Related Manuals for Changchai 3M78 Series
Summary of Contents for Changchai 3M78 Series
- Page 1 Production license：XK06-002-00185 Implementation Standards: Q/320400CC044、 Q/320400CC070 Changchai brand V402/3M78/M403TCI series Multi-cylinder national four diesel engine maintenance manual...
- Page 2 Changchai brand diesel engine is widely used as the ideal power for tractors, harvesters, construction machinery, generator sets, tricycles and other machinery. Changchai brand diesel engine has superior quality level, plus the user - your correct operation and regular maintenance according to the provisions, do not make the diesel engine with disease operation, Changchai brand diesel engine will be able to help you to make a fortune.
- Page 3 1. Each time you start the diesel engine, must idle (3 ~ 5) minutes, after the normal operation of the diesel engine parts, before running high-speed operation. Do not allow cold suddenly increase the throttle, otherwise it will damage the corresponding parts, accelerate the damage to the diesel engine moving parts (supercharger, etc.), thus shortening the service life of the diesel engine.
- Page 4 ▪ We do not assume warranty obligations for engine related failures caused by the use of non-compliant diesel or engine oil！ ▪ Users are recommended to contact Changchai after-sales service department for after-treatment desulfurization, ash cleaning maintenance and other paid services every 1500 hours of use.
- Page 5 Warning Markers This instruction manual and the safety warning marks used on the product and their meanings are as follows. Danger Dangerous means that the situation is critical and, if not avoided, could result in serious personal injury or casualty. Warning Warning means that there is a potential hazard which, if not avoided, could result in serious personal injury or death.
- Page 6 moving parts. If other parts of the body or clothing near the moving parts, once the cooling fan, flywheel or output shaft hooked, may cause personal injury. Users of diesel engines exposed moving parts should be equipped with protective devices. ▪...
- Page 7 Warning (3) Disposal of waste ▪ Put the used oil into a suitable container. Do not pour used oil directly outdoors, into sewers, rivers or the sea. ▪ Disposal of waste must comply with the relevant legal regulations. Hand over the waste to a professional waste recycling company for centralized disposal.
- Page 8 1 Main technical specifications and technical data of diesel engines 1.1 Main technical specifications of diesel engines Model V402 3M78 M403TCI Type Inline, water-cooled, four-stroke, direct injection Pressurized Air intake method Naturally aspirated intercooling Number of cylinders Cylinder diameter×piston 80×79 78×85 78×85 stroke（mm)
- Page 9 1.2 Tightening torque of main bolts and nuts V402 3M78 M403TCI Cylinder head bolts(N·m) 55～ 60 80～ 90 Main bearing cover bolts(N·m) 45～ 50 Connecting rod bolt(N·m) 26～ 30 50～ 55 Flywheel bolts(N·m) 75～ 85 80～ 90 Belt pulley bolts(N·m) 110～...
- Page 10 2 Notes on the use of electronically controlled fuel systems 2.1 Electronically Controlled Common Rail System The structural components and operating principles of the common rail fuel injection system. 2.1.1 Structure and composition of common rail fuel injection system The following figure shows the structural composition of the high pressure common rail fuel injection system.
- Page 11 (2) High-pressure fuel supply section The high-pressure fuel supply part consists of high-pressure fuel pump, pressure control valve, fuel metering valve, etc. The role of this system is to further pressurize the fuel sent from the fuel pump and deliver it to the high-pressure fuel pipe, and the fuel pressure at the outlet of the high-pressure fuel pump can reach 160-200MPa.
- Page 12 Principle of operation of common rail fuel injection system When the ignition switch is turned on, the starter motor drives the diesel engine to rotate and the low-pressure fuel pump starts to pump fuel to the high-pressure fuel pump. When the pumping pressure of the oil delivery pump is greater than the spring force of the regulator installed on the high-pressure oil pump, the regulator will be opened and the low-pressure fuel will enter the oil channel of the high-pressure oil pump and connect to the plunger chamber of...
- Page 13 Common Rail Fuel Injection System Control Strategy. Schematic diagram of ECU function structure The common rail system uses an electronic control unit (ECU) for optimal injection control and related diesel engine and vehicle functions based on various sensor signals monitored in real time and dynamically optimized calculations by the built-in diesel engine management system program.
- Page 14 advantages of low fuel consumption, low emission and high power, meeting the requirements of customers and emission regulations for diesel engines. the ECU supports diesel engine management modules such as intake system, exhaust after-treatment system, as well as vehicle speed, gears and other functions, realizing the integrated management of diesel EFI control system.
- Page 15 (7) When it comes to the failure of oil supply system parts or electronic control system parts, please go to the professional maintenance unit to deal with it.
- Page 16 3 Use and operation of diesel engines 3.1 Precautions for use (1) Use should be adjusted and maintained in accordance with the maintenance methods and regulations introduced in this manual. (2) Not allowed to start immediately after full load work at high speed, must be gradually transition from low-speed no-load to high-speed full load.
- Page 17 (6) Must strictly control the weight of the load, do not allow overload, otherwise it will affect the reliability and service life of the diesel engine. (7) Newly installed or replaced injectors should be medium-speed low-load break-in, the break-in time should not be less than 30 minutes. (8) In the process of operation, such as the discovery of abnormal phenomena, to stop in time.
- Page 18 the correct viscosity of the oil according to the ambient temperature, see the following chart. In order to keep your engine in good condition, users should try to use high quality diesel engine oil. Warning: Different brands of engine oil should not be mixed at the same time. 3.2.3 Cooling water If you use well water, spring water or other mineral hard water, you should add the right amount of softening agent, such as sodium carbonate (soda ash), sodium hydroxide (caustic...
- Page 19 △ The boiling point of ethylene glycol is 194.4℃, so the water in the antifreeze is easy to evaporate, so it should be filled with clean water after using for a period of time. △ If it is not rust-proof antifreeze, the scale should be removed frequently. When the diesel engine used for a long time, the surface of the cooling water cavity will form scale, affecting the heat dissipation of the diesel engine, for this reason should be regularly cleaned up the scale, the removal method is as follows:...
- Page 20 for the oil sump storage quantity. (3) Check the amount of oil stored in the fuel tank, open the fuel tank switch, make the diesel oil flow to the diesel pump, and eliminate the air in the fuel system. (4) Check the battery and connection line. (5) Check the cooling system and add enough water.
- Page 21 leakage, should be immediately excluded. (5) The operation of the charging generator must be charged to the battery, the ammeter pointer points to "+". (6) The new or overhauled diesel engine, in the operation of 50 hours (or 2000km), before allowing full-speed full load operation.
- Page 22 4 Adjustment and maintenance of diesel engines 4.1 Valve clearance adjustment Diesel engine maintenance or technical maintenance, must check and adjust the valve clearance. Valve clearance and air distribution mechanism adjustment methods are as follows: (1) Disassemble the cylinder head cover, check and tighten the bolt of the valve rocker arm seat.
- Page 23 Diagram for adjusting the tension of the fan pulley 4.3 Thermostat precautions Note: It is strictly forbidden to remove the thermostat to run the engine. When the coolant temperature through the thermostat reaches about 68 ℃, the thermostat water valve begins to open, when the coolant temperature through the thermostat reaches about 80 ℃, the thermostat water valve is completely open.
- Page 24 5 Technical maintenance of diesel engines In order to make you better use and prevent the failure of diesel engine in use and prolong the service life of diesel engine, the user should carry out maintenance in time and carefully according to the following procedures during use. 5.1 Daily Maintenance (1) Check whether the oil sump oil level in the oil dipstick between the two lines and close to the upper line near the new or long-discontinued diesel engine in the injection of oil to the...
- Page 25 (7) Inject grease to the parts with oil cups. (8) Clean the dust in the air inlet pipe and exhaust pipe and muffler. (9) Change the cooling water every 200 hours or according to the turbidity of water quality, take out the thermostat, start the diesel engine and constantly change the speed, so that the flow rate of cooling water fluctuates and flush the sediment in the cooling system;...
- Page 26 (10) Check the piston ring opening clearance and clear the carbon in the piston head and piston groove. (11) Check the front and rear crankshaft oil seals, such as hardening and damage, should be replaced in a timely manner. In addition to the above-mentioned regular maintenance, users can carry out more detailed maintenance work according to the actual situation.
- Page 27 if the oil is insufficient (note: wipe off the waste oil in the camshaft oil storage cavity while putting the oil in). New or overhauled diesel engines need an oil change after 50 hours of operation. 5.5 Sealing of diesel engines (1) If the diesel engine is ready to stop running for a long time, after stopping it should drain the oil, cooling water and fuel while it is hot, and clean the oil pan and oil filter.
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Page 28: Diesel Engine Troubleshooting
6 Diesel Engine Troubleshooting 6.1 Diesel engine does not start Cause of failure Exclusion method 1. Low starting speed (1) The charging voltage should be greater than 10 (1) Insufficient battery power or loose volts; tighten the connector; repair the terminal if connectors. - Page 29 6.2 Abnormal oil pressure Cause of failure Exclusion method 1. No oil pressure, or too low pressure (1) The oil level is too low or deteriorated and thin. (1) Add oil or replace oil. (2) oil pipe rupture; pipe joint is not pressed tight (2) Weld;...
- Page 30 (3) the cylinder seepage into the water. (3) Check the cylinder head gasket. (4) Identify the cause of the fault and (4) the fault of the electronic control system eliminate it, clear the fault code 3. Blue smoke from the exhaust (1) Piston ring wear is too large, or due to the lack of elasticity of carbon accumulation, the oil oil into (1)Clean or replace the piston ring.
- Page 31 when you feel the vibration of the piston touch). rod bushings, connecting rod tile; replace the cylinder head gasket. 3. The piston touches the bottom of the cylinder head. A heavy and powerful knocking sound can be 3. Replace the cylinder head gasket. heard.
- Page 32 the water volume is insufficient; the cylinder head system and water jacket; check the gasket is broken and the gas enters the waterway. water pump impeller clearance; fill the water; replace the cylinder head gasket. 3. Electronic control system injection is not normal 3. Identify the cause of the failure and eliminate 6.8 Excessive oil consumption Cause of failure...
- Page 33 Cause of failure Exclusion method 1. Cylinder head gasket leakage. 1. Replace the cylinder head gasket. 2. Cylinder head or body leakage. 2. Overhaul and replacement. Annexes: Diesel engine packing list Serial number Name Unit Quantity Diesel engine Diesel engine maintenance manual Portion Diesel engine product certificate of conformity Portion...
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