FAW Jiefang Automotive 485 Operation & Maintenance Manual
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FAW Jiefang Automotive 485 Operation & Maintenance Manual

4dw series
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  • Page 2 When ordering engine accessories, please tell us the Model, declared power and speed, order No., month and year of manufacture, and serial No. of the diesel engine(s) you purchased, so that our company can provide you with correct accessories. FAW Jiefang Automotive Company, Ltd. Wuxi Diesel Engine Works August 2006...
  • Page 3 Written by: Zhai Yonghui Huang Qiwei Yang Xueming Reviewed by: Wang Xinze Li Peiran Yao Zugen...
  • Page 4 Contact phone numbers of our Works are as follows: Sales Company: 0510-85013436 (fax) Main engine dept.: 0510-85014990-8362, 8363 Accessories dept.: 0510-85014990-8370, 85010814 Service dept.: 0510-85014990-8372, 8373 FAWDE 24h hotline: 0510-85017315 Production License No.: XK06-002-00014 FAW Jiefang Automotive Company, Ltd. Wuxi Diesel Engine Works August 2006...

  • Page 6: Table Of Contents

    CONTENTS (I) Right view of 4DW81-46 diesel engine ………………………..……………………… 1 (II) Left view of 4DW81-46 diesel engine ………………………………………………… 2 (III) Front view of 4DW81-46 diesel engine ……………………………………………….. 3 (IV) Vertical view of 4DW81-46 diesel engine ……………………………………..……… 4 (V) Power output end of 4DW81-46 diesel engine ………………………………………… 5 Chapter I Technical Characteristics ……………………………………………………..………...
  • Page 7 VI. Severe vibration .………………………………………………………………..……… 45 VII. Engine overheat ………………………………………………………………..……… 46 VIII. Too much engine-oil consumption …………………………………………………… 46 IX. Speed increased greatly …………………………………………………………….… 46 X. Engine stops by itself …………………………………………………………...…… 46 XI. Rough idle ………………………………………………………………...………… 47 XII. Engine-oil raised high ………………………………………………………….……… 47 Annex Fit Clearance Table ……………………………………………………………..………...

  • Page 8: (I) Right View Of 4Dw81-46 Diesel Engine

    (I) Right view of 4DW81-46 diesel engine...

  • Page 9: (Ii) Left View Of 4Dw81-46 Diesel Engine

    (II) Left view of 4DW81-46 diesel engine...

  • Page 10: (Iii) Front View Of 4Dw81-46 Diesel Engine

    (III) Front view of 4DW81-46 diesel engine...

  • Page 11: (Iv) Vertical View Of 4Dw81-46 Diesel Engine

    (IV) Vertical view of 4DW81-46 diesel engine...

  • Page 12: (V) Power Output End Of 4Dw81-46 Diesel Engine

    (V) Power output end of 4DW81-46 diesel engine...

  • Page 13: Chapter I Technical Characteristics

    Chapter I Technical Characteristics I. Technical parameters for 4DW(B00) diesel engine & its variants Model/designation 4DW81-46/B01 4DW81-50/B05 4DW81-49/B71 DW91-63/B41 4DW91A63/B45 Type 4-cylinder, in line, 4-stroke, water-cooled, direct-injection Aspiration mode Natural air-suction Ignition sequence 1-3-4-2 Cylinder diameter (mm) × piston stroke 85×95 85×100 90×100...

  • Page 14: Main Technical Data

    II. Main technical data 1. Valve timing Intake valve opens 12°±2° before T.D.C. Intake valve closes 38°±2° behind B.D.C. Exhaust valve opens 50°±2° before B.D.C. Exhaust valve closes 12°±2° behind T.D.C. Valve lash (at cold state) Intake valve: 0.28-0.33 mm Exhaust valve: 0.28-0.33 mm T.D.C.
  • Page 15 (4) Main oil-duct engine-oil pressure 196 ～ 441 (2 ～ 4.5) kPa (at declared working condition) Engine-oil pressure when idling (kPa) no less than 98 4. Tightening torque for important bolts (N·m or kgf·m) (1) Bolts on connecting rod 60～70 (6 - 7) (2) Bolts on cylinder head 118～137 (12 - 14) (3) Bolts on main bearings 120～140 (12 - 14)

  • Page 16: External Characteristic Curve Of 4Dw Engines

    III. External characteristic curve of 4DW engines 1. External characteristic curve of 4DW81-46 (B01)
  • Page 17 2. External characteristic curve of 4DW81-50 (B05) (37kW, 3200 r/min)

  • Page 18: Chapter Ii Operation

    Chapter II Operation I. Precautions 1. When using the diesel engine, it is necessary to make adjustment and maintenance as per this Manual. 2. When the engine is cold-started, pre-heating is necessary. Pre-heating time should be 20s～30s, and no more than 40s. 3.
  • Page 19 If ambient temperature occasionally exceeds its limit, only starting performance will be affected, and the engine itself will not be damaged. Engine oil should be kept clean, free of pollution by dust or impurities. After the engine oil is added, it is necessary to inspect the oil level inside the crankcase sump as follows: pull out the oil dipstick and clean it with gauze, then insert it back;...
  • Page 20 ambient temperature is below 0℃ and the engine has difficulty in starting, cooling water can be heated to higher than 80℃ so that it can be used normally. Selection of cooling water: For engines with advanced water-cooling, its cooling system have a very high requirement for cooling medium used.
  • Page 21 (6) Check the storage battery if full. Check each terminal in electrical system if wired correctly and reliably. (7) Check each accessory of engine if connected reliably (fuel-injection pump, fuel-transfer pump, diesel oil filter, water pump, fan, charging generator and its support, fan belt, starting motor, engine-oil filter and heat-radiator etc).

  • Page 22: Chapter Iii Maintenance

    Chapter III Maintenance To prolong the service life of the diesel engine, following maintenance procedures should be followed. I. Daily care 1. Check the engine-oil level in the crankcase sump if it is between the two scale marks and close to the upper scale mark. For an engine that is new or has not been used for long time, after the engine-oil is filled to the upper scale mark, run the engine at a low speed for 5～10 min then stop it, and measure the oil level with the oil dipstick.

  • Page 23: Maintenance After Running Every 500H

    10. Check the battery for its voltage. Specific gravity of electrolyte should be 1.28～1.29 (atmospheric temperature is 15℃), and should normally be no less than 1.27. Additionally, check if the electrolyte level is 10～15mm higher than plate electrode, and if sufficient, distilled water should be supplemented.

  • Page 24: Storage

    9. Check the working status of thermostat. 10. Check each part of starting electric equipment. Check fasteners if secured, and check wire ends if closely contacted, and it should be replaced if scorch-trace found on it. 11. Check each part of engine, and repair and adjust them if necessary. In addition to above information on maintenance, users may perform more detailed maintenance depending on actual conditions.

  • Page 25: Chapter Iv Structure

    Chapter IV Structure I. Cylinder head On the cylinder head, are fitted intake and exhaust valve, valve seat, valve guide (pipe), valve spring, valve rocker and support. The cylinder head is secured onto the engine body by bolts. When securing the bolts, it is necessary to use a torque wrench, to tighten them one by one, by several times, as per the sequence shown in Fig.2.
  • Page 26 because valve guide wear-off can lead to partial grinding of the sealing surface, causing poor sealing. After grinding is done, pour some kerosene or diesel oil into the air-way, to see if the valve leaks and check for its tightness. Normal width of the sealing surface between valve and valve seat is 1.2～1.7mm.

  • Page 27: Engine Body

    II. Engine body 1. Engine body The engine body is of gantry design. On the top surface, there are cylinder jacket-opening and bolt holes, and additionally there are water-hole through to cylinder cover. Near the back end, there is lube oil hole, by which the cylinder cover is lubricated.

  • Page 28: Piston & Connecting Rod

    jacket opening. The flange plane on cylinder jacket should be 0.04～0.12 mm higher than engine body top face, so that the cylinder cover gasket can press closely on it, ensuring the tightness between the cylinder jacket and cylinder cover. See Fig.5. 1-Engine body 2-Cylinder liner Fig.
  • Page 29 Inspect the open gap, before the piston ring is fitted. Lie the piston ring flat to the place, which is 15～20mm away from the top face of cylinder; The open gap should, measured with a feeler gage, be 0.25～0.4 mm. See Fig.6. Trimming with a file is possible if the gap is too small, and match it again if the gap is too big.

  • Page 30: Crankshaft & Flywheel

    100～120℃. With a appropriate forcer being padded, gently tap the piston pin out or push the pin in. Clean engine oil should be applied into the pinhole and connecting rod sleeve. After the piston pin is fitted, other retaining ring should be fitted. 4.

  • Page 31: Camshaft

    2. Flywheel Outer ring nests gear ring. Scale line, used to watch the fuel-supply advance angle, is marked on the flywheel. On the flywheel, it is prohibited to directly install a machine which is towed transversely by pulley; otherwise the main bearing can be damaged. Bearing seats should be added and fitted onto the two ends of the pulley, if user needs to use the transversely towed machine.

  • Page 32: Gear System

    VI. Gear system 1. Timing gear Gearing system consists of timing gear and timing idle gear on crankshaft, timing gear on camshaft, and timing gear and timing gear seat etc on fuel-injection pump. Each timing gear is marked with timing-mark. When fitting the gear, marks should correctly be followed where is engaged., so as to ensure correct moving relationship between moving parts.

  • Page 33: Fuel & Speed-Governing System

    by a socket wrench. Take out together the timing gear and the advancer, and then take the timing gear from them. See Fig.10. Loosen the three fixing nuts on the pad of fuel-injection pump, then the pump can be pulled out. When mounting the timing gear of fuel-injection pump, be ensure that theφ7 hole (R34.5) aligns with the M6 hole (R34.5) on the coupling disc of the advancer, and joined by M6 bolt.
  • Page 34 filtered, the fuel oil will enter the fuel-injection pump. Inside the pump, high pressure is produced, by which the fuel will, via high-pressure fuel pipe, be atomized and injected into the combustion chamber, where the fuel is combusted. 1. Fuel-transfer pump With a single-function roller design, the fuel-transfer pump consists of hand-pressed fuel-transfer pump, roller, piston, piston spring, pump body, fuel-in/-out check valve and fuel-in/-out pipe fittings etc.
  • Page 35 1-Diesel oil filter 2-Speed regulator 3-Fuel-transfer pump 4-Fuel-injection pump 5-High-pressure fuel pipe 6-Fuel injector 7-Fuel return pipe 8-Advancer Fig. 11 Fuel & speed-regulating system 2. Diesel oil filter Diesel oil filter is used to remove the impurities in diesel oil. It consists of casing, filter seat and filter element etc.
  • Page 36 On the speed governor is also fitted a maximum fuel flow position-limit screw, which is connected with speed-governing spring thrust-plate. This screw is used to limit maximum fuel-supply flow-rate, and prevent the engine from overloading at each gear of speed. For the maximum fuel flow position-limit screw, the adjustment work has already been done before delivery, and should not be performed during operation.
  • Page 37 1-Respirator and fuel filling port 2-High-speed limiting screw 3-Idle-speed limiting screw 4-Max. fuel flow-rate limiting screw 5-Sliding sleeve Fig. 12 T7B Speed governor...

  • Page 38: Lubricating System

    1-Screw cap 2-Washer 3-Pressure-adjusting spring 4-Push rod 5-Injection nozzle cap 6-Washer 7-Needle valve couple Fig. 13 Fuel injector VIII. Lubricating system Lubricating system consists of engine-oil collector, engine-oil pump, engine-oil filter and pipes, as shown in Fig.14. The diesel engine adopts pressure lubrication and splash lubrication. Pressure lubrication is used for crankshaft main bearing, connecting rod bearing, camshaft bush, fuel-injection pump seat bearing and rocker shaft bush etc, while splash lubrication is used for cylinder jacket, piston pin, connecting rod bush, cam and tappet, and valve and valve guide etc.
  • Page 39 branch leads to camshaft bearing, and then to cylinder cover, to lubricate rocker arm bearing; other branch leads to idle-gear bearing, passes to timing gear chamber branch oil-passage, and then to the timing gear seat bearing of fuel-injection pump. 1-Crankcase sump 2-Engine-oil collector 3-Assembly of piston and connecting rod and cylinder jacket 4-Engine-oil pump 5-Driving gear of engine-oil pump 6-Engine-oil filter 7-Gearing system 8-Engine-oil pressure gauge 9-Valve rocker arm...

  • Page 40: Cooling System

    The filter can periodically be replaced. The filter is equipped with safety valve. In case of clogging, open the safety valve to let oil enter into main oil-passage, but this will make it lose filtering effect. Therefore, it is necessary to periodically clean and replace the filter element, as per requirement in "Maintenance".
  • Page 41 be off, and the cooling water flows through small-circulation pipe, without through heat-radiator, and directly enters into water pump. Thus the small circulation in body is realized. When water-out temperature is higher than 70～80℃, thermostat will be full on, and at this moment cooling water flows via the thermostat to the upper water chamber of heat-radiator, and flows along flat copper pipe, to the lower water chamber of heat-radiator.
  • Page 42 1-Water pump housing 2-Pump belt pulley 3-Pump shaft 4-Grease cup, M8 × 1 5-Water seal II F-12 6-Pump impeller 7-Connecting plate 8-Connecting plate gasket 9-Pump gasket Fig. 16 Water pump 3. Thermostat The thermostat is tubular and wax type, is fitted in a casing at water-out, at the front end of cylinder cover.

  • Page 43: Electrical System

    Tightness of the belt can be judged appropriate, if the belt between fan and generator pulley is pressed down by hand a distance of 10～20 mm. It is possible to make adjustment, after loosening the bolts on generator bracket and support. X.
  • Page 44 on the cover should be kept un-clogged, and battery outer surface should be kept clean and dry. After discharging, the battery must be re-charged within 24h, to avoid sulfuration on plate electrode, and long time delay is prohibited. If the battery needs be stored for long time, then it should firstly be fully charged (i.e., Battery should be so charged that inside it air-bubbles occur).

  • Page 45: Oil-Pressure Sensor & Water-Temperature Sensitive Plug

    regulator is on, and the generator can charge the battery, but the starting motor cannot start, to avoid accidents. XI. Oil-pressure sensor & water-temperature sensitive plug With double metal-piece design internally, the oil-pressure sensor and water-temperature sensitive plug are matched for electro-thermal type meters. Inside, there is silver contact for conduction.

  • Page 46: Chapter V Adjustment

    Chapter V Adjustment I. Adjustment of valve lash When the engine is overhauled or maintained, it is necessary to check and adjust valve lash or clearance. Adjusting procedure of valve lash and valve timing mechanism is as follows: 1. Dismantle the hood of cylinder cover, and check and tighten/press the nuts on valve rocker arm seat.

  • Page 47: Adjustment Of Fuel Injector

    III. Adjustment of fuel injector Testing and adjustment for fuel injector should be performed on a tester. The purpose is to adjust the fuel-injecting pressure and eliminate faults. If fuel-injecting pressure inside the oil injector is too high or too low, fuel-injection is abnormal, and part(s) is damaged, when the engine runs, faults will occur, such as the occurrence of black smoke, decrease of power and speed, increase of exhaust temperature or knock of cylinder etc.

  • Page 48: Fuel Injection Pump

    (2) When the needle-valve couple is jammed or atomization is poor, it is necessary to clean it. The jammed needle-valve couple should at first be immersed in kerosene for some time, then the needle-valve should be clamped by a pair of wire pliers lined with cloth, and turned gently and pulled out.

  • Page 49: Chapter Vi Troubles & Troubleshooting

    Chapter VI Troubles & Troubleshooting Trouble causes Remedial methods I. Engine does not start 1. Low starting speed (1) Battery runs low, or connecting terminals (1) Recharge it: tighten the terminals; repair are loosened. wire-post if necessary. (2) Starting motor's carbon brush contacts (2) Repair or replace the carbon brush.

  • Page 50: Abnormal Engine-Oil Pressure

    Trouble causes Remedial methods II. Abnormal engine-oil pressure 1. No or little pressure for engine-oil (1) Engine-oil level too low; oil deteriorates or (1) Add the oil; change the oil. is thinned. (2) Oil pipe is broken; pipe joint not tight (2) Weld, tighten or replace it.

  • Page 51: Insufficient Power

    Trouble causes Remedial methods (2) Cooling water temperature is too low. (2) Increase the temperature of cooling water. (3) Moisture enters cylinder (3) Inspect the gasket of cylinder cover. 3. Blue smoke emitted in exhaust gas (1) Piston ring severely worn off, or elasticity (1) Clean or replace the piston ring.

  • Page 52: Abnormal Sound

    Trouble causes Remedial methods V. Abnormal sound 1. Fuel-supply advance angle is too big, and 1. Adjust the advance angle. metal-knock rhythmic sound can be heard from inside of cylinder. 2. Oil nozzle drips oil, and needle valve is 2. Clean, repair or replace the needle valve jammed, causing the sound like "ta, ta, ta".

  • Page 53: Engine Overheat

    Trouble causes Remedial methods VII. Engine overheat 1. Fuel enters into crankcase; or engine-oil is 1. Inspect and replace piston ring; change mixed by water, it becomes thinner; too much engine-oil; inspect oil level; inspect wearing or less engine-oil; low flow-rate and pressure of conditions of inner/outer rotor;...

  • Page 54: Rough Idle

    Trouble causes Remedial methods XI. Rough idle 1. Un-uniform oil flow-rate in each cylinder; oil 1. Make the flow-rate uniform; repair or injector drips oil; pull-rods shifting-fork screw replace oil nozzle needle-valve couple, is loosened. secure shifting-fork screw 2. Gap between shifting-fork and adjusting-arm 2.

  • Page 55: Annex Fit Clearance Table

    Annex Fit Clearance Table...

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