC Remar

Item D series engine 4B series engine
nt Unit 498T ks
Connecting
N·m 100-120 60~70 100~110
rod bolt
Main bearing
N·m 180-200 140~160 140~160
bolt
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2.2 Data size
factories.
Poston ring-D series natural inlet
The first ring--------------------------------------------------------------- Trapezoid barrel-face ring, modular cast iron
The second gaseous ring----------------------------------------------------------------- Twisted taper-face ring, alloy cast iron
Oil ring--------------------------------------------------------------------------------------- Compression coil spring
Width of the first ring---------------------------------------------------------------------------- 3.0mm
Width of the second ring------------------------------------------------------------------------ 2.5mm
Width of the second ring------------------------------------------------------------------------ 5mm
The clearance of the first ring in groove---------------------------------------------------- (0.08~0.12)mm
The clearance of the second ring in groove------------------------------------------------ (0.05~0.09)mm
The clearance of the third ring in groove--------------------------------------------------- (0.04~0.075)mm
The closed clearance of the first ring-------------------------------------------------------- (0.3~0.5)mm
The closed clearance of the second ring---------------------------------------------------- (0.45~0.65)mm
The closed clearance of the third ring------------------------------------------------------- (0.25~0.45)mm
Piston ring -4B series natural inlet

The first gaseous ring-------------------------------------------------- Barrel-face ring, with chamfer at top of inner surface
The second gaseous ring------------------------------------------------------------------------ cone, cast iron
Oil ring---------------------------------------------------------------------------------------- YH11 chromium-copper alloy cast iron
Width of the first ring--------------------------------------------------------------------------- 2.5mm
Width of the second ring----------------------------------------------------------------------- 2.5mm
Width of the second ring----------------------------------------------------------------------- 5mm
The closed clearance of the first ring-------------------------------------------------------- (0.3~0.5)mm
The closed clearance of the second ring---------------------------------------------------- (0.25~0.45)mm
The closed clearance of the third ring------------------------------------------------------- (0.2~0.4)mm
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Piston ring - QC490T/ QC495T /QC498T natural inlet

The first gaseous ring-------------------------------------------------- Barrel-face ring, with chamfer at top of inner surface
The second gaseous ring------------------------------------------------------------------------ cone, cast iron
Oil ring---------------------------------------------------------------------------------------------- alloy cast iron
Width of the first ring--------------------------------------------------------------------------- 2.5mm
Width of the second ring----------------------------------------------------------------------- 2.5mm
Width of the second ring----------------------------------------------------------------------- 5mm
Opening clearance of the first ring----------------------------------------------------------- (0.25~0.45)mm
Opening clearance of the second ring------------------------------------------------------- (0.3~0.5)mm
Opening clearance of the third ring---------------------------------------------------------- (0.3~0.5)mm
Connecting rod -D series natural inlet

Type------------------------------------------------------------------------ H section
Locating of connecting rod cap and connecting rod body----------------------------- Tooth type
The original installation hole diameter of large end------------------------------------- 70mm
The original installation hole diameter of small end------------------------------------ 32mm
Centre distance------------------------------------------------------------------------------------ 192mm
Connecting rod -4B series natural inlet

Type-------------------------------------------------------------------------------------------------- H section
Locating of bearing cover and connecting rod-------------------------------------------- bolt pin
Connecting rod-QC490T/ QC495T /QC498T natural inlet

Type-------------------------------------------------------------------------------------------------- H section
Locating of bearing cover and connecting rod-------------------------------------------- bolt pin
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Connecting rod bearing-D series

Type---------------------------------------------------------------------------------------------- steel back, aluminum / tin material
Width of connecting rod bearing--------------------------------------------------------- 31mm
Thickness of connecting rod bearing---------------------------------------------------- 2mm
Connecting rod bearing-4B series

Type---------------------------------------------------------------------------------------------- steel back, aluminum / tin material
Connecting rod bearing-QC490T/QC495T/QC498T

Type---------------------------------------------------------------------------------------------- steel back, aluminum/tin material
Piston pin -D series natural inlet

Type---------------------------------------------------------------------------------------------- full floating type
Outer diameter-------------------------------------------------------------------------------- 36mm
Clearance fit in the piston pin hole------------------------------------------------------- (-0.03~0.096)mm
Piston pin-4B series natural inlet

Type---------------------------------------------------------------------------------------------- full floating type
Outer diameter ------------------------------------------------------------------------------- 28mm
Clearance fit in the piston shaft sleeve ------------------------------------------------- (0~0.018)mm
Piston pin - QC490T/ QC495T /QC498T natural inlet

Type --------------------------------------------------------------------------------------------- full floating type
Outer diameter-------------------------------------------------------------------------------- 32mm
Clearance fit in the piston shaft sleeve------------------------------------------------- (0.001~0.016)mm
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Small end bushing-D series natural inlet

Type-------------------------------------------------------------------------------------------------- full floating type
Outer diameter------------------------------------------------------------------------------------ 40mm
Inner diameter------------------------------------------------------------------------------------- 36mm
The clearance of small end shaft sleeve and piston pin-------------------------------- (0.011~0.031)mm
Small end bushing-4B series natural inlet

Small end bushing-QC490T/ QC495T /QC498T natural inlet

Main shaft-D series
Main journal diameter--------------------------------------------------------------------------- ￠80mm

The maximum wearing capacity and ovality of main journal and rod journal---- 0.10mm
Width of front main journal-------------------------------------------------------------------- 33mm
Width of central main journal----------------------------------------------------------------- 35mm
Widths of all other main journals------------------------------------------------------------ 35mm
Diameter of connecting rod journal--------------------------------------------------------- 66mm
Width of connecting rod journal------------------------------------------------------------- 40mm
Flange diameter----------------------------------------------------------------------------------- 105mm
Axial clearance of crankshaft------------------------------------------------------------------- 0.12~0.30 mm
The maximum allowable axial clearance---------------------------------------------------- 0.4 mm
Corner radiuses of main journal and connecting rod journal-------------------------- 4 mm
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Main shaft-4B series

The maximum wearing capacity of journal and crank pin------------------------------ 0.22 mm
Width of main journal--------------------------------------------------------------------------- 31mm
Diameter of crank pin---------------------------------------------------------------------------- 54mm
Width of crank pin-------------------------------------------------------------------------------- 34mm
Corner radius of journal and crank pin------------------------------------------------------- R73mm
Main shaft-QC490T/QC495T/QC498T

The maximum wearing capacity and ovality of journal and crank pin--------------- 0.25 mm
Width of main journal--------------------------------------------------------------------------- 31mm
Diameter of crank pin---------------------------------------------------------------------------- 62mm
Width of crank pin-------------------------------------------------------------------------------- 32mm
Corner radius of journal and crank pin------------------------------------------------------- R85 mm
Crankshaft gear-D series

Number of teeth----------------------------------------------------------------------------------- 26 teeth
Aperture--------------------------------------------------------------------------------------------- 43mm
Diameter of crankshaft gear hub-------------------------------------------------------------- 72.62 mm
Gear transition fit on crankshaft--------------------------------------------------------------- H7/h7
Crankshaft gear- 4B series

Aperture--------------------------------------------------------------------------------------------- 38mm
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Crankshaft gear-QC490T/QC495T/QC498T
Aperture--------------------------------------------------------------------------------------------- 40mm
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3. Disassembly of crank-link mechanism
3.1 Disassembly of piston rod assembly
1. See Chapter 1 in this Part for disassembly of valve

mechanism.
2. See Chapter 4 in this Part for disassembly of oil
sump.
3. Disassemble connecting rod bolt A, take out
connecting rod cap B and connecting rod bearing C,
and take out piston rod assembly from the cylinder
barrel.
A- Connecting rod bolt

B-Connecting rod cap
C-Connecting rod bearing
D-Connecting rod body
E-Connecting rod bushing
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3.2 Disassembly of connecting rod, piston and

piston ring
1. Refer to Section 3.1 of this chapter for disassembly

of piston rod assembly.
2. Disassemble piston ring B with appropriate piston
ring expander.
Notice:
Piston rings should be perserved with corresponding
pistons.
A- Piston
B-Piston ring assembly
C-Ring piston in hole
D-Piston pin
E-Connecting rod assembly
3. Disassemble the ring C in hole, take out piston pin
D, and take out connecting rod assembly E from
piston A.
Notice:
Use hand to push out piston pin when disassembling
it, if it is too tightly secured, you should heat the
piston to 40/50 ℃ (100/120 ℉ ) to facilitate
disassembly of piston pin.
4. Use appropriate tools to press out connecting rod
bushing.
Notice:
Use special tools to disassemble connecting rod
bushing to avoid damage.
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3.3 Disassembly of crankshaft H-Engine body
1. Disassemble bolt I, and flywheel assembly J.

2. Disassemble bolt K, and flywheel housing L.
Notice:
Guard against damages to crankshaft rear oil seal
when disassembly of flywheel.
K
L
I-Fixed bolt
J
J-Flywheel assembly
K-Fixed bolt
I
L-Flywheel housing

sump.
4. See Chapter 7 of this Part for disassembly of gear
chamber.
5. Disassemble main bearing cover bolt A, use a
hammer to knock on both sides of bearing cap B, and
fully disassemble the main bearing cover.
Notice:
Guard against loss when disassembling main bearing
housing with thrust plate.
Main bearing cover, bolt, upper and lower main
bearing and thrust plate of each journal are not
allowed to be mixed.
6. Hoist out crankshaft E horizontally.
Notice:
Guard against loss of thrust plate during hosting.
A- Main bearing bolt

B-Bearing cap
C-Upper main bearing
D-Upper thrust plate
E-Lower bearing of crankshaft
F- Lower thrust plate
G- Lower main bearing
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F- Connector
3.4 Disassembly of cylinder sleeve – dry type
Special tools:
Tools for disassembly / replacement of cylinder sleeve

Notice:
If the multiple cylinder sleeves needed to be
disassembled or installed too tight, then use press
machine; if there is only one cylinder sleeve, use
manual operating tool.
sump.
mechanism.
3. Refer to Section 3.1 of this Chapter for disassembly
of piston rod assembly;
of crankshaft.
5. Put tool D on the top surface of cylinder body and
on the center of cylinder sleeve E, and ensure the tool
base dose not press onto the top of adjacent cylinder
sleeve flange.
6. Put bearing C in the groove on top of the tool, and B
face the surface of bearing towards the groove
bottom.
A
7. By mounting screw B on top of bearing and tool,
C
keep handle A in the groove of bearing top, and
adjust the screw in this position to make its end stay
in the bottom of the cylinder liner; Install connector F
to the mounting screw and keep it against cylinder D
sleeve bottom, make sure two lugs on top of the
connector are stuck on the screw plane, install
washers and nuts and fix nuts onto the connector.
E
8. Use lubricating oil or similar oil to lubricate handle
ratchet and the screw, operating handle pulls cylinder
sleeve from the top of the cylinder body.
A- Handle
B-Screw F
C-Bearing
D-Special tools
E-Cylinder sleeve
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3.5 Disassembly of cylinder sleeve – wet type
Special tools:
Tools for disassembly / replacement of cylinder sleeve
Notice:
If the multiple cylinder sleeves needed to be
disassembled or installed too tight, then use press
machine; if there is only one cylinder sleeve, use
manual operating tool.
sump.
mechanism.
of piston rod assembly;
of crankshaft.
B
5. Put tool D on the top surface of cylinder body and
on the center of cylinder sleeve E, and ensure the tool
A
base dose not press onto the top of adjacent cylinder
sleeve flange. C
6. Put bearing C in the groove on top of the tool, and
face the surface of bearing towards the groove
bottom. D
7. By mounting screw B on top of bearing and tool,
keep handle A in the groove of bearing top, and
adjust the screw in this position to make its end stay E
in the bottom of the cylinder liner; Install connector F
to the mounting screw and keep it against cylinder
sleeve bottom, make sure two lugs on top of the
connector are stuck on the screw plane, install
washers and nuts and fix nuts onto the connector.
8. Use lubricating oil or similar oil to lubricate handle
ratchet and the screw, operating handle pulls cylinder F
sleeve from the top of the cylinder body.
A- Handle
B-Screw
C-Bearing
D-Special tools
E-Cylinder sleeve
F- Connector
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4. Installation of crank-link mechanism
4.1 Connecting rod bushing installation
Notice:
Connecting rod bushing shall be replaced by
professional personnel.
Check:
◆Check if connecting rod is deformed.

Notes: Check parallelism of connecting rod big end
and small end bearing holes on the sides of
connecting rod axial line, and the result shall not
exceed the limit of ±0.25mm, and the limit is
±0.06mm after small end bushing installation.
◆Check if the small end bushing is wore or damaged,

and replace new parts if necessary.
◆Clean connecting rod hole and remove all sharp

edges.
1. Install connecting rod bushing A to connecting rod
body B small end.
Notice:
Guarantee that bushing lubricating hole pressed in
coincides with the lubricating hole at the top of
connecting rod.
2. Boring bushing hole.
Notice:
Use the way of interval boring to process bushing hole,
and ensure center distance between connecting rod
small end bushing hole and big end base hole meets
the requirements
3. Honing bushing hole.
A- Connecting rod bushing

B-Connecting rod body
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4.2 Install piston pin
Notice:
◆Remove all carbon deposit on top of the piston.
◆Use clean lubricating oil to lubricate piston pin; If

piston pin installation is very tight, before the piston
pin installation, heat the piston to 40-50℃ (100-120
℉), then conduct installation.
Check:
◆Check the engaging between piston pin and small

end bushing and check if the piston pin is wore.
1. Install collar C on one side of the piston, gently
knock piston pin D into the piston pin hole inner end
face 2mm, and the remaining gap just be put
connecting rod small end in.
Notice:
Connecting rod and piston are not installed in reverse
direction, so pay attention to the marks on piston and
connecting rod and perform assembly in marked
direction.
2. Align connecting rod small end hole with piston pin
mounting hole, and gently knock the piston pin D in.
Expose circlip mounting slot on the other side.
3. Install the collar C on the other side into piston
circlip slot.
Notice:
After assembling, the piston can flexible swing
without catching.
The clearance between connecting rod small end
bushing and piston pin accessories 0.0075-0.0125mm.
The fit clearance between piston pin hole and piston
pin at room temperature is -0.0025mm.
A- Piston
B-Piston ring assembly
C-Collar
D-Piston pin
E-Connecting rod assembly
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4.3 Piston ring assembly installation
Notice:
Before installation, clear up the piston and piston ring
assembly.
Smear appropriate amount of lubricating oil at piston
ring mounting slot.
Piston ring opening degree shall not exceed eight
times of radial thickness.
Mounting sequences: Oil ring-second gas ring - first
gas ring
1. Install spiral support spring within oil ring.
Notice:
Support ring and support spring opening direction are
mutually staggered by 90°-120°.
2. Install oil ring outer ring with piston ring dilator.
3. Install second gas ring with piston ring dilator.
4. Install first gas ring with piston ring dilator.
Notice:
In order to avoid leakage of combustible gas mixture
from the opening gap of the piston ring, at the time
of assembly, opening direction of each gas ring shall
be staggered by 90 - 120°, and keep away from the
piston pin hole location.
The side marked shall be faced to piston top when
installing piston rings.
A- Piston ring assembly

B-Piston
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4.4 Installation of piston rod assembly

Tightening torque -------------(100-120) N•m
Special tools:
Piston ring compressor
Notice:
Smear appropriate amount of clean engine oil around
cylinder hole before assembly.
1. Refer to Section 4.2 of this Chapter for piston pin
installation.
2. Refer to Section 4.3 of this Chapter for piston ring
installation.
3. Install connecting rod bearing bush C to connecting
rod cap B and connecting rod D, and ensure
connecting rod bearing bush positioning lug is
correctly installed into the groove.
4. Smear appropriate amount of clean lubricating oil
on connecting rod bearing bush C. Hand piston
connecting rod assembly, face piston top, and put
piston rod assembly B into piston ring compressor A,
use a wooden stick to gently knock piston top to push
it into cylinder sleeve C, and get connecting rod D big
end stuck in crankshaft journal.
Notice:
The end marked shall face to engine front in piston
connecting rod mechanism installation;
Piston connecting rod mechanism shall be not rotated
after installed into cylinder sleeve.
If using old pistons, piston rings and connecting rods,
ensure that they are to be installed in the original
cylinder.
5. Install on connecting rod cap B, and tighten it with
bolt A.
Note:
Ensure that the mark number on connecting rod cap
is same as the number on connecting rod and they
are on the same side.
After fastening bolt, rotate the crankshaft to check
swing flexibility.
A- Connecting rod bolt

B-Connecting rod cap
C-Connecting rod bearing
D-Connecting rod body E F G
E-Piston ring compressor
F- Piston rod assembly
G- Engine body
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4.5 Check the height of the piston in the cylinder

block
Special tools:
Piston height measuring tool
Dial indicator
Notice:
Clean up cylinder upper surface to ensure clean and
free of dirt.
1. Place piston height measuring tool on the top

surface of the cylinder block and adjust dial indicator
to zero position.
2. Rotate the crankshaft, so that the measured
cylinder piston is near top dead center, and place the
tool on top of the piston carefully, so that the probe is
in contact with the piston in piston pin axis line.
3. Slowly rotate crankshaft to ensure the piston stay
in highest point and record the reading on the dial
indicator.
D series/QC490T/QC495T/QC498T:
The height of the piston on the top surface of cylinder
block ------0.5mm
4B series:
The height of the piston on the top surface of cylinder
block ------0.35mm
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4.6 Installation of the crankshaft Main bearing cap bolt torque -------(140~160)N•m
Axial clearance:(0.085-0.27) 5mm
1. Rotate the cylinder H, so that its bottom faces up
and its front end surface faces forward.
2. Install upper bush G of main shaft bushing into the
cylinder main bearing hole, and install lower bush C
of main shaft bushing into main bearing cap B, and
smear appropriate amount of lubricating oil on the
surface.
Notice:
Positioning lip on main shaft bushing shall be stuck in
positioning slot.
3. Install upper trust washer F to both sides of
crankshaft fifth journal. Install lower trust washer D to
both sides of fifth bearing cap.
Notice:
When installing, the side of thrust washer with oil
passage faces outside (namely, towards the
crankshaft), and smear appropriate amount of clean
grease on the back to prevent crankshaft falling when
installing.
The upper and lower thrust washers shall be a pair.
4. Crankshaft E shall be installed by levelly lifting into
the cylinder main bearing hole. Gently knock each
main bearing cap to push them into main bearing
housing, and screw fastening bolts.
Notice:
Main bearing cap is engraved with a order number,
and install according to the order number.
Main bearing cap fastening shall follow the sequence
from the middle to the sides, and after fastening a
main bearing cap, ensure crankshaft turning be
smooth without catching and then tighten the next
main bearing cap.
A- Main bearing cap bolts

B-Main bearing cap
C-Crankshaft upper main shaft bushing
D-Upper thrust plate
E-Crankshaft
F- Lower thrust plate
G- Crankshaft lower main shaft bushing
H-Engine body
D series:
Main bearing cap bolt torque -------(180~200)N•m
4B series/QC490T/QC495T/QC498T
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4.7 Installation of cylinder sleeve – dry type
Special tools:
Cylinder sleeve press-fitter
Notice:
Do not knock cylinder sleeve with a hammer.
1. Thoroughly wash cylinder sleeve mounting holes,
and wipe clean.
2. Thoroughly wash cylinder sleeve outside surface
with safety solvent.
3. Embed cylinder sleeve B into cylinder sleeve
mounting holes from up to down.
A
Notice:
Keep cylinder sleeve vertical
4. Use cylinder sleeve press-fitter A to press cylinder
B
sleeve B into cylinder C.
Notice:
After the installation, cylinder sleeve end shall be
(0.04-0.20) mm above cylinder plane.
C
A- Cylinder sleeve press-fitter

B-Cylinder sleeve
C-Engine body
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4.8 Installation of cylinder sleeve - wet type
Special tools:
Cylinder sleeve press-fitter
Notice:
Do not knock cylinder sleeve with a hammer.
Thoroughly wash the liner mounting holes, rust, dirt
and other debris and the outer surface of the cylinder
liner lower bearing sleeve at the shoulder, and wipe
clean.
1. The water sealing ring C mounted on the cylinder

liner B.
Note：
On the cylinder liner, the lower support ring for
cleaning and rust, burrs and sharp and clear.
Seal hydrosphere must use the new pieces, and no
aging, cracks, small elasticity and uneven thickness
etc..
After installing the cylinder liner seal hydrosphere not
warp, and properly tensioned.
2. The cylinder liner B into the liner from the top
A
mounting holes.
Note：
Before loading the body, in a sealed water laps at the
right amount evenly soapy water or clean oil. B
3. Use Cylinder sleeve press-fitter A, press-fit liner B

C
to the body D.
Note：
D
Cylinder pressure mounted perpendicular guarantee.
After the installation of the cylinder liner ends on a
plane higher than 1.4mm, fully compacted liner
cylinder liner on the plane of not less than 1.2mm.
A-Cylinder sleeve press-fitter

B-Wet type cylinder liners
C-Water sealing ring
D-Engine body
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Chapter 3 Cooling System
Special tools
13/16 Open-end wrench
16/ 19 Open-end wrench
8mm Socket spanner
10mm Socket spanner
13mm Socket spanner
Digital display torque wrench
Item Measurement Unit Parameters Remarks
Water pump connected to

N·m 25
the engine body
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2.2 Data size
Water pump - D series

Type ---------------------------------------------------------------------------------------------------------- centrifugal, belt drive
Impeller hole diameter --------------------------------------------------------------------------------- 15.9mm
The outside diameter of impeller shaft ------------------------------------------------------------- 28mm
Impeller interference fit tolerance on shaft -------------------------------------------------------- U7/h6
Clearance from impeller to the pump --------------------------------------------------------------- (0.3-0.5)mm
Bearing diameter ----------------------------------------------------------------------------------------- 35mm
Bearing hole diameter ----------------------------------------------------------------------------------- 18mm
Bearing interference fit tolerance in the pump body -------------------------------------------- U7/h6
Water pump - 4B series

Type ----------------------------------------------------------------------------------------------------------- centrifugal, belt drive
Impeller hole diameter ----------------------------------------------------------------------------------- 84mm
The outside diameter of impeller shaft --------------------------------------------------------------- 15mm
Impeller interference fit tolerance on shaft ---------------------------------------------------------- U7/h6
Clearance from impeller to the pump ----------------------------------------------------------------- (0.4-0.6)mm
Bearing diameter -------------------------------------------------------------------------------------------- 30mm
Bearing hole diameter ------------------------------------------------------------------------------------- 16mm
Bearing interference fit in the pump body ------------------------------------------------------------ U7/h6
Water pump -QC490T/QC495T/QC498T

Type ------------------------------------------------------------------------------------------------------------- centrifugal, belt drive
Impeller hole diameter ------------------------------------------------------------------------------------ 84mm
The outside diameter of impeller shaft --------------------------------------------------------------- 16mm
Impeller interference fit tolerance on shaft --------------------------------------------------------- U7/h6
Clearance from impeller to the pump ----------------------------------------------------------------- (0.4-0.6)mm
Bearing diameter -------------------------------------------------------------------------------------------- 35mm
Bearing hole diameter ------------------------------------------------------------------------------------- 35mm
Bearing interference fit in the pump body ------------------------------------------------------------ U7/h6
Thermostat
Type ------------------------------------------------------------------------------------------------------------- wax type thermostat
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3. Disassembly and adjustment of cooling system
3.1 The composition of cooling part D series
A- Fan B-Fan cushion block C-Water pump pulley D-V belt E-Thermostat cover
F- Cylinder cap front shroud G- Pump gasket H-Pump assembly I-Water pump inlet pipe
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3.2 The composition of cooling part 4B series
A-Bolt B-Washer C-Cooling fan D-Fan cushion block E-Water pump pulley F- Bolt
G-Water pump H-Bolt I-Thermostat cover J-Thermostat cover gasket K-Thermostat
L-Pump gasket M-Bolt N-Bolt O-Pump flange cushion block P-Pump flange gasket
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3.3 The composition of cooling part QC490T/QC495T/QC498T series
A-Bolt B-Cooling fan C-Fan cushion block D-Water pump pulley E-Water pump belt
F-Thermostat cover G- Thermostat cover gasket H-Thermostat I-Pump components
J-Pump gasket K-Water inlet pipe L-Pump gasket M-Pump liner N-Pump lining gasket
O-Thermostat housing liner P-Pump flange cushion block Q-Pump flange gasket
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3.4 The disassembly of the fan and pulley D series
1. Loosen the alternator tension bolt to loosen belt D.

2. Disassemble the fan fixing bolts, and remove fan A,
fan cushion block B, pump pulley C, and V-type belt D.
A-Fan
B-Fan cushion block
C-Water pump pulley
D-V- type belt
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3.5 The disassembly of the fan and pulley

4B/QC490T/QC495T/QC498T series
1. Loosen the alternator tension bolt to loosen belt A.

2. Loosen tension wheel to loosen belt B.
A- Fan - alternator belt

B-Crankshaft - fan belt
3. Disassemble bolt C, and remove fan D, fan gasket E

and pulley F.
C-Bolt
D-Fan
C
E-Fan cushion block
D E F G
F- Pulley
G- Pump assembly
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3.6 The disassembly of pump assembly D series

of fan and pulley.
2. Loosen hose clamp, and disconnect connecting
tube C between cylinder cap front shroud B and
pump D.
3. Disassemble retaining bolts and remove pump
assembly D and cylinder cap front shroud B.
Notice:
Non-professionals do not disassemble the pump.
Disassembling internal pump parts must use a special
tool to avoid damage to other parts.
Pump gasket is disposable, which must be replaced
with new parts during installation.
A- Thermostat housing
B-Cylinder cap front shroud
C-Small circulation pipe
D-Pump assembly
E-Pump gasket
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3.7 The disassembly of pump assembly 4B series

of fan and pulley.
2. Disassemble bolt A, and disassemble thermostat D,
gasket C and thermostat housing B.
A
3. Disassemble bolt G, and remove pump assembly E,
gasket F, pump flange cushion block G and gasket H.
C B
Notice:
D
E
A- Bolt
F
B-Thermostat cover
C-Thermostat cover gasket
D-Thermostat
E-Pump assembly
F Pump gasket
G
G- Bolt I H I
H-Pump flange cushion block
I-Pump flange gasket
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3.8 Disassembly of pump components

QC490T/QC495T/QC498T series

of fan and pulley.
2. Disassemble bolt A, and disassemble thermostat D,
gasket C and thermostat housing B.
3. Disassemble bolt F, and disassemble pump inlet
tube G, gasket H, pump assembly I, gasket J and pump
cushion block K.
Notice:
A-Bolt
B-Thermostat cover
C-Thermostat cover gasket
D-Thermostat
E-Pulley block
F-Bolt
G- Water inlet pipe
H-Inlet tube gasket
I-Pump assembly
J-Pump cushion block and gasket
K-Pump cushion block
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3.9 Disassembly of water pump D series
Note:
Non-professionals do not disassemble the pump
assembly.
1. Disassemble the bolt, gasket D and pump block E.
2. Remove shaft bearing B and water seal with a
puller.
3. Disassemble pump impeller
Notice:
Be careful not to damage impeller and water seal.
Pump shaft bearing is prohibited to be disassembled
without professional tool.
A- Pulley terminal pad

B-Shaft bearing
C-Pump housing
D-Pump seat gasket
E-Pump block
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3.10 Disassembly of water pump 4B

/QC490T/QC495T/QC498T series
Note:
Non-professionals do not disassemble the pump
assembly.
1. Disassemble nut B, and remove pump combined
part.
2. Disassemble pump impeller F from pump shaft
with a puller, and remove pump shaft bearing D and
water seal E in sequence.
A
Notice:
B F
Be careful not to damage impeller and water seal. C D E
Pump shaft bearing is prohibited to be disassembled
without professional tool.
A-Pump housing
B-Nut
C-Washer
D-Pump shaft bearing
E-Water seal
F- Pump blade
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4. Assembly and adjustment of cooling system
4.1 Pump installation
Notice:
Clean cylinder head surface and passage of coolant
and lubricating oil; Water jacket can be cleaned with
special solvent, and it shall be used according to
manufacturer instructions.
1. Pump installation and disassembling sequence is in
reverse order.
Notice:
In addition to replacing gaskets and seal rings, the
parts shall be inspected and measured in order to
replace new parts on those beyond allowable wear
ranges.
A- Pulley terminal pad

B-Shaft bearing
C-Pump housing
D-Pump seat gasket
E-Pump block
Note:
◆ Fit clearance of pump shaft and bearing

(0.010-0.012) mm。 Overhaul allows (0.010-0.030)
mm.
◆Fit of pump bearing and bearing hole is usually

(-0.02-0.02) mm, and overhaul allows (-0.02-0.044)
mm.
◆After installation of pump impeller, it shall generally

be higher than pump shaft (0.1-0.5) mm.
◆ After installing the pump, the gap between

impeller outer edge and pump casing chamber is
usually lmm; Gap between impeller and pump cover
shall be (0.075-l) mm.
◆Outlet hole below the pump shall be unblocked.
◆During installation, pay special attention to axial

clearance between pump impeller and pump housing,
and the clearance between pump impeller and pump
housing radial seal position.
◆Fill enough grease at lubrication points.

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4.2 Installation of pump assembly and other

components
Pump assembly, thermostat, fans and other

components, shall be mounted in reverse order of
disassembly.
Notice:
All joint surfaces must be clean.
When installed, all gaskets shall replace new parts.
Belt tension degree --------------------98N
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Chapter 4 Lubrication System
Note:
Introduction of special tools
13mm open-end wrench or spline end wrench
Engine oil pump assembly in

N.m 25
the engine body
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2.2 Data size
factories.
Lubrication system-D series
Engine oil pump -------------------------------------------------------------------------------- Gear pump
Lubrication system - 4B series/QC490T/QC495T/QC498T

Engine oil pump -------------------------------------------------------------------------------- Differential rotor
Type ----------------------------------------------------------------------------------------------- 1 each at inside and outside
Clearance between outer rotor and housing (4B series) ----------------------------- (0-0.047) mm
Clearance between outer rotor and housing (QC490T/QC495T/QC498T) ------- (0.08~0.158)mm
Clearance between inner rotor and outer rotor ---------------------------------------- (0.07~0.18)mm
Axial clearance of rotor and assembly ---------------------------------------------------- (0.06~0.12)mm
Oil Filters - D series

Type ----------------------------------------------------------------------------------------------- Spin type
Filter bypass valve opening pressure ------------------------------------------------------ 150~200KPa
Oil Filters - 4B series/QC490T/QC495T/QC498T

Type ------------------------------------------------------------------------------------------------ Spin type
Filter bypass valve opening pressure ------------------------------------------------------- 149~196KPa
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3. Disassembly and assembly of lubrication part
3.1 Disassembly of engine oil pump assembly
Notice:
Discharge engine lubricating oil before Disassembly,
and store the oil in a clean barrel.
1. Disassemble bolt G and oil sump D.
2. Disassemble bolt E and bolt F, then remove engine
oil pump assembly B.
A- Engine body
B-Engine oil pump assembly
C-Oil sump gasket
D-Oil sump
E-Bolt E
F
F- Bolt
B
G- Bolt C D
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3.2 Disassembly of engine oil filter assembly and

engine oil cooler
1. Disassemble bolt C, and remove engine oil filter

assembly B and gasket A.
Notice:
If independently replacing engine oil filter cartridge, G
E F
use special tools to remove the oil filter in
counterclockwise to remove the filter cartridge.
D
2. Disassemble bolt G and inlet tube F, then remove
bolt D and engine oil cooler E.
A- Engine oil filter L gasket

B-Oil Filters
C-Bolt C
D-Bolt
E-Engine oil cooler
F- Oil inlet pipe
G- Bolt
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4. Disassembly and assembly of lubrication part
4.1 Engine oil pump assembly installation
Install in reverse order of disassembly of engine oil

pump assembly.
Notice:
Released engine oil shall be added in after filtration
and sedimentation; if engine oil is insufficient, add
engine oil of the same grade as required amount.
When replacing new engine oil, choose engine oil
grades consistent with ambient temperature.
4.2 Installation of engine oil filter assembly and

engine oil cooler

filter assembly and engine oil cooler.
Notice:
During installation, the gasket must be replaced with
new parts.
When installing filter cartridge, firstly fill clean engine
oil, and smear appropriate amount of lubricating oil
on cartridge seal ring.
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Chapter 5 Starting System
Introduction of special tools

18mm Socket spanner
2. Torque requirement
Starter is connected with

N.m 80
flywheel housing
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3. Disassembly of starting system
Notice:
Before disassembly, first to disconnect battery
cathode ground wire.
1. Loosen starter harness fixing nut and disconnect

the starter assembly and the engine harness.
2. Disassemble nut B and starter assembly C.
A- Flywheel housing
B-Nut
C-Starter assembly
4. Installation of starter system

filter assembly.
Notice:
When harness connecting, prevent short circuit of
bonding
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Chapter 6 Oil Feeding System
Note:
Introduction of special tools: 13mm socket spanner
Fuel injection pump is

N.m 70
connected with gear chamber
2.2 Data size
factories.
Fuel injection pump gear- D series
Number of teeth ------------------------------------------------------------------------------------------------------ 52 teeth
Aperture ---------------------------------------------------------------------------------------------------------------- 50mm
Fuel injection pump gear - 4B series
Aperture ---------------------------------------------------------------------------------------------------------------- 50mm
Fuel injection pump gear -QC490T/QC495T/QC498T
Aperture ---------------------------------------------------------------------------------------------------------------- 50mm
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B-Fuel injection pump assembly

3. Disassembly of oil feeding system
3.1 Disassembly of oil feeding system subsidiary

parts
Notice:
Before disassembly, place a drip pan at the bottom of
oil tube.
1. Disassemble fuel injection pump inlet tube F.
2. Disassemble injector oil return tube F.
3. Disassemble high-pressure tubing group assembly A.
4. Disconnect diesel filter inlet and outlet tube, and

remove diesel filter D.
Note:
After fuel pipe disassembly, conduct protection on all
joints of injector, high-pressure pumps and other
components, in order to avoid dust or debris
damaging parts.

B-Injector oil return tube combination
C-Hollow bolt
D-Diesel filter
E-Diesel filter flowlines
F- Fuel injection pump inlet tube
3.2 Disassembly of fuel injection pump assembly
1. Refer to Section 2 of Chapter 7 for disassembly of

gear chamber cover and fuel injection pump timing
gear.
2. Disassemble nut A and take fuel injection pump
assembly out.
Notice:
When disassembling fuel injection pump, store
woodruff key well.
A- Nut
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4. Oil feeding system assembly F- Fuel injection pump inlet tube
4.1 Fuel injection pump assembly installation
Install in reverse order of fuel injection pump

disassembly.
Notice:
Correct engine timing after fuel injection pump
installation.
A- Nut
B-Fuel injection pump assembly
4.2 Installation of oil feeding system subsidiary

parts
Install in reverse order of disassembly.

Notice:
Before installation of high pressure fuel tube, ensure
that the pipeline joints are clean and free of dirt.
After high-pressure fuel tube installation, first to
fasten fuel injection pump terminal, final to fasten the
injector terminal.
Using original factory diesel filter is very important,
and using wrong filter cartridge, will damage fuel
injection pump.

B-Injector oil return tube combination
C-Hollow bolt
D-Diesel filter
E-Diesel filter flowlines
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Chapter 7 Subsidiary Parts Disassembly Assembly And Adjustment
1. Data and Dimensions
factories.
Idler wheel and hub

Number of teeth ---------------------------------------------------------------------------------------------- --- 53 teeth
Aperture ------------------------------------------------------------------------------------------------------------ 60mm
Idler wheel and hub

Number of teeth -------------------------------------------------------------------------------------------------- 53 teeth
Aperture ------------------------------------------------------------------------------------------------------------ 50mm
Idler wheel and hub

Number of teeth ----------------------------------------------------------------------------------------------- --- 42 teeth
Aperture ------------------------------------------------------------------------------------------------------------ 49mm
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2. Gear room disassembly and assembly
Dismantling When installing crankshaft pulley, prevent damaging

crankshaft front oil seal.
1. See Chapter 3 in this Part for disassembly of the
cooling system
2. Disassemble fixing bolts and crankshaft pulley (30)
and flat key.
3. Disassemble fixing bolts and gear room cover (25).
23-Generator
24-Gear chamber
25-Gear room cover
26-Water pump
27-Belt of alternator
28-Belt tensioner
29-Water pump belt
30-Crankshaft pulley
4. Disassemble timing gear A, B, C, D, E fixing bolts,

and timing gears in sequence.
5. Disassemble fixing bolts and gear chamber housing.
A- Hydraulic bump gear

B- Camshaft timing gear
C- Crankshaft gear
D- Idler gear
E- Fuel injection pump timing gear
Mounting:
Notice:
In addition to gear pump drive gear in gear room, the
other gears must align timing marks during
installation.
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3. Structure chart of fuel injection pump
BQ pump appearance view
A- Fuel injection pump B-Fuel supply pump C-Governor screw
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BQ pump structure
1-Antifouling cap 2-Delivery valve holder 3-O type rubber sealing ring-I 4-Volume reduction body
5-Delivery valve adjustment washer 6-Delivery valve spring 7-Delivery valve gasket
8-Delivery valve matching parts 9-Plunger matching parts 10-Nut M6 11-Washer 6 12-Washer
13-Pre-stroke adjustment gasket 14-Flange sleeve 15-Plunger bushing locating pin
16-O type rubber sealing ring- III 17-O type rubber sealing ring- II 18-O type rubber sealing ring- IV
19-Adjustable gear ring 20-Support 21-Stud 22-Washer 23-Oil inlet and outlet connector
24-Bonded washer 25-Antifouling ring 26-Oil return connector screw 27-Steel ball 6G40b
28-Spring of oil return valve 29-Washer 30-Screw 31-Inlet tube connecting bolt 32-Oil channel plug
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33-Name plate 34-Rivet for name plate 2x5 35-Washer 36-Gear lever cap
37-Oil transfer pump seal ring 38-Stud 39-Key 3x6.5x16 40-Idle speed limit screw 41-Camshaft
42-Camshaft adjustment gasket 43-Tapered roller bearing 30203 44-Bearing cap adjusting gasket
45-O type rubber sealing ring 46-Bearing cap 47-Skeleton-type rubber oil seal B16x28x7 48-Screw M6x14
49-Protective jacket 50-Washer 12 51-Nut M12 52-Plunger spring upper seat 53-Plunger spring
54-Plunger spring lower seat 55-Tappet body 56-Roller pin 57-Roller 58-Roller bushing
59-5Bolt M6x14 60-Bottom cover plate 61-Bottom cover plate seal gasket 62-Positioning screw
63-Washer 64-Bleed screw 65-Washer 66-Pump body 67-Cylindrical pin D5x12
68-Gear lever bushing 69-Return spring 70-Return spring collar 71-Collar 9 72-Gear lever
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Speed regulator
1-Flying block parts 2-Washer 3-Nut M12x1-25 4-Speed regulation sleeve 5-Connecting rod
6-Connecting pin 7-Plug pin 8-Connecting sleeve 9-Speed regulation lever 10-Adjusting gasket
11-Gasket 12-Open-end collar 3-5 13-T support block 14-Screw M6x10 15-Washer 6
16-Speed regulation spring hooks 17-Speed regulation spring 18-Spring tension plate
19-Speed regulation arm 20-rivet 4x11 21-Bearing HK081210 22-Spacer sleeve
23-Speed regulation lever washer 24-Starting spring 25-Pin A3x16 26-Embedded lump
27-Sealing gasket 28-Back shell 29-High speed limit screw 30-High speed limit nut 31-Respirator parts
32-Washer 33-Bulkhead 34-Name plate 35-rivet 2x4 36-Split pin 2x10 37-Speed regulation handle
38-Bolt M5x10 39-Handle pin 40-Spring rocker arm 41-Washer 5 42-Bolt M5x15 43-Nut M8
44-Washer 8 45-Return spring 46-O type seal ring 9x1-8 47-Collar 9 48-Speed regulation shaft
49-Speed regulation shaft adjustment gasket 50-Screw M5x10 51-Parking shaft washer
52-Parking shaft connecting plate 53-Return spring 54-Parking shaft 55-O type seal ring 5x1-8
56-Collar 6 57-Counter shaft 58-Oil drain screw 59-Washer 60-Washer 6 61-Washer 6
62-Bolt M6x25 63-Support plate 64-Support sleeve 65-Bolt M5x16 66-Washer 5 67-Washer 5
68-Back shroud 69-Gasket 70-Positioning screw 71-Washer 72-Dipstick handle 73-Bush
74-Washer 75-Nut M16x1 76-Positive corrector thread sleeve 77-Positive corrector spring
78-Positive corrector mandril 79-Nut M10x1 80-Preload adjustment thread sleeve
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81-Slotted flat set screw M5x15 82-Nut M5 83-Protective cap 84-Lead sealing wire 85-Lead sealing
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4. Fuel injector
4.1 Maintenance equipments and tools
Note:
Introduction of special tools: Bench clamp
Hand pressure testing stand
Spline end wrench
Torque wrench
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Injector screw cap N.m 29-39
4.3 Disassembly and assembly of fuel injector
Dismantling nozzle assembly.

1. Unscrew the tight cap F;
2. Successively disassemble the injector nozzle
matching part E, intermediate link block D, pressure
adjusting spring C and pressure adjusting shim B.
A- Fuel injector body

B-Pressure adjusting shim
C-Pressure adjusting spring
D-Intermediate link block
E-Injection nozzle matching part
F- Tight cap
G- Copper gasket
Mounting
Notice:
Rinse the injection nozzle matching part with clean
diesel;
Do not touch the matching surface of nozzle with
your fingers.
When assembling, the tight cap is required to be
tightened with your fingers first and then with torque
wrench.
If the nozzle seat is burned or eroded, replace the
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Test
1. Rinse the nozzle with clean diesel;
Note:
Do not touch the matching surface of nozzle with
your fingers.
2. Tilt the injection nozzle matching part in 45
degrees, and pull the needle valve body out at 1/3 of
the length of needle valve cylindrical working surface;
3. Release the needle valve, and the needle valve can
drop to its original position by its own weight.
4. Repeat Step 2 and Step 3 and turn the needle valve
at an angle each time.
Note:
If the needle valve can not smoothly decline, replace
the injection nozzle matching part.
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4.4 Fuel injector atomization in the spray
Notice:
Poor atomization can cause high fuel consumption
rate, poor power performance, black smoke and
other phenomena.
Test conditions:
Hand-press fuel injector calibrator, external
high-pressure oil pipe and light diesel oil.
Warning:
Do not put your fingers near the oil spit hole.
Test procedures and results:

1. Pump the oil for several times, and then wash the
fuel injector quickly.
2. Slowly press the oil pump handle and observe the
pointer of pressure gauge. The highest pressure value
indicated by the pointer before its suddenly falling is
the opening pressure of needle valve of the fuel
injector.
Note: If the opening pressure is unqualified, please
disassemble the fuel injector to regulate the adjusting
shim.
3. Press the oil pumping handle slowly and steadily,
so that the fuel injector ejects the oil at 30-40
times/min. Observe whether the ejective pocket of oil
shall be well atomized and evenly distributed, and
each oil ejection shall be quick and efficient with
silvery sound but without leakage in the whole
process.
Notice:
The oil shall not be gathered around the needle valve
head before and after the oil ejection.
4. The pressure drop-out valve shall not be greater
than 25% of the actual opening pressure within 4s
after the oil pumping pressure is 1MPa lower than the
actual opening pressure; meanwhile, there is no
leakage in the sealed parts.
5. Press the oil pumping handle slowly and steadily,
so that the fuel injector ejects the oil at 60-80
times/min; the obviously visible vaporous deflection,
splashed particles and continuous oil column or
distinguishable local uneven concentration shall not
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5. Flame heater plug
Installed on the
N.m 60-70
intake-tube
5.2 Disassembly and assembly of flame preheating

plug
Dismantling
1. Disconnect the fuel inlet pipe B and rattail of the
flame preheating plug
2. Disassemble the flame preheating plug C.
A- Fuel injection pump

B-Pipeline of flame preheating plug
C-Flame heater plug.
Mounting
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Part 3 Inspection, Adjustment, Diagnosis and

Troubleshooting
Chapter 1 Dynamic inspection
1. Overview
Inspect the consumption of engine oil regularly or

irregularly according to the working time and
conditions of the engine, to supply engine oil timely.
Avoid the matter of engine oil affecting the normal
use of the engine.
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2. Inspect the engine oil level
Inspection conditions:
◆Stop the machine on the horizontal ground.
◆Turn off the ignition switch.
◆Keep the gear shift lever at the neutral position.
◆Tension the parking brake
◆Shut down the engine for 5 min.
Inspection steps:
◆Clean the space around the oil dipstick.
◆Pull out the oil dipstick, and wipe it clean.
◆Install the oil dipstick and make sure that it is

installed in place.
◆Pull out the oil dipstick, and check if the oil level
shown on the dipstick is acceptable.
TOP
Normal conditions:
LOW
◆The oil level is at the lowest position.
◆The engine oil is not too thick, thin, sticky or watery
◆No smell of diesel fuel.
◆There shall be no visible metal objects, impurities

or deterioration inside the engine oil
Abnormal conditions
◆Add fuel to meet standard requirements according

to the mark of oil level gauge
◆Replace the dirty oil and oil filter.
◆Refer to the Operating Instruction of Engines for

specific requirements.
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3. Inspect the level and status of coolant
Inspection conditions:
◆Stop the machine on the horizontal ground.
◆Turn off the ignition switch.
◆The radiator cap feels not too hot to handle
◆Tension the parking brake
Inspection steps:
◆Clear up the surrounding of radiator cap
◆ Rotate the radiator cap first to discharge the

pressure
◆Disassemble the radiator cap
◆Inspect the level and status of coolant
◆Inspect the radiator and water pipe
◆Inspect the cooling fan
Normal conditions:
◆The radiator and water pipes are in good conditions

and without leakage
◆The coolant level shall not be 5mm lower than the

sealing surface of the radiator cap (the liquid level of
those with storage tank shall be between the scribed
line of “Full” and “Low”)
◆ The coolant is clean without oil stains, rust,

deterioration or foreign matters inside
◆The water pipes are connected reliably and without

leakage
Abnormal conditions:
◆Maintain or replace the radiator
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4. Inspect the fan and the belt
1. Inspect the water pump belt.

Inspect whether there are cracks, notch, deformation
and abrasion on the water pump belt. Replace and
inspect the belt tension if necessary: As shown in
Figure 7-5, when pressing the central part of the belt
with the force of about 98N, the press amount of new
water pump belt is about 7mm-9mm, and that of old
one is about 11mm-13mm. Otherwise, it shall be
adjusted.
A-Belt
Belt tension --------98N
2. Inspect the fan.

When assembling the fan, attention shall be paid to
the direction of rotation, the surface with
identification bear forward.
Visually inspect whether the fan blade is damaged
Whether the fixed bolt of fan is tightened
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5. Inspect the fuel system
The fuel system transports the fuel with fuel delivery

pump from fuel tank to the high pressure oil pump
through the fuel filter and the low-pressure oil line,
and then the high pressure pump pumps out the fuel
which will be ejected into the cylinder by fuel injector
(with pressure of 21-23MPa) via the high pressure oil
line for compressed combustion; The redundant fuel
will flow back into the fuel tank via the oil return pipe
of the injector.
Notice:
The fuel pressure inside the fuel injection pump,
high-pressure oil line and fuel injector is very high, so
do not loosen any pipe joints when the engine
running. Otherwise, it may cause personal injury and
property damage.
Wait for 10min at least after shutting down the
engine, and loosen the pipe joint of the high-pressure
fuel system slowly when the oil pressure reduced.
Switch in pressure gauge to measure and inspect the
fuel pressure.
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6. Inspect the inlet and outlet system
1. The air flows from the air cleaner into the air intake
manifold through the heater, and then flows to the
airway of the cylinder head; it will be pressed into the
cylinder after entering the intake valve for
compressed combustion.
2. The combusted exhaust gas flows into the air vent

of the cylinder head via the exhaust valve and then is
exhausted from the silencer via the exhaust pipe.
Inspect whether there is leakage of the air intake and
exhaust systems to ensure that all hose clamps have
been tightened.
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7. Inspect the electrical system
The battery may release explosive gases. To avoid causing severe personal injury, keep the engine compartment
well ventilated before starting to work. Always disconnect the negative cable (-) of the battery first and connect it
at last. Basic electrical system of battery, starting motor, alternator and key switch: Inspect whether the battery
connectors and wirings are connected as required; all necessary leads and parts must be matched strictly and
then determine if the electric system has any problem based on the service behavior of the engine; the specific
maintenance requirements shall meet the maintenance methods for electrical system failure.
Electric system sketch

1-Generator 2-Oil pressure sensor 3-Water temperature sensor 4-Oil pressure gauge
5-Water temperature gauge 6-Ammeter guage 7-Voltage regulator 8-Fuse case
9-Starting relay 10-Starter 11-Accumulator cell 12-Ignition lock 13-Preheating plug
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8. Idling test of engine
Engine test is a combined process of running-in and

performance test for engine. The running-in process
provides an operation opportunity to ensure that all
parts can be matched precisely and cooperated fully.
Performance test allows us to conduct the final
adjustment for the engine performance.
Engine dynamometer or chassis dynamometer can be
used in the engine test. If there is no dynamometer,
the engine test must be performed with simulate
dynamometer.
Notice:
Inspect the dynamometer first before the test. The
performance of the engine must be able to be tested
when the engine runs at the maximum speed and
power (full power).
Minimum idle speed of engine ------------700 r/min
Maximum idle speed of engine ------------2650r/min
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Chapter 2 Operating Principle
1. Valve mechanism
1.1 Functions of the valve mechanism
The cylinder head is used for sealing the top face of

the cylinder and constituting the combustion
chamber and the working chamber together with the
cylinder and piston. As the cylinder head directly
contacts to high pressure gas and bears the bolt
pretightening force, gas pressure and alternating
stress, so the cylinder head is required to have certain
strength and stiffness, and shall be reliable and have
smooth interface, to ensure positive sealing.
Function:
When the working cycle of the cylinder requires
changing the air by opening the air valve, the
crankshaft will drive the camshaft to rotate by the
drive mechanism, so that the cam bulge on the
camshaft will drive the rocker arm to rotate by the
tappet, push rod and adjusting screw, and the other
end of the rocker arm will push the air valve
downward and compress the spring in the meanwhile.
When the peak of the cam bulge turns around the
tappet, its trust against the tappet reduces, and the
opening of air valve gradually decreases under the
action of spring tension until final closing. The valve
closes tightly under the action of the spring tension in
the compression and power stroke.
Open and close the intake valve and exhaust valve on
time according to the requirements of working cycle
and ignition order in all cylinders of the engine, to
allow enough fresh air to enter the cylinder and to
discharge the exhaust gas from the cylinder.
A- Camshaft
B-Tappet
C-Push rod
D-Air valve
E-Valve rocker arm
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1.2 Valve timing
Valve timing is the actual time of opening and closing

of the intake valve and exhaust valve, which usually
expressed by an annular chart relative to the
Valve timing diagram
crankshaft corner of crankshaft corner position of
upper and lowers dead centers. This chart is called
valve timing chart. The check valve
Intake valve On Before upper dead center 18±3°

Intake valve Off After bottom dead center 54±3°
Exhaust valve On Before bottom dead center 62±3° Direction of turning
Exhaust valve Off After top dead center 18±3°
In theory, the intake valve of four-stroke engine opens

when the crankshaft corner is at the upper dead
center and closes when the crankshaft corner is at the
lower dead center; The exhaust valve opens when the
Close
crankshaft corner is at the lower dead center and
Open
closes when the crankshaft corner is at the upper
dead center. The intake period and the exhaust period
respectively occupy 180° of crankshaft corner. But the
actual engine has high rotate speed of crankshaft and Next stop valve
each stroke of the piston needs a short time. The
intake and exhaust process in such short time may
often cause the engine in under-inflation or with
residual exhaust, so the engine power decreases.
Therefore, modern engines tend to lengthen the
intake and exhaust time, that is, the opening and
closing time of air valve is not just the time the
crankshaft corner at the upper and lower dead
centers but respectively the advanced or delayed
certain point, so as to improve the status of air intake
and exhaust and the dynamic property of engine.
The valve timing is different for different engines
owing to their different structural styles and rotating
speeds. Reasonable valve timing shall be determined
by trial and error according to the performance
requirements of the engine.
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2. Crankshaft and connecting rod mechanism
2.1 Operating principles
Functions:
The crankshaft and connecting rod mechanism is the
drive mechanism for the internal combustion engine
to complete working cycle and energy conversion,
used to transfer power and change mode of motion.
During the work, the crankshaft and connecting rod
mechanism changes the reciprocating motion of the
piston into the rotational motion of the crankshaft in
the power stroke and outputs power outward; but in
the other three strokes, namely, the intake,
compression and exhaust strokes, it changes the
rotational motion of the crankshaft into the
reciprocating motion of the piston.
In general, crankshaft and connecting rod mechanism
is the tool used by the engine to generate and
transfer power and then change the thermal energy
generated from combustion into mechanical energy.
Work conditions:
Sustain high-temperature, high-pressure, high-speed
and chemical corrosion.
Operating principles:
In the power stroke, the piston sustains the expansion
pressure generated by combustion gas and changes
the linear motion of the piston into the rotational
motion of the crankshaft via the connecting rod, and
then outputs power outward. Relying on the rotatory
inertia of the crankshaft and flywheel, the connecting
rod drives the piston to move vertically and complete
the exhaust, intake, compression and other auxiliary
strokes to prepare for the next power stroke.
A- Crankshaft
B-Connecting rod assembly
C-Piston
D-Flywheel ring gear part
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2.2 Introduction to the component
Compositions:
Engine body
Components Cylinder body, cylinder sleeve, cylinder Connecting rod bearing:
head, cylinder head gasket and oil sump, etc.
Protect the rod journal and the rod hole.
Piston and connecting rod:

Crankshaft:
Piston, piston ring, piston pin and connecting rod, etc.
Change the gas pressure from the piston and
connecting rod into torque to export. It can also be
used to drive the valve mechanism and other auxiliary
Crankshaft and flywheel: devices of the engine.
Crankshaft and flywheel ring gear parts, etc. Working conditions: Bear the gas pressure, inertial
force and inertia moment. Sustain the impact of the
variable load.
Functions:
Thrust plate:
Sustain the gas pressure and rotate the crankshaft
with piston pin and connecting rod. Ensure that the crankshaft connecting rod system can
operate normally when the crankshaft is under the
Work environment: Those acting on the piston action of axial force.
include gas pressure and reciprocating inertial force.
As the piston top directly contacts with the high
temperature gas, the temperature of the piston top is Flywheel:
very high. The piston slides at high speed along the
cylinder wall under the action of lateral pressure. Store part of the power transported into the
crankshaft in the working procedure, to overcome
resistance in other stroke and to drive the crankshaft
Piston ring: and connecting rod mechanism to cross the upper
and lower dead centers, so as to ensure the
The gas ring is mainly used for sealing and heat uniformity of the angular spin rate and output torque
transfer. of the engine, and to pass the power of the engine to
the clutch at the same time.
The oil ring is mainly used for striking off the engine
oil splashed on the cylinder wall and spraying a even
oil film on the cylinder wall.
Piston pin:
The piston pin is used to connect the piston and
connecting rod, and to transfer the force sustained by
the piston to the connecting, vice versa.
Connecting rod:
Transfer the force of piston to the crankshaft and
change the reciprocating motion of the piston into
the rotational motion of the crankshaft.
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3. Lubrication system
The lubricating system is used

To transport enough clean lubricating oil to the
friction surface of all driving parts when running the
engine, and to form oil film between the friction
surfaces to form liquid friction, so as to reduce the
friction resistance, lower power consumption, reduce
friction loss to improve the operational reliability and
durability of the engine.
Lubrication modes:
Pressure lubrication and splash lubrication
Composition of the lubrication system

Engine oil pump
Oil Filters
Oil sump
Suction filter
Lubricating oil pipeline
A
A- Gear train
B-Idler gear shaft
C-Engine oil pump B
D-Oil strainer
E-Oil sump
C F
F- Oil Filters
E
D
Functions of lubricating oil:

Lubricating---using oil film to minimize the abrasion
between parts
Sealing---using oil film to prevent fuel gas from
leaking
Cooling---lubricating oil can absorb heat
Cleaning and rust prevention---taking away metal
objects, impunities and acid content
Vibration reduction and buffering---using oil film to
buffer vibration
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4. Fuel supply system
4.1 Theoretical introduction
System functions: The fuel system transports the fuel

with fuel delivery pump from fuel tank to the high
pressure oil pump through the fuel filter and the
low-pressure oil line, and then the high pressure
pump pumps out the fuel which will be injected into
the cylinder by fuel injector (with pressure of
21-23MPa) via the high pressure oil line for
compressed combustion; The redundant fuel will flow
back into the fuel tank via the oil return pipe of the
injector.
4.2 Fuel injector
Operating principles:
High-pressure oil pump transports high-pressure
diesel oil into the lower end of the needle valve
through inlet connector and oil duct and makes it act
on the pressure-bearing cone of the needle valve.
When this pressure is higher than the pretightening
force of the high-pressure spring, the needle valve is
lifted. The high-pressure diesel oil inside the annular
oil cavity of the needle valve is ejected at high speed
along the crack formed by the needle valve and the
body; when the fuel injection pump stops feeding oil,
the pressure inside the annular cavity decreases and
the needle valve drops into the body under the action
of the high-pressure spring, stopping ejecting oil.
A- Fuel injector body

B-Pressure adjusting shim
C-Pressure adjusting spring
D-Intermediate link block
E-Injection nozzle matching part
F- Tight cap
G- Copper gasket
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5. Cooling system
Functions:
Make the engine keep appropriate temperature range proper for about 1/3-1/2 of the bearing cavity or it may
under all working conditions. cause the bearing overheat.
Cooling mode:
Forced circulation and sealed water cooling type,
namely, using water pump to increase the pressure of
the coolant and forcing it to circulate inside the
engine.
Compositions:
It consists of water pump, radiator, cooling fan,
thermostat, supply bucket, engine body, cylinder
sleeve, cylinder head and other accessory devices.
The cooling system consists of cooling water tank,
water pump fan assembly, thermostat parts and
connecting hose, etc. The whole cooling system is the
forced circulation and sealed water cooling type.
1. Cooling water system: When running the diesel,
the crankshaft pulley drives the water pump to rotate
via the belt, and presses cooling water into the water
cavity to cool the cylinder sleeve, body and cylinder
cap, and then flows into the thermostat. When the
outlet water temperature is lower than 70℃, the
thermostat closes and the cooling water flows back to
the water cavity of the body and to the water pump
again through the corresponding holes at the bottom
of the cylinder head and on the upper plane of the
body, so as to realize the minor-cycle. When the
outlet water temperature is higher than 70℃-80℃,
the thermostat will open fully, while the cooling
water flows into the upper water chamber of the
water tank via the thermostat and then flows into the
lower chamber via the radiating pipe. In this process,
the cooling water is cooled by the air absorbed or
exhausted by the fan, to realize a major cycle.
2. Water pump: The centrifugal water pump is used
for this diesel. During the use, when the water seal is
worn and the weep hole beneath the pump casing
leaks, water seal shall be replaced. Do not seal off the
weep hole, or else, water will enter into the bearing,
causing it worn quickly. If too much water is leaked
and the bearing gives out abnormal noises, the
bearing shall be considered to be replaced.
Inject grease into the oil nozzle of the water pump,
which shall be conducted about every 200 working
hours for diesel. The grease it #4 albany grease. The
lubricating oil should not be too much, and it is
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3. The thermostat is made of bellows and is single

valve type, which is installed in the delivery port at
the front end of the cylinder cap. It contains liquid
that is sensitive to temperature, to automatically
control the valve. The thermostat is type 155B.
The thermostat valve remains closed when the
temperature of the cooling water inside the diesel is
lower than 70℃, and the cooling water is in internal
minor-cycle; when the temperature is high than 70℃,
the cooling water is in major cycle; when the
temperature exceeds 85℃, the thermostat opens
fully.
Notice:
When the diesel cold starts, if water is exhausted
from the discharging tube while the temperature is
lower than 70℃ or no water is exhausted from the
discharging tube while the temperature is lower than
70℃, this means that the thermostat fails and shall
be dismounted for inspection.
Do not remove the thermostat casually, for cooling
water with extremely low temperature will affect the
normal running of the diesel engine.
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6. Electric system
6.1 Introduction to the starter
6.1.1 Structure principle of the starter
C D E
B F
G I
A
H J
K L
M
S
R Q
P
AA
N N
Y
T
X W O
V U
A- Single-acting clutch B-Shift fork seat C-Fork shaft D-Fork E-Clamp ring F- Gasket
G- Waterproof rubber sleeve H-Rubber gasket I-Solenoid switch J-Armature assembly
K-Stator assembly L-Carbon brush holder assembly M-Rear cover N-Waterproof rubber gasket
O-Planet gear ring coverplate P-Rubber pad Q-Planetary gear ring R-Ball S-Planetary gear
T-Planet pinion shaft U-Bump-type rubber blanket V-Internal friction plate W-Bearing
X-Shock absorber Y-External friction plate Z-Planet pinion shaft rand AA-Front end housing
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6.1.2 Use and maintenance of the starter
1. Notice for daily use of the starter
◆Inspect the connection status of all parts and the

degree of tightness of wires regularly.
◆Clean up the oxide on the wires and binding posts

and the dust and oil stain on the starter to keep them
clean.
◆ Preheat the starter for 10-15 seconds before

starting it in cold day, and then use it.
◆The starter can only work for a short time, so each

starting time shall not be longer than 5s. If it fails to
start for the first time, then start it again after 45-60
seconds.
◆ Loosen the starting switch immediately after

starting the engine to avoid wearing the starter.
2. Maintenance for the starter after using for one

year:
◆Clean up the oil stains and dirt inside the starter

and on the interfaces.
◆Inspect whether the commutator surface is bright

and clean, the brush is jammed inside the brush
holder, the brush is connected to the commutator
appropriately, and the brush is installed high enough
(the height of QD1536S starter shall not be lower
than 10mm). If the commutator surface has been
slightly burned, it can be polished with No. “00”
abrasive paper. If it has been severely burned with
out-of-round more than 0.08mm, it must be reworked
and polished with No. “00” abrasive paper.
◆ Inspect the pressure of brush return spring

(measure with the spring balance); the pressure of
QD1536S return spring against brush shall range from
1.2kg to 1.5kg, or else, it shall be adjusted or
replaced.
◆Use a brush or a rag to remove old grease and dust

from the stator and rotor. lubricate rotor spline, shaft
sleeve and inside hole of the shaft sleeve with lithium
grease during installation.
◆inspect the technical status of the field winding.
◆check the overrunning clutch for binding.
◆check the condition of solenoid copper contact and

stationary contact. If there are any burn-out or black
spots, use a piece of No. 00 sandpaper to smooth it.
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6.2 Alternator Structure and Principle
Alternator Overview
An alternator is a three-phase AC generator that converts mechanical energy into electrical energy through a
rotating magnetic field. A set of diode rectifiers are used to convert AC to DC, which charges the battery and
provides power to automobile electrical components.
Alternator Diagram
Brushless generator structure figure
Rectifier diode
Back bearing Pump frame

Rear end cover
Inner stator coil
Rotor assembly
Regulator Bearing plate
Front-end shield
The wind
vane
Inner stator Real

core
Fore
Rear end cover
bearing Grab pole Outer stator
Belt Axle
pulley assembly
sleeve
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Precautions
1. Wire connection
An alternator must be connected to the battery in parallel. Cable connections must be tight and secure. Avoid
any looseness or bad connection. The air conditioner must use different cables from those of other electrical
components. the cross section of the cable for electrical components except A/C must satisfy the following
requirement: when current is 35A, ф≥6mm2 ; when current is 70A, ф≥13mm2 ; when current is 100A, ф≥20mm2.
For exciting and signal wires, ф=0.75~1.5mm2. for lead wire of exciting coil or signal wire, ф=0.75~1.5mm2. The
output leads from the alternator to the battery or to other electrical components shall be as closer as possible, to
reduce voltage drop. Alternator indicator output terminal is marked D+, between which and terminal B+ a charge
indicator light (2W) must be wired. Neutral terminal is marked N, to which a relay switch, charge indicator light
can be wired. A phase terminal marked W can be connected to tachometer sensor, relay switch, charge indicator
light, etc., with a maximum current output of 500mA. When connecting the tachometer with a sensor, the
pole-pair number of the rotor claw pole must be given (6 or 8 pole-pairs).
2. Mechanical assembly
◆Adjust tensioner arm to keep the proper tension on the belt. Tighten all the nuts on the alternator to the
required torques.
◆Ensure the alternator brackets are strong and rigid enough.
◆For the alternator with pump, ensure the air hose and oil hose are unblocked.
3. Assembly and drive system

Check all the fastening bolts on the alternator for looseness. Check if the drive belt is at specified tension (20-30
kg). If the belt is too loose, it will slip (burning rubber smell will come out) when the alternator is operating at
high speed and has a heavy duty, thus cause decreased alternator output. Also the alternator that is overheated
will lead a shorter bearings life. The drive belt that is too tight may cause damage to alternator bearings, friction
between rotor and stator, or broken mounting ear
◆An interference between the alternator and any other component may cause alternator short circuit and the
internal electrical component burn-out. Continuous collision also can cause damage to the electrical components
inside the alternator.
4. Unusual noise of the alternator
◆The causes for unusual noise from an operating alternator: bearing damage, friction between rotor and stator,
noise from the rectifier that is broken down Check to see if the drive belt is too tight, if the alternator adjustment
bracket allows adjustment of the alternator positon for tight spaces with the engine brackets, and if the
alternator vibration is normal.
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6.3 Thermostart
Principle and composition of the thermostart

A thermostart plug produces flame in the air inlet to assist in the starting of diesel engines.
A thermostart contains a thermostart plug and fuel line.
D B
C
A-Thermostart plug B-Join battery positive C-Fuel line D-Join diesel filter
Whether to use a thermostart to assist in engine starting depending on the engine temperature the driver
estimates. Generally speaking, a thermostart is used when ambient temperature is at around 0°C. it is not
necessary to use a thermotart when the temperature is above 5°C.
Before starting the engine, push down the thermostart switch and wait for 30 to 50 seconds. Turn the ignition
key switch to the preheating position. At this time the fuel will be supplied through the fuel filter to the glow
plug, which will spray flam in the air inlet. After the engine starts, turn off the thermostart switch to cut the
power off the glow plug.
Notice:
Do not power on the glow plug over 60 seconds in general, because it may burn out the plug.
no preheating or too short preheating time will not help with engine start.
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Chapter 3 check and adjustment
1. Valve lash clearance
Cause: 2. Air leak at cylinder head cover gasket.
Low compression in one or more cylinders, black

smoke in exhaust, unusual noise.
Equipment:
An open-end wrench, a flat-headed screwdriver, and a
feeler gauge.
Test procedures and adjustment
1. Remove the cylinder head cover. Check and tighten
rocker arm support studs.
2. Rotate crankshaft until cylinder #1 and #4 are in 7
TDC position (at this time the notch 0 on the
crankshaft pulley is exactly align with the pointer on
the timing belt cover. There must be a cylinder whose
intake and exhaust valves are both closed. The piston
of this cylinder is exactly at TDC of the compression
stroke.
3. Loosen the fastening nuts and rotate the adjusting
screws with a flat-head screwdriver. Insert the feeler
gauge into intake and exhaust valves of cylinder #1,
intake valve of cylinder #2, and exhaust valve of
cylinder #3 respectively, check and adjust the valve
lash to a range of 0.30-0.35mm when the engne is
cold.
4. Turn the adjusting nut to an extent that the
pushrod can be spun with fingers. When done the
proper adjusting, tighten the adjusting nut tight
enough to prevent loose.
5. Rotate the crankshaft one revolution (i.e. 360
degree) according to cylinder firing order, that is, for
three-cylinder engine: 1-3-2; for four-cylinder engine:
1-3-4-2. Check and adjust the valve lash the same way
described above (note that do not in reverse order).
Specifications:
Intake valve lash (cold): 0.30-0.35mm
Exhaust valve lash (cold) : 0.35- 0.4mm
Test results:
If the problem still exists after the adjustment, check
for other reasons.
1. Carbon buildup on piston rings, piston rings are
stuck or worn.
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1-Feeler gauge
2-Rocker arm
3-Adjusting screw
4-Locking nut
5-Push rod
6-Valve spring
7-Valve lash clearance
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2. Cylinder pressure
Cause:
Low compression in cylinders. White smoke in
exhaust.
Equipment:
a pressure gauge, an open-end wrench.
Connection:
Connect the sensor to the glow plug hole, then
connect the pressure gauge.
Test procedures:
First connect the pressure gauge to the cylinder #1,
then #2, #3, and #4, observe the reading change on
the gauge.
Specification
Pressure readings: 2400 kPa±175 KPa
Test results:
The following reasons shall be considered if the
pressure is not in the range.
1. Valve leak
2. Valve spring is broken
3. Improper valve lash
4. Carbon buildup on piston rings, piston rings are
stuck or worn.
5. Air leak at cylinder head cover gasket.
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3. Fuel injection pump timing check
Cause:
High fuel consumption, poor power performance,
black smoke in exhaust
Equipment:
Special socket wrench or open-end wrench.
Test procedures:
1. Eliminate the air in the fuel system, keep rotating
the crankshaft until the injection pump is full of fuel.
Remove the high pressure fuel pipe from the cylinder
#1, blow out the left fuel in the hole of the connector
of the fuel outlet valve seat. Slow rotate the
crankshaft in positive direction, while watching the
fuel surface in the connector hole. At the moment the
fuel surface waves, stop rotating the crankshaft
immediately.
2. Check to see if the dial on the flywheel aligned with
the mark on the bell housing meets the optimum
value.
3. If the fuel injection advance angle is too large or
too small, loosen the three nuts on triangular flange
in the injection pump. increase or reduce the
injection advance angle by turning the injection pump
outwards or inwards. tighten the three nuts on the
triangular flange. Check the injection advance angle
again until the requirement is met.
Specifications:
injection advance angle: 16°±1°
Test results:
if the injector timing is okay, check for other reasons.
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4. Fuel injection pump calibration
Cause:
Uneven fuel supply to each cylinders, and low fuel
pressure.
Equipment:
Fuel pump bench
Test procedures:
1. Install a fuel pump on the bench, connect a
standard fuel injector, and regulate the amount of
fuel delivered to the cylinders.
2. If there is obvious uneven fuel supply to each
cylinder, rotate the plunger to regulate the amount of
fuel delivered to the cylinders.
3. Keep rotating the plunger clockwise or
counterclockwise to reduce or increase the pump
volume until the fuel supply to each cylinder is even
enough to meet the requirement.
Specifications:
Unevenness of the fuel supply to each cylinder: rated:
10%, correction:10%, at idle: 30%
Test results:
If there is no problem as to unevenness of fuel supply
to each cylinder, check for other reasons.
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5. Fuel injector atomization
Cause:
Black smoke from a diesel engine, low engine power
output, rising fuel consumption, etc..
Equipment:
Pressure gauge, open-end wrench, fuel injector bench
Test procedures and adjustment
1. Manually pump fuel until the pressure reach
10.78Mpa, and continue to slowly pump the fuel to
the rated injection pressure. Check the nozzle hole for
any dripping or leak. If dripping or leak still exists after
repeated tests, remove the nozzle, flush, check,
smooth or replace it, then conduct the test again.
2. Regulating the injection pressure: remove the
adjusting capnut, and adjust injection pressure to
rated value by loosening or tightening the adjusting
screw. Then tighten pressure adjusting capnut, and do
the test again.
3. Observing the fuel mist quality: conduct fuel
atomization about once a second. The fuel mist shall
be fine and even mist without any visible fuel spray,
uneven spray or only one side spray. A clear sound
can be heard when shutting off the fuel delivery.
Specification
Injector set pressure: 23~24MPa
Test results:
If the injection pressure is lower than injector set
pressure, clean and smooth the nozzle, or replace
with a new qualified nozzle.
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6. Oil pressure check
Cause:
This check is to determine if there is wear on the
bearings or lubricating oil system components.
Equipment:
•pressure gauge assembly
•hose assembly
•thermometer
Connection:
1. Remove the oil pressure sensor
Note: the threads are 1/8 NPT threads, which need
special adaptors and hoses with pressure range in
(0—700)KPa ((0—6.9) bar or (0—100) psi)
2. Connect pressure gauge and hose assembly
Important Notice: If the pressure readings are lower
than 72 kPa (0.72 bar or10.5 psi), the engine will
shut off.
3. Place the thermometer in the place where the oil
filter is.
Note: working at an extreme condition that is
bearable for engine and oil pressure gauge will cause
the readings of the gauge as high as 582KPa (5.82 bar
of 85 psi). It won’t cause damage to engine.
4. Run the engine for about 5 minutes until the oil
reaches the specified temperature. Then check the oil
pressure.
Specification
Oil temperature ------------------------------------------------------------------- (at 825 rpm) 93°C (200F)
Oil temperature ------------------------------------------------------------------- (at 2500 rpm) 105°C (220F)
Minimum allowed oil pressure (at 825 rpm) ------------------------------- 100 kPa (1 bar or 15 psi)
Minimum allowed oil pressure (at 2500 rpm) ----------------------------- 277—483 kPa (2.77—4.83 bar or 40—70 psi)
Test results:
If the oil pressure is not within the specifications,
check the oil pressure regulating valve for damage,
broken spring or stuck valve. (Refer to Chapter 4 of
this Part to perform a repair as needed).
A-Thermometer
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7. Check and adjustment of the starter pinion place
1. Pinion to shim ring clearance

Power on the solenoid to pull the plunger totally
close to the solenoid. this moves the starter pinion to
the farthest position. Check the clearance between
the edge of the pinion gear and the shim ring. It shall
be 0.5-3mm. If not, adjust the clearance. a shim can
be placed under the solenoid switch to ensure the
pinion gear mesh is proper.
2. Installation place of the pinion gear
when installing the starter, keep a clearance of
3-5mm between the edges of the pinion gear and ring
gear. If the clearance is not in the range, add shims
between the installation surface of the starter and
flywheel housing to ensure the pinion gear have a
proper mesh.
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Chapter 4 Diagnosis and Troubleshooting
1. White smoke
Step Inspection parts Failure cause Correction
Fuel injector pressure lower

Repair or replace fuel injector (Refer
1 Fuel injector than 23MPa, inefficient fuel
Section 3 of Chapter 6 in Part 2).
atomization, and leak.
2 Coolant temperature Low coolant temperature. Warm up the coolant.
Cylinder gasket, head cover or Replace it (Refer Section 3 of Chapter 2 in

3 Cylinder
cylinder damage. Part 2).
Timely drain the water from the fuel, or

4 Fuel Water in fuel.
change the fuel.
2. Blue smoke
Piston rings are worn out, or lack of elasticity

Replace the piston ring (Refer
1 Piston ring due to carbon buildup, resulting in oil entering
Section 4 of Chapter 2 in Part 2).
into combustion chamber.
2 Oil Engine oil level is too high. Drain the oil to the correct range.
Upper and lower compression rings installed Reinstall compression rings

Compression
3 wrong way around, or their openings offset less (Refer Section 3 of Chapter 2 in
rings
than 180°, resulting in oil carry-over. Part 2).
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3. Black smoke or gray smoke
Injector or nozzle damage or obstructed, Maintenance or replacement (Refer

1 Fuel injector resulting in inefficient fuel atomization and to Section 6 of Chapter 3 in this
incomplete combustion. Part).
1. Regulate the fuel injection

1. Late injection, causing part of fuel
advance angle to 16°±1° (Refer to
combusted during exhaust process;
Fuel injection Section 4 of Chapter 3 in this Part).
2 2. Inadequate fuel supply to each cylinder of
pump 2. Perform pump calibration (Refer
the injection pump, causing uneven
to Section 5 of Chapter 3 in this
combustion.
Part).
1. Valve is not sealing properly, causing low Grind the valve or adjust the valve
3 Air valve cylinder compression ratio; lash (Refer to Section 1 of Chapter 3
2. Valve open slow, engine runs rough. in this Part).
Clean air cleaner or replace the air

4 Air filter Air cleaner is restricted, low air intake.
filters.
5 Load Load is excessive. Reduce the load to specified range.
4. Low compression in cylinders
Intake and exhaust The valves are not sealing Grind the valves (Refer to Section 4 of
1
valves properly. Chapter 1 in Part 2, or adjust valve lash).
Replace it (Refer Section 3 of Chapter 6 in

2 Valve spring Valve spring is broken.
Part 2).
Adjustment (Refer to Section 1 of Chapter 3

3 Valve lash clearance Valve lash is not proper.
in this Part).
Carbon buildup on piston rings, Clean out the carbon buildup or replace
4 Piston ring piston rings are stuck or worn with new parts (Refer Section 4 of Chapter
out. 2 in Part 2).
Cylinder cover Cylinder head bolts are loose or Tighten the bolts to 135-150 N.m or
5
Cylinder head gasket cylinder head gasket is cracked. replace the head gasket.
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5. Air intake system restriction
Air filters are cracked, air cleaner is Replace the air filters or clean air
1 Air filter
restricted. cleaner.
2 Air intake system Air intake line is obstructed. Clean the air intake line.
6. Black smoke in exhaust
1 Load Load is excessive. Reduce the load to specified range.
Plunger spring of the injection pump is Replace or repair fuel injection

2 Fuel injection pump broken, or tolerance of fuel supply to each pump (Refer to Section 5 of
cylinder excesses the specifications. Chapter 3 in this Part).
Adjustment (Refer to Section 1 of

3 Valve lash clearance Valve lash is not proper.
Chapter 3 in this Part).
Replace the spring or grind the

Valve spring is loose or valve is not sealing
4 Air valve valve (Refer Section 4 of Chapter 1
proper.
in Part 2).
Fuel injection Adjustment (Refer to Section 1 of

5 Fuel injection advance angle is not proper.
advance angle Chapter 3 in this Part).
Replace or clean the air filters or

6 Air intake system Air filters or air intake line are obstructed.
air intake line.
Maintenance or replacement
Fuel atomization is inefficient, or nozzle
7 Fuel injector (Refer to Section 6 of Chapter 3 in
leaks.
this Part).
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7. Unusual noise of the diesel engine
Inspection
Step Failure cause Correction
parts
Fuel injection Fuel injection advance angle is too large; Regulate the fuel injection advance
1
advance angle rhythmic metal tapping sound in cylinders. angle to 16°±1°.
Maintenance or replacement (Refer

2 Fuel injector Injector is dripping or needle valve is stuck.
to Section 6 of Chapter 3 in this Part).
Valve lash is too large, and there is clear, Adjustment (Refer to Section 1 of
3 Air valve
rhythmic tapping sound. Chapter 3 in this Part).
Adjustment (Refer to Section 1 of

4 Piston Piston is touching the valve.
Chapter 3 in this Part).
Cylinder head Cylinder head gasket is not thick enough;

5 Replace the cylinder head gasket.
gasket piston is touching the cylinder head.
Valve spring, Valve spring is broken, pushrod is bending,

Replace the damaged components
6 pushrod, tappet is worn, and making the valve
(Refer to Chapter 1 in Part 2).
tappet sounds tapping.
The clearance between piston and cylinder Repair or replace the major engine
Piston and sleeve is too large, but the tapping sound is components (pistons, piston rings,
7
cylinder sleeve becoming lighter as the diesel engine piston pins, and sleeves) (Refer to
temperature rises. Chapter 1 and 2 in Part 2).
The gap between the connecting rod

Connecting rod bearings is too large. A sudden drop of Replace connecting rod bearings
8
bearing rotational speed leads to a heavy knocking (Refer to Chapter 2 in Part 2).
noise.
The gap between connecting rod lining and

Connecting rod Replace the connecting rod and
piston pin are too large. The sound is light
9 lining and piston pin bushing (Refer to Chapter
but harsh, especially clear when engine is
piston pin 2 in Part 2).
at idle.
Worn thrust bearings cause a larger axial

Crankshaft
10 gap. Crankshaft motion makes a tapping Replace thrust bearings.
thrust bearings
noise when engine runs at idle.
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8. Engine is not running properly or frequently shut off
Air intake line is obstructed; under

1 Fuel tank cap Clean or replace the fuel tank cap.
pressure in fuel tank.
Diesel grade is not correct or fuel level is Change to the correct grade of diesel
2 Fuel tank
low in the tank. or fill the supply tank.
3 Air filters Air filters are dusty or plugged. Clean or replace air filters.
4 Fuel oil filter Fuel filters are obstructed. Replace it.
5 Sediment cup Sediment bowl is shut off. Turn on the sediment bowl.
Intake and exhaust The gap between the inlet and exhaust Adjustment (Refer to Section 1 of
6
valves valve is improper. Chapter 3 in this Part).

7 Fuel injector Fuel atomization is inefficient.
Replace the four major engine

Four major engine The four major engine components worn components (piston, piston rings,
8
components out. piston pins, and cylinder sleeves)
(Refer to Chapter 1 and 2 in Part 2).
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9. Low power output

Fuel filters or
Fuel inlet/outlet lines or
1 fuel transfer Clean or replace the fuel tank cap.
strainer is obstructed.
pump
Injector is damaged or
plugged; injector pressure is Maintenance or replacement (Refer to Section 6 of
2 Fuel injector
not proper or fuel atomization Chapter 3 in this Part).
is not inefficient.
1. Pump plunger wears excessively;
Fuel injection Injection pump is pumping 2. Governor spring is deformed and loose;
3
pump steadily. 3. Injection pump is malfunctioning. Refer to
Chapter 3 of this Part to repair the injection pump.
4 Fuel system Air enters into fuel system. Expel air from the fuel lines.
Fuel injection Fuel injection advance angle is
5 Regulate the fuel injection advance angle to 16°±1°.
advance angle not proper.
The tolerance of fuel supply to Check and correct the unevenness of fuel supply to
6 Fuel supply each cylinder excesses the each cylinder to the specifications (rated: 10%,
specifications. correction: 10%, at idle: 30%)
Air intake pipe
7 Air intake system restriction. Clean or replace air filters.
air cleaner
The gap between the inlet and Adjustment (Refer to Section 1 of Chapter 3 in this
8 Air valve
exhaust valve is improper. Part).
Replace the worn components as necessary, and
adjust valve timing:
Components of valve Air intake valve opens prior to TDC 12±3°;
9 Valve timing
mechanism wear excessively. Air intake valve closes after BDC 38±3°;
Air outlet valve opens prior to BDC 50±3°;
Air outlet valve closes after TDC 14±3°.
Air leaks between injector Clean out carbon buildup or tighten the retaining
10 Injector seat
seat and cylinder head. nuts.
Cylinder cover
Cylinder cover bolts are loose. Adjust cylinder head nut torque to 145~155 N.m.
11 cylinder head
Cylinder head gasket leaks. Replace the cylinder head gasket.
gasket
Carbon buildup on piston
Clean out the carbon buildup or replace with new
12 Piston ring rings, piston rings are stuck or
parts (Refer Section 4 of Chapter 2 in Part 2).
worn.
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10. Oil and water mix
Cylinder sleeves, Cylinder sleeves or water seal rings are

1 Replace it.
water seal rings damaged.
2 Cylinder head gasket Cylinder head gasket cracks. Replace it.
3 Cylinder cover Cylinder head cracks. Replace it.
4 Engine body Cylinder cracks. Replace it.
11. Engine running overspend
The governor is out of work when the

1 Governor linkage is stuck at the full open position,
resulting in engine runaway.
Governor sliding Maintenance or replacement (Refer

2 Governor sliding disc bushing is stuck.
disc bushing to Section 5 of Chapter 3 in this Part).
Reduce the oil level to specified

The problem of engine oil carry-over is range or replace the major four
3 Oil
serious. engine components (Refer to Chapter
1 and 2 in Part 2).
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12. Engine speed surges
Inspection
parts
Maintenance or replacement (Refer to

1 Fuel injector Fuel dribble in the injector.
Section 6 of Chapter 3 in this Part).
The gap between fork and adjusting arm is

Fork and Replace it. (Refer to Section 5 of
2 too large; steel ball and sliding disc have
adjusting arm Chapter 3 in this Part).
dent on them due to wear.
Check and correct the unevenness of

Fuel supply to each cylinder is uneven; the
Fuel injection fuel supply to each cylinder to the
3 axial gap of injection pump and camshaft is
pump specifications (rated: 10%, correction:
too large.
10%, at idle: 30%).
Sliding disc Maintenance or replacement (Refer to

4 Sliding disc bushing is stuck.
bushing Section 5 of Chapter 3 in this Part).
13. Engine is overheat
Add coolant to 5mm above the radiator

Coolant level is low or there is air in
1 Coolant cover sealing surface or eliminate the air
cooling hose.
from the cooling hose.
Radiator and
Sediment buildup in water tank and
2 cooling system Use cleaner to flush the cooling system.
hose.
hose
Replace the water pump, or adjust the

belt tension (when exerting a force of
Water pump
about 98N on the middle part of the belt,
3 assembly or fan Water pump leaks or fan belt loose.
for a new belt, the dent shall be about
belt
7-9mm deep; for an old belt, the dent
shall be about 11-13mm deep).
4 Thermostat Thermostat does not open. Replace the thermostat.
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14. Coolant temperature is out of normal
Inspection
parts
1 Load Engine is overloaded for a long time Reduce load to normal range.
Adjust valve timing

Air intake valve opens prior to TDC 12±3°
2 Valve timing Valve timing is not proper Air intake valve closes after BDC 38±3°
Air outlet valve opens prior to BDC 50±3°
Air outlet valve closes after TDC 14±3°
Fuel injection Fuel injection advance angle is not Regulate the fuel injection advance angle
3
advance angle proper to 16°±1°
Add coolant to 5mm above the radiator

coolant level is low or there is air in
4 coolant cover sealing surface or eliminate the air
cooling hose
from the cooling hose
5 Water tank It is not clean inside the water tank Sediment buildup in water tank and hose
Replace the water pump, or adjust the

belt tension (when exerting a force of
about 98N on the middle part of the
6 Water pump Water pump leaks or fan belt loose
belt, for a new belt, the dent shall be
about 7-9mm deep; for an old belt, the
dent shall be about 11-13mm deep)
7 Thermostat Thermostat does not open Replace the thermostat
Lubricating oil level is below or above

specification; lubricating oil pressure is
Add lubricating oil with a grade above CD
8 Oil low; lubricating oil was diluted and
to specified level (5L-6L).
deteriorated, or the oil grade is not
proper
Piston ring leaks; pistons and cylinder

Piston ring, Replace for new components as
9 sleeves wear out; gas enters into
cylinder sleeves necessary
crankcase
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15. Zero or low lubricating oil pressure
Lubricating oil level is below or above Add lubricating oil with a grade above
1 Oil
specification CD to specified level (5L-6L).
Lubricating oil
2 Oil line is obstructed or leaking Clean or repair the oil line
line
3 Oil Filters Lubricating oil filter is plugged Clean or replace the fuel tank cap
Oil pressure Oil pressure gauge is not reading the Replace oil pressure gauge or oil
4
gauge actual pressure sensor
Clean or replace the fuel tank cap

5 Engine oil pump Oil pump is plugged or deteriorated
(Refer Section 4 of Chapter 4 in Part 2)
Oil pump bypass Replace for new bypass valve and

6 Bypass valve failed or is damaged
valve adjust the set pressure to 600KPa.
7 Oil pump gasket The gasket cracks Replace it.
8 Oil line Oil line is obstructed Clean the oil line
16. Lubrication oil pressure high
Inspection
parts
Oil pump Bypass valve is plugged or the set pressure Check to see if the set pressure is
1
bypass valve is too high 600KPa.
Use oil with proper viscosity

2 Oil viscosity The oil grade is not correct
according to ambient temperature
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17. Lubricating oil temperature high
Inspection
parts
Use oil with proper viscosity an grade

Lubricating oil level is low or the oil grade is above CD according to ambient
1 Oil
not correct temperature, and add the oil to
specified range (5L-6L)
Lubricating oil Lubricating oil pressure is not in the range Refer to “Zero or low lubricating oil
2
pressure of 200-400KPa pressure”.
Replace the four major engine

Four major components (piston, piston rings,
Piston ring leaks; pistons and cylinder
3 engine piston pins, and cylinder sleeves)
sleeves wear out; gas enters into crankcase
components
(Refer to Chapter 1 and 2 in Part 2)
18. Lubricating oil consumption excessive
Use oil with proper viscosity and

1 Oil The oil grade is not proper grade above CD according to
ambient temperature
Check and repair piston rings,

Severe friction between pistons and cylinder piston and cylinder sleeves
Piston, cylinder
2 sleeves; oil carry-over causing excessive oil
sleeves (Refer Section 4 of Chapter 2 in
consumption
Part 2)
Reinstall or replace compression

Upper and lower compression rings installed rings
3 Piston ring
wrong way around; excessive wear; oil carry-over (Refer Section 4 of Chapter 2 in
Part 2)
Front and rear oil seals on crankshaft crack and

4 Oil seal Replace it
leak
All gaskets on
5 Leaks from sealing on oil pan, gear chamber, etc. Replace it
the vehicle
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19. Starting motor low speed
1 Battery Battery voltage is low Charge the battery
2 Starter Bad contact or deterioration Clean or replace the fuel tank cap
Pinion of the motor does not mesh with ring Adjust the starting motor installation
3 Starter
gear place
20. Engine will not start or difficult to start
Air intake line is obstructed; under

1 Fuel tank cap Clean or replace the fuel tank cap
pressure in fuel tank
Use fuel with correct grade according to the

2 Fuel Fuel grade is not correct
ambient temperature
3 Sediment cup Sediment bowl is shut off Turn on the sediment bowl
Air in the fuel lines or fuel lines are

4 Fuel lines Expel the air out or clean the fuel lines
obstructed
5 Battery Battery has failed or voltage is low Replace or charge the battery
6 Fuel oil filter Fuel filters are obstructed Clean or replace the fuel tank cap
Engine speed is lower than 90rpm at Check and repair the starting motor (Refer to
7 Starter
the start moment Section 6 of Chapter 2 in this Part).
Use oil with proper viscosity an grade above CD

Lubricating oil is contaminated, or not
8 Oil according to ambient temperature, and add the
meet the viscosity requirement
oil to specified range (5L-6L)
Injector nozzle is dirty or plugged, or Clean or replace the fuel tank cap (Refer to
9 Fuel injector
has fuel dribble Section 6 of Chapter 3 in this Part).
Fuel injection Injection pump timing is not correct or Perform pump calibration or replace the pump
10
pump injection pump failed (Refer to Section 5 of Chapter 3 in this Part).
Intake and The gap between the inlet and exhaust Adjustment (Refer to Section 1 of Chapter 3 in this
11
exhaust valves valve is improper Part).
Four major The four major engine components Replace the four major engine components
12 engine wear out; cylinder pressure is (piston, piston rings, piston pins, and cylinder
components maintained at 2400KPa sleeves) (Refer to Chapter 1 and 2 in Part 2)
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SHANDONG LOVOL HEAVY INDUSTRY INTERNATIONAL TRADING CO,. LTD

Add: NO.192 Beihai S.Rd., Fangzi District, Weifang, Shandong,China.
Zip code:261206
Website:www.lovol.com.cn
163
Specifications and designs are subject to change without prior notice.
Machines shown may include optional parts.

Manual de Mantenimiento TB504 Motor

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Manual de Mantenimiento TB504 Motor

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D/4B/QC Diesel Engines

THE PEOPLE’S REPUBLIC OF CHINA

Chapter 1 Safety Precautions

This is a safety symbol. Safety symbols are found on

The tips for operating procedure and safety

Do not touch the engine body while the engine is

Other symbols are described in the tractor

3. Engine hoisting equipment

Correct equipment and method shall be used for

Before hoisting the engine, check that the lifting eyes

Chapter 2 Technical parameters

1. Main technical parameters

Model Unit QUANCHAI

Model —— QC4102T50 QC4102T55 QC4105T55 QC4105T60 QC4108T65 QC4108T70 QC4108T75

Type —— Upright, four-stroke, water-cooled

Rated power kW 36.8 40.4 40.4 44 48 51.5 55

Maximum torque N·m 212-217 227-233 240-245 235-250 260-270 260-270

Lubrication mode —— Mandatory and splash lubrication

Startup mode —— Electrical starting

Model Unit QUANCHAI

Model —— 4B4-35M22 4B2-40M22

Type —— Upright, four-stroke, water-cooled

Cylinder bore × stroke mm 85×100 90×100

Rated power kW 25.7 29.4

Rated rotation speed r/min 2350 2400

Fuel consumption under rated

Lubrication mode —— Pressure lubrication

Startup mode —— Electrical starting

QC490T/QC495T/QC498T series engine

Model Unit QUANCHAI

Model —— QC490T40 QC495T45 QC495T50 QC498T50

Four-stroke, water-cooled, upright, direct injection combustion

Cylinder bore × stroke mm 90×105 95×105 98×105

Rated power kW 29.4/2400 33.1/2400 36.8/2400 36.8/2400

Cylinder sleeve form —— Wet type Dry type

Rated rotation speed r/min 2400

Maximum torque N·m 155 170 175 190

Rotating speed at maximum

The fuel consumption rate

The minimum fuel

Engine oil consumption

Lubrication mode —— Pressure lubrication

Startup mode —— Electrical starting

3. Main performance parameters of diesel engine

Model QC4102T50 QC4102T55 QC4105T55 QC4105T60 QC4108T65 QC4108T70 QC4108T75

Type Four-stroke, water-cooled, upright, direct injection combustion chamber

Way of air inlet Naturally aspirated

Number of cylinders × cylinder bore × piston

Total displacement L 3.857 4.087 4.324

Cylinder distance mm 124

Ignition order 1-3-4-2

Net quality of engine kg 430

Size of engine (length/width/height) mm 932×626×760

Cylinder sleeve form Dry cylinder sleeve

Compression ratio 17:1

Rated air inlet volume of engine m3/h ≥236 ≥250 ≥265

Model QC4102T50 QC4102T55 QC4105T55 QC4105T60 QC4108T65 QC4108T70 QC4108T75

Total power /rotating speed (KW/rmin) 12h

Power/rotating speed (KW/rmin) 12h power of

Rotating speed at maximum torque point r/min 1650±100 1680±100

The fuel consumption rate with the rated working

The minimum fuel consumption rate with external

Engine oil consumption rate (12h working

Low idling speed r/min 700±30