Hyundai SIDA Series Manual
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Hyundai SIDA Series Manual

Hyundai SIDA Series Manual

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DIESEL ENGINE
Model - SIDA Range
Engine Manual

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Summary of Contents for Hyundai SIDA Series

  • Page 1 DIESEL ENGINE Model - SIDA Range Engine Manual...
  • Page 2 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Main views of Diesel Engines Page 2 SIDA instruction - water marked...
  • Page 3 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Page 3 SIDA instruction - water marked...
  • Page 4 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Page 4 SIDA instruction - water marked...
  • Page 5 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Page 5 SIDA instruction - water marked...
  • Page 6 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Page 6 SIDA instruction - water marked...
  • Page 7 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1. Main specifications & data for diesel engines Technical Performance Parameters of Diesel Engines Model SD4BM70 Type Inline,fourstroke,water-cooled,direct injection combustion chamber Number of cylinders Bore(mm)×stroke(mm) 102×115 Total displacement(L) 3.76 Compression ratio 17:1 Rated power/rated speed 70/3200 ≥230/1800~210 Max.torque/speed(N·m/r/min)
  • Page 8 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Main bearing bolt 200~240(20-24) Flywheel bolt 100~140(10-14) Starting jaw 200~240(20-24) Clutch bolt 70~110(7-11) 3. Main adjusted date Type SD4BM Intake valve open 24℃ Intake valve close 48℃ Port timing Exhaust valve open 65.3℃ Exhaust valve close 29.3℃...

  • Page 9: Operation

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 2. Operation 2.1 Specifications of fuel The sulfur content in fuel for diesel engines should be lower than 0.5%. If the weather is cold in winter, the fuel with low condensation point should be used. The choice of fuel type depends on the ambient temperature.
  • Page 10 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Type 5W/3 10W/ 15W/ 15W/ 20W/ Grade L-ECC Ambient >25 -20～ -20～ -10～ -10～ -10～ -10～ 5～3 Temperature ～25 (℃ ) 2.3 Specifications Of Coolant Soft water (tap water, river water or rain water), instead of hard water (well water or spring water), should be filled into the cooling system of the engine for hard water contains CaCO3 and MgCO3.
  • Page 11 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION cause the serious fault of scuffing. The procedures are as follows: Unscrew the water temperature sensor (or the hexagon-headed plug) on the front end of the coolant outlet pipe and inject coolant into the cooling system, until there is no bubble in the coolant flowing from the coolant temperature sensor.

  • Page 12: Maintenance

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION The engine should run at low speed for several minutes after its load is removed, and it should not be stopped until the coolant temperature drops lower than 60℃. If the cooling water contains no antifreeze fluid while the ambient temperature is below 5℃, the cooling water should be drained after stopping to protect the parts, such as the cylinder block, from cracking.
  • Page 13 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Charge grease to the water pump bearing Second The same with the first level maintenance level main Change the oil in oil pan and injection pump, clean the oil pan -tenance and oil collector ( 100 hrs) Change the fuel filter element Clean fuel tank, fuel supply pump strainer and fuel pipes...
  • Page 14 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION then take out the filter element to remove the dust. Tap by hand or wooden stick at the two ends of the element while rotating it so that dust could be shaken off. It could be done to blow the element from the inner side with clean compressed air not higher than 600kPa, if the filter element is found blocked or damaged, the new air filter should be changed, and the quality of the new air filter should satisfy the relevant...

  • Page 15: Cylinder Block

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION out the oil, and then fill new oil. 3.2.8 check fuel supply advance of the injection pump There is no strict regulation for the interval of checking fuel supply advance angle. Under the condition of deterioration in performance of the engine, advance angle of the injection pump should be firstly checked.
  • Page 16 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION holes of the cylinder head, and there is a lubricating oil hole near the rear face to lubricate oil to the cylinder head. There is a water inlet chamber of the water pump at front face of the cylinder block. Flywheel housing and rear oil sealing cover are mounted at the rear face.

  • Page 17: Cylinder Head

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1-Cylinder block 2-Cylinder liner Figure 1:The distance that the cylinder liner flange is higher than the cylinder block top face Oil sump is stretched by cast aluminum or steel plate. Be careful not to leave fibre like thread waste cloth on the wall, when you clean the inside of the oil sump, in order to avoid blockages in the copper wire net of the oil collector and oil filter core.
  • Page 18 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Figure 2: Tightening sequence of cylinder head bolts Cylinder head is assembled on the cylinder block with cylinder head bolts. Torque wrench should be adopted to fasten the cylinder head bolts in turn according to the sequence of figure2 to achieve the required torque.
  • Page 19 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION quantity An assembled valve guide pipe should surpass the surface of cylinder head of about 12.5~13mm. Constanly check the valve clearances, The incorrect clearance not only affect the correct timing and valve sealing. But also Some other faults such as when the clearance gets larger, the noise coming from the transmission appliance of the valves will increase, and smaller, will lead to the valves’...
  • Page 20 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Figure 6:Measuring the piston ring end surface clearance Figure 5:Measuring open clearance of piston ring Check the gap clearance before assembling the piston ring. Put the piston ring in the place 15~20mm away from the top surface of the cylinder block. Using a feeler to check the gap clearance within a value between 0.3~0.4mm, see figure 5.
  • Page 21 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 4.3.3 Piston Pin When assemble or dismantle the piston pin, firstly assemble a retaining ring at one end of the piston(or dismantle retaining rings on both ends). Put the piston into the oil(or boiled water)and heat it to a degree of 100~120℃, gently knock the piston out or push it in with a suitable punch.

  • Page 22: Timing Gears

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 4.5.1 Camshaft Cam outline is symmetrical, the inlet and exhaust cam outline are different. When the camshaft is rotating, cam pushes valve tappet, push rod, rock arm and valve to control the air inlet and outlet of each cylinder separately. There is a thrust flange at the front end of the camshaft, and a camshaft thrust plate is assembled at the front face of the cylinder block.
  • Page 23 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Special tools are needed when you dismantle or assemble the crankshaft timing gears. Camshaft timing gear can be pulled out by puller or pushed out by press device. Clearance fit is adopted between the timing idle gear and the cylinder block, and they shall be tightened with bolts.
  • Page 24 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 4-connecting disk washer 5-Gear box 6-Timing gear Figure 8:Injection pump transfer motion connecting disk 4.7Fuel system and speed governing system Fuel and speed governing system is the main operating part of diesel engine. It consists of fuel transfer pump, fuel filter, fuel injection pump, governor, high and low pressure pipes, injectors and so on.
  • Page 25 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION hand transfer pump, roller wheel parts, piston, piston spring, fuel transfer pump body, inlet and outlet check-valves and joints of inlet and outlet fuel pipes, etc. The fuel transfer pump is driven by an eccentric wheel on the fuel injection pump camshaft, the eccentric wheel pushes the tappet and the tappet pushes the piston, then press transferred the fuel to the fuel injection pump chamber.
  • Page 26 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1-Nut 2-Gasget 3-Pressure regulating 4-Tappt 5-Injector lock nut 6-Gasket 7-Needle valve couple Figure 10:Injector 4.7.3 fuel supply pump Plunger type fuel supply pump (See Fig.11) is mounted on the side of injection pump, sucking fuel from fuel tank via fuel filter to supply fuel to injection pump.
  • Page 27 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Pump handle Fuel outlet pipe Fuel inlet pipe Fig. 11 Fuel supply pump 4.7.4 Governor Governor adopts T7B or T110 type, full-scale mechanical centrifugal governor, mainly consists of driving parts, sliding disk parts, and sliding bush, governing spring and governing controlling shaft etc.
  • Page 28 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1-Inspirator and oil filler 2-High speed limit screw 3-Idle speed limit screw 4-Limit screw of max. oil volum 5-Sliding bush Figure 12:Governor 4.8 Intake and exhaust system Intake and exhaust system consists of intake connection pipe, air heater, strainer, intake pipe, exhaust pipe, etc.
  • Page 29 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION The diesel engine adopts forced lubrication and splash lubrication. Crankshaft main bearings,connecting rod bearing, camshaft bushes, fuel injection pump seat bearing and rocker arm shaft bushes etc. adopt forced lubrication, cylinder liners, piston pins, connecting rod bushes, cams and valve guide pipes adopt splash lubrication.
  • Page 30 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Rotor type oil pump is adopted. The rotor in the oil pump is fixed on the shaft by a pin. The drive gear assembled on the crankshaft drives the oil pump gear. Pressure limiting valve is fixed on oil pump body to adjust the oil volume and pressure.
  • Page 31 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION The cooling water in the radiator is pumped into general water channel of the cylinder block by water pump. One way flows directly into the cylinder head, and first cools the valves and triangle area of combustion chamber through water inlet guide sleeves, the other way enters the outside of the cylinder liners tangentially, then circles the cylinder liner and flows to the cylinder head.
  • Page 32 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Water pump is centrifugal type. The water inlet chamber is set at the front end face of the cylinder block. Two E60202 bearing is adopted as holder by the water pump. Water seal is of ceramic and graphite structure. The water pump is driven by the crankshaft pulley and fan belt.

  • Page 33: Troubleshooting

    NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1-Accumulator 2-Starter 3-Wire 4-Ammeter 5-Ignition 6-Regulator 7-Charging generator Figure 16: Electrical system 5. TROUBLE SHOOTING In this part, the symptoms, causes and remedies of the common faults are described as follows for reference. 5.1Difficult To Start Or Failure Of Engine To Start Table 5-1 Causes...
  • Page 34 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 8.poor tightness caused by sticking, loss 8.clean or replace piston rings of elasticity, break of piston rings 9.valve leakage 9.check for the sealing between valves and valve seats. Repair and grind the sealing surface of valve, readjust the valve clearance 10.too cold in winter 10.use heater to warm up the engine...
  • Page 35 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Cause Remedies 1.air entrapped into fuel system 1.deaerate the fuel system 2.blocked in fuel lines or fuel or fuel 2.clean the blocked parts or replace filter fitter element 3.fuel supply pump inefficient 3.repair or replace the fuel supply pump 4.crankshaft seizure 4.caused by too low oil pressure or no pressure.
  • Page 36 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 8. Excessive clearances due to badly 8..Change the all of gears. worn gear, knocking sound may be heard from gear housing Excessive axial clearance 9 change the thrust plate of crankshaft or crankshaft. knocking sound in idling camshaft, ensure the correct clearance operation 10.
  • Page 37 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION conic sealing surface leaks valve conic sealing surface 2 Blue smoke 2.1 Piston ring gaps located at the same 2.1 relocate in 120°spacing side 2.2 Piston ring seizure or badly worn 2.2 check and remove 2.3 Drop or damage of oil seal if valve 2.3 replace the oil seal of valve guide stem...
  • Page 38 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 1. insufficient oil in oil pan 1. refill oil 2. oil pressure gauge or sensor inaccracy 2. replace oil pressure gauge or sensor 3. excessive clearance between crankshaft 3. replace worn main bearing shell or journal and main bearing shell crankshaft 4.
  • Page 39 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION contact disk burnt 5.13 Injector Faults Table 5.13 Causes Remedies 1. Little or no fuel injected (1) Needle sticks with barrel (1) Clean, lap or replace (2) Needle and barrel badly worn (2) Replace Causes Remedies 2.
  • Page 40 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION Table 5.15 Causes Remedies 1. Idling unstable or too high (1) Control arm not been put to the (1) Check and adjust (2) Ring gear and regulating rack (2) Check and adjust stick 2.
  • Page 41 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION 5.18 Increase Of Oil Consumption Table 5.18 Causes Remedies 1.serious external leakage of oil 1.check leaks outside engine, crankshaft oil seal, and replace the broken parts 2.clogging in air filter 2.clean or replace air filter element Causes Remedies 3.block in crankcase ventilation inlet...
  • Page 42 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION shaft  Piston pin  Clearance 0~0.014 Piston pin hole hole    1st compression 2.605  ring 0.09~0.14  clearance 2.685 Piston ring groove  2nd compression 2.35  ring 0.06~0.10 ...
  • Page 43 NOT TO BE REPRODUCED WITHOUT PRIOR PERMISSION shaft   Exhaust valve seat interference -0.025~-0.125 Cylinder head hole   shaft   Intake valve  Clearance 0.025~0.062 Valve guiding pipe hole    shaft  Exhaust valve  Clearance 0.050~0.085 Valve guiding pipe...
  • Page 44 GENPOWER LTD Isaac Way, London Road Pembroke Dock, UNITED KINGDOM, SA72 4RW T: +44 (0) 1646 687 880 F: +44 (0) 1646 686 198 E: info@hyundaipowerequipment.co.uk www.hyundaipowerequipment.co.uk...

This manual is also suitable for:

Sd4bm70

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