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1、Contents Chapter 1 Main Technical Specifications and Parameters of Engine 1.Main Technical Specifications.1 2.Specifications of Main Parts.2 3.Main Parameters for Inspection and Adjustment2 4. Tightening Torque for Main Bolts and Nuts.3 Chapter 2 Start-up, Operation and Shut-down of Engine 1.Prepara
2、tion before Start-up4 2.Start-up Procedure.4 3.Inspection Carried out in the Course of Operation4 4.Shut-down.4 Chapter 3 Usage and Maintenance of Engine 1.Notices on Routine Maintenance and Usage.5 2.Running-in of New Engine5 3.Selection of Engine Oil.5 4.Maintenance Interval and Maintenance Items.
3、6 Chapter 4 Storage and Reuse of Engine 1.Long-term Storage of Engine12 2.Start-up after Long-term Storage.12 Annex 1: List of Wearing Parts.13 -1- Chapter 1 Main Technical Specifications and Parameters of Engine 1. Main Technical Specifications 1. Model 4JB1 2. Type In-line, intercooled and directi
4、on-injection type, with dry cylinder liner 3. Number of Cylinders 4 4. Bore 93 5. Stroke (mm) 102 6. Displacement (L) 2.771 7. Compression Ratio 18.2 8. Power (KW) 39 9. Rated Speed (rpm) 2500 10. Maximum Torque (N.m) 175 11. Speed at Maximum Torque (rpm) 18002000 12.Minimum Specific Fuel Consumptio
5、n (g/KW.h) 230 13. Idle Speed (rap) 75050 14. Firing Order 1-3-4-2 15. Rotation direction of crankshaft (facing towards flywheel) Anticlockwise 16. Lubrication Mode Pressure otherwise the parts of the diesel engine may get corroded. (3) Generally, the consumption of cooling fluid means that there is
6、 leakage in the cooling system. In such case, be sure to get the cooling system inspected at the service station Inspect the tension of fan belt: Under the force of 100N, the flexibility of new belt must be 8 to 10mm, and the flexibility of old belt must be 9 to 11mm. Inspect whether there is crack
7、or fatigue fracture on fan belt. When the transmission of motion fails, please replace the belt immediately. -11- Technical Maintenance for Fuel Pump Fuel pump is the heart of the diesel engine, and it is composed of many precision parts. The correct technical maintenance for fuel pump will ensure t
8、he normal operation of diesel engine and prolong the service life of the fuel pump. (1) Since HFC4DA1-C diesel engine adopts a VE distribution-type fuel pump that is lubricated by diesel fuel, be sure to use the light diesel fuel that meets the provisions as specified in GB252-1994. It is prohibited
9、 to use any diesel fuel that contains water. Since the diesel fuel lubricates the VE fuel pump, the diesel fuel that contains water may lead to poor lubrication and then the damage to parts of fuel pump. Before being used, the diesel fuel should be deposited for at least 48 hours. When adding the di
10、esel fuel, be sure to use clean container and tools, so as to prevent the introduction of any dust or dirt. (2) Inspect the leakproofness of the pipeline of the fuel system from time to time, observe whether there is local overheating or abnormal noise. (3) Be sure to inspect whether the fuel pump f
11、ixing bolt is loosened after every 200 service hours of the diesel engine. (4) Before leaving the factory, the fuel pump has been properly adjusted on the basis of the conditions of the diesel engine, and lead seals have been attached to the relevant portions. In the course of use, it is prohibited
12、to dismantle or remove such lead seals. Without the testing conditions required, no user may dismantle or adjust the fuel pump assembly randomly. (5) If the diesel engine will be out of service for long time, be sure to discharge away all diesel fuel in the fuel pump, and add the anti-rust oil. Noti
13、ces on Technical Maintenance (1) You are advised to, in accordance with the procedures, classes, items and quality for technical maintenance as specified in this Service Manual, maintain the diesel engine. Even when you are busy, be sure not to omit any maintenance item or prolong the maintenance in
14、terval with any excuse. (2) The class-3 maintenance should be carried out in door, so as to prevent dust from getting into the machine. (3) Some maintenance items or adjustment items that have high technical requirements and are complicated should be carried out by professional technical personnel o
15、r at the authorized service station. -12- Chapter 4 Storage and Reuse of Engine 1. Long-term Storage of Engine 1) Discharge away all cooling water from the radiator, cylinder body and water pump, and then start up the engine and make it run for half an hour (30 minutes) so as to fully evaporate the
16、cooling fluid. 2) Dismantle the battery. 3) The engine must in good technical conditions, and its surface must be clean. 4) Screw off the fuel injector of each cylinder, add about 30g dehydrated engine oil into each cylinder, turn the crankshaft for 15 to 20 rounds, and then mount the fuel injectors
17、. 5) Apply the dehydrated lubricating oil to each lubrication point. 6) Loosen the fan belt. 7) Discharge away all fuel from the fuel tank and then clean up the fuel tank. 8) Wrap up the engine with protective material, seal up all vents and ports on the engine that are not equipped with sealing mea
18、ns. The warehouse wherein the engine is placed should be well ventilated, and it is prohibited to store the engine together with any corrosive article. 2. Start-up after Long-term Storage 1) Clear away the anti-rust oil/grease. 2) Apply lubricating oil to each lubrication point in accordance with th
19、e provisions. 3) Add cooling water. 4) Add engine oil. 5) Add diesel. 6) Inspect the electrolyte in the battery. 7) Connect the battery, and then apply Vaseline onto the binding posts. 8) Inspect the tightness of electric circuits and pipelines. 9) Start up the engine in accordance with the start-up
20、 procedure mentioned above. -13- Annex 1: List of Main Wearing Parts Serial No. Part No. Name Quantity (piece) 1 1002411FA Upper Main Shaft Bushing 5 2 1002412FA Lower Mai Shaft Bushing 5 3 1004026FA Connecting Rod Bushing 8 4 1004024FA01 First Compression Ring 4 5 1004025FA01 Second Compression Rin
21、g 4 6 1004030FA01 Oil Ring 4 7 1100200FA01 Fuel Absorber Assembly 4 8 Fuel Injection Nozzle Pair 4 9 1002220FA Cylinder Cap Washer Subassembly 1 10 1307024FA Fan Belt 1 11 1010300FA01 Engine Oil Filter & Cooler Assembly 1 12 1003016FA Valve Oil Seal 8 13 1002420FA Front Crankshaft Oil Seal 1 14 1002
22、430FA Rear Crankshaft Oil Seal 1 15 1002107FA Camshaft Bush (front) 1 16 1002108FA Camshaft Bush (middle, rear) 1 for each 17 3701310FA Electrical Heater Plug 4 18 1307210FA Thermostat 1 19 1003012FA Intake Valve 4 20 1003011FA Exhaust Valve 4 21 1003102FA Valve Guide 8 22 1003209FA Valve Adjusting
23、Screw 8 23 1003211FA Valve Adjusting Nut 8 24 1003015FA Valve Spring 8 25 1003018FA Intake Manifold washer 1 26 1008015FA Bent Intake Pipe Washer 1 27 1002016FA Observation Hole Cover Washer 1 28 1003020FA01 Exhaust Manifold washer 1 29 1002011FA Timing Gear Chamber Washer 1 30 1002013FA Gear Chamber Cover Sealing Ring 1 31 1100352FA Fuel Pump Flange Sealing Ring 1 32 1307229FA Thermostat Case Washer 1 33 1307011FA Water Pump Sealing Ring 1 34 1307221FA Water Outlet Washer 1 35 1307741FA Water Inlet Pipe Washer 1