Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Service Manual of 12M26 Series Diesel

Engine for Land Power Generators

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Foreword
This series diesel engine features the advantages of excellent technical indicators (compact
structure, reliable operations, and high power performance, economy, and emission), rapid start,
simple operations, convenient maintenances, and especially advanced emission indicator that meet
the international advanced emission standards.
The contents of this service manual are the safety precautions, maintenance methods, and
instructions about inspection, adjustment and troubleshooting of 12M26 diesel engines. We have
expended every effort to make the contents of this service manual systematic, simple and practical.
Judging the malfunction cause of diesel engine is a really precise work. Before the cause is
basically identified, do not disassemble the diesel engine casually, or it will not only eliminate the
malfunction, but also lead to more serious malfunction due to improper assembly after disassembly.
The servicing of critical components particularly the electronic control system and the turbocharger
shall be performed by experienced personnel using dedicated instruments. Persons who are
inexperienced or have no such instruments may not remove or adjust them.
Following the continuous increasing and improvement of 12M26 series diesel engine
variants, all changes will be made without further notice. Please access http://www.weichai.com
to obtain the latest product information.
Recommendations and opinions on further product improvement from you are welcome.
February 2016

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Special Notice
 Before the operations, the operator of the diesel engine must carefully read this
maintenance manual and strictly abide by the operation and maintenance practices specified in the
operation and service manual.
 The diesel engine has tested strictly in accordance with the testing specification of our
company at the time of delivery. It’s prohibited to adjust the ECU data or increase the power of the
diesel engine without permission. Note that failure to observe this requirement shall invalidate the
warranty provided by Baudouin Power;
 The rotor of the turbocharger generally rotates at high speeds when the engine is in
operation. It is strictly prohibited to have any moving objects (for examples, hands, tools, cotton
yarns) appear near the inlet of the turbocharger, otherwise serious injury or damage could occur.
The rotor can only be removed by turbocharger maintenance specialists or by the service stations
authorized by Baudouin Power.
 The number of use for significant bolts is limited and shall not exceed the specified reuse
number.
 The oil and fuel added to the diesel engine must be of the designations specified in this
service manual. Dedicated clean filters must be used for the addition. Before addition, the fuel shall
settle for 72 hours. Before driving the vehicle, check that the coolant and oil levels meet the
requirements;
 It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply
of non-filtered air into the cylinders.
 While using a new engine, the user shall fulfill the 50h commissioning;
 After the cold start of the diesel engine, slowly increase the engine speed, instead of
running at high speed suddenly or long-term idling. After the running under heavy load, run the
engine at low speed for 5~10min before stopping the engine, instead of stopping the engine
suddenly (except special cases);
 After the engine is stopped, if the temperature of working environment is probably below
0℃ and the coolant without antifreeze additive is used, fully drain the coolant from the water tank
and engine;
 The checking and repair for all parts of the electric system must be fulfilled by the
professional electric technicians;
 The checking and repair for all parts of electronic control system must be fulfilled by the
professionals of our service station;
 The diesel engine is oil sealed at the time of delivery to prevent rusting. The oil sealing
period for diesel engine is generally one year. At the expiration of one year, check and take
necessary supplemental measures.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Contents
Chapter I General Information .................................................................................................... 1
1.1 External View of the Diesel Engine .............................................................................. 1
1.2 Model Meaning of Diesel Engine ................................................................................. 3
1.3 Basic parameters of diesel engine ................................................................................. 3
1.4 Operation Notice for New Diesel Engine...................................................................... 4
1.5 Hoisting of Diesel Engine ............................................................................................. 4
1.6 Unpacking of Diesel Engine.......................................................................................... 4
1.7 Preparations before Start ............................................................................................... 6
1.8 Startup of Diesel Engine ................................................................................................ 6
1.9 Running of Diesel Engine ............................................................................................. 7
1.10 Stop of Diesel Engine ................................................................................................... 8
Chapter II Maintenance Guide .................................................................................................. 10
2.1 Fuel, Lubricating Oil, Coolant, and Auxiliary Materials for Diesel Engine ............... 10
2.1.1 Fuel ..................................................................................................................... 10
2.1.2 Engine lubricating oil ......................................................................................... 10
2.1.3 Engine coolant .................................................................................................... 11
2.1.4 Auxiliary materials ............................................................................................. 11
2.2 Daily maintenance ....................................................................................................... 13
2.2.1 Daily service ....................................................................................................... 13
2.2.2 Daily Maintenance ............................................................................................. 13
2.3 Level-specific maintenance ......................................................................................... 15
2.4 Maintenance for Long-Term Storage of Diesel Engine .............................................. 20
Chapter III Typical Malfunctions and Troubleshooting of Diesel Engine ................................ 21
3.1 Diagnostic method ....................................................................................................... 21
3.2 General malfunction causes and troubleshooting of diesel engine ............................. 22
3.2.1 Start failure of diesel engine ............................................................................... 22
3.2.2 Stop of engine shortly after start ........................................................................ 22
3.2.3 Low power .......................................................................................................... 23
3.2.4 Excessive fuel consumption ............................................................................... 24
3.2.5 Black exhaust gas ............................................................................................... 24
3.2.6 White or blue exhaust gas .................................................................................. 25
3.2.7 Deposit of engine oil at air inlet port and air inlet pipe of turbocharger ............ 25
3.2.8 Unstable speed .................................................................................................... 26
3.2.9 Engine oil pressure too low ................................................................................ 26
3.2.10 High coolant temperature ................................................................................. 27
3.2.11 Excessive wear of parts .................................................................................... 27
3.2.12 Excessive noise................................................................................................. 28
3.2.13 Working failure of starter motor ....................................................................... 28
3.2.14 Weak starter motor ........................................................................................... 28
Chapter IV Dismantling and Assembling of Engine ................................................................. 30

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Service Manual of 12M26 Series Diesel Engine for Land Power Generators

4.1 Overview ..................................................................................................................... 30

4.1.1 Danger signs ....................................................................................................... 30
4.1.2 Safety signs......................................................................................................... 31
4.1.3 Tools ................................................................................................................... 31
4.1.4 Precautions for health protection ........................................................................ 32
4.1.5 Environmental protection measures ................................................................... 33
4.1.6 Precautions for dismantling and assembling of diesel engine ............................ 33
4.2 Cylinder head subassembly ......................................................................................... 34
4.2.1 Cylinder head ..................................................................................................... 34
4.2.2 Dismantling procedures ...................................................................................... 34
4.2.3 Assembling procedures ...................................................................................... 35
4.2.4 Disassembling, checking, repair, and assembling essentials .............................. 35
4.3 Engine Block Group .................................................................................................... 45
4.3.1 Flywheel cover ................................................................................................... 45
4.3.2 Cylinder block .................................................................................................... 47
4.3.3 Oil sump and piston cooling nozzle parts .......................................................... 50
4.4 Crank Connecting Rod Mechanism ............................................................................ 53
4.4.1 Crankshaft and flywheel subassembly ............................................................... 53
4.4.2 Piston and connecting rod .................................................................................. 56
4.5 Valve mechanism ......................................................................................................... 61
4.5.1 Rocker arm ......................................................................................................... 61
4.5.2 Camshaft ............................................................................................................. 63
4.5.3 Timing gear ........................................................................................................ 66
4.6 Intake and exhaust system ........................................................................................... 70
4.6.1 Intake and Exhaust Systems ............................................................................... 70
4.6.2 Turbocharging system ........................................................................................ 72
4.6.3 Turbocharger ...................................................................................................... 78
4.7 Fuel system .................................................................................................................. 88
4.7.1 Fuel System ........................................................................................................ 88
4.7.2 Fuel filter ............................................................................................................ 90
4.7.3 Fuel pump ........................................................................................................... 93
4.8 Cooling System ......................................................................................................... 102
4.8.1 Cooling circuit .................................................................................................. 102
4.8.2 Thermostat ........................................................................................................ 102
4.8.3 Water pump ...................................................................................................... 104
4.8.4 Fan .................................................................................................................... 104
4.9 Lubrication System.................................................................................................... 108
4.9.1 Lubrication System........................................................................................... 108
4.9.2 Oil cooler .......................................................................................................... 113
4.10 Startup system .......................................................................................................... 114
4.10.1 Start-up system ............................................................................................... 114
4.10.2 Starter ............................................................................................................. 118

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

4.10.3 Malfunction diagnosis and troubleshooting of charging system .................... 126

4.10.4 Generator ........................................................................................................ 131
Annex A Recommended Torque for Standard Bolts ............................................................... 136
Annex B Recommended Torque for Hollow Bolts ................................................................. 137
Appendix C Fit Clearances for Main Parts of Diesel Engine ................................................ 138

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Chapter I General Information

1.1 External View of the Diesel Engine

Front end

Figure 1-1 Front exterior view of 12M26 series diesel engine

1 Water pump, 2 alternator, 3 Manual engine oil pump, 4 Diesel engine water outlet port (to
water inlet port of water tank), 5 Fan pulley, 6 Fuel pre-supply pump, 7 Oil pan

Left end

Figure 1-2 Left side of 12M26 diesel engine

8 Radiator and pipeline (optional), 9 Fan, 10 Turbocharger, 11 Air filter, 12 Starter motor, 13
Engine oil filler port and dipstick, 14 Engine oil filter, 15 Engine oil cooler, 16 Water pump water
inlet port (to water tank water outlet port)

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Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Right end

Figure 1-3 Right side of 12M26 diesel engine

17 Fuel filter, 18 Ventilator

Rear end

Figure 1-4 Rear side of 12M26 diesel engine

19 Fuel pump

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

1.2 Model Meaning of Diesel Engine

12 M 26 G XX /5 e

Emission certification instructions

Speed instructions
Typical generator output (ESP)/KVA
G-drive: First letter of generator

Displacement per cylinder

Baudouin series

No. of cylinder

1.3 Basic parameters of diesel engine

Table 1-1 Performance parameter of 12M26 diesel engine
SN. Item Unit 12M26
1 Intake mode —— Inter-cooling
2 Number of cylinders —— 12
3 Bore/Stroke mm 150/150
4 Total piston displacement L 31.8
5 Compression ratio —— 15.7
10 Minimum stable idling speed r/min 750±30
13 Maximum burst pressure MPa 15
Oil consumption at rated working
15 g/(kW·h) ≤0.5
condition
16 Downstream oil pressure of oil filter MPa 0.4~0.6
17 Engine oil pressure of secondary oil way MPa ≥0.12
18 Engine oil temperature ℃ 85~105
19 Coolant temperature ℃ 75~95
20 Diesel inlet temperature ℃ 38±3
21 Intake temperature after inter-cooler ℃ 50～60
22 Exhaust temperature after turbine ℃ ≤500
23 Air leakage of pistons L/min ≤300
Opening of intake valve °CA 34º prior to top dead center
Valve Closing of intake valve °CA 40º after bottom dead center
24
timing Opening of exhaust valve °CA 70º prior to bottom dead center
Closing of exhaust valve °CA 34º after top dead center
25 Firing order —— A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
26 Rotation direction —— Counter-clockwise (facing towards flywheel)
27 Intake and exhaust valve gap (cold state) mm 0.3±0.03
28 Smoke number at rated working condition FSN ≤1.5
30 Oil sump capacity L 113
mm×mm×
31 Overall dimensions 2615×1525×1760
mm
32 Net weight kg 2910

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

1.4 Operation Notice for New Diesel Engine

 Maintenance period of diesel engine
First maintenance (P) (30~50) running hours of new engine
Level 1 maintenance (WD1) Every 250 running hours of diesel engine
Level 2 maintenance (WD2) Every 500 running hours of diesel engine
Level 3 maintenance (WD3) Every 1000 running hours of diesel engine
Level 4 maintenance (WD4) Every 3000 running hours of diesel engine

 Fulfill the daily maintenances as per the relevant requirements of the Operation Manual.

1.5 Hoisting of Diesel Engine

During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist
in tilted or unidirectional manner. Hoist up and down slowly. (See Figure 1-1).

Figure 1-5 Diesel Engine Hoisting

1.6 Unpacking of Diesel Engine

 After the diesel engine is unpacked, the user shall firstly count the diesel engine and its
accessories as per the delivery packing list, check the exterior of diesel engine for presence of
damage and the connectors for presence of looseness, and then fulfill the following works:
(1) Wipe the anti-rusting layer and anticorrosive agent on the exposed parts;
(2) Check the water plug and oil plug for presence of blockage, check for water temperature
and oil temperature sensors, and ensure that all parts to be self-provided are completely fitted.
Notice: Do not start the diesel engine before it’s correctly installed and connected at the final

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

position. When the diesel engine is running in an enclosed environment, keep well ventilated to
ensure that the exhaust gas is drained to the open air.
 Adding of engine oil
(1) The engine oil shall meet the specification; otherwise it will probably lead to insufficient
engine oil pressure and thus abnormal wear and difficult start. The engine oil must be extremely
clean.
(2) Tightening the drain plug.
(3) Open the oil filler cap and add the engine oil. The engine oil must be filtered by the filter
screen before adding.
(4) Place the diesel engine at a level position and withdraw the oil dipstick to check the oil
level. For the first adding of oil, add the oil till the oil level reaches the upper limit of oil dipstick.
(5) Tighten the oil filler cap.
 Adding of fuel
(1) The diesel used shall meet the specification.
(2) Keep clean the diesel. It's better to place the diesel under stationary state for more than 72
hours before adding. The diesel shall be added into the fuel tank via the built-in filter screen.
 Air bleeding of fuel system
(1) Loosen the outlet port thru screw of the fuel delivery pump by half turn. Operate the
manual pump of fuel delivery pump, till the diesel overflows, and then tighten the thru screw.
(2) Loosen the air bleeding screw on the fuel filter. Operate the manual pump of fuel delivery
pump, till the diesel overflows, and then tighten the air bleeding screw.
(3) Loosen the fuel return port thru screw of fuel pump, operate the manual pump of fuel
delivery pump, till the diesel overflows, and then tighten the air bleeding screw.
(4) Continue to operate the manual pump, check the fuel pipeline for presence of leakage, and
then tighten the manual pump.
 Adding of coolant
The coolant is mixed from softened clean water and anticorrosive agent or antifreeze. Ensure
to strictly abide by the specification of the additive manufacturer during mixing.
Add coolant through the water filler port of radiator or heat exchanger and bleed the air from
the cooling circulation system.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

1.7 Preparations before Start

 Check the coolant level.
Check the coolant level. If the coolant is insufficient, add coolant. If the diesel engine remains
hot, do not add a great deal of coolant. Dramatic temperature change could cause damage to the
parts. If there is no coolant under special cases, it’s allowed to slowly add cold water in moderate
temperature. Add the coolant through the filler port, till the coolant overflows. Start the engine.
While the engine is running (1,000r/min), continue to add the coolant, till the coolant level is stable,
and finally install the filler port cap.
 Checking of fuel level
 Check the engine oil level
The engine oil level shall be between upper and lower markings of the oil dipstick. If
necessary, add engine oil through the engine oil filler port.
 Check all accessories of diesel engine for reliable connections and solve any abnormal
phenomenon. Check the starter system for normal wiring and check and ensure that the battery is
sufficiently charged. Open the valve of the fuel tank. Using the electric oil pump equipped with the
primary filter, remove air from the fuel system.

1.8 Startup of Diesel Engine

 Before starting the engine, operate the acceleration and stop control levers on the fuel
injection pump to ensure flexible motions. Rotate the crankshaft of diesel engine for several turns
to ensure smooth rotation.
 Rotate the key to position “1” to power on the control panel. The “oil pressure warning
lamp" automatically turns on for 10s (Test of under-low engine oil pressure safety line). It’s
recommended to test the indicator lamps, bulbs, and buttons once (by pressing the touch button 10
on the control panel).
 Rotate the key to position “START” to start the engine and then release the key. The key
automatically returns to position “1”.
At the start of diesel engine, if the diesel engine fails to start within 10s, immediately release
the button and wait for 1min before retry. If the engine can’t be started by three consecutive
attempts, stop the attempt and find out and solve the malfunction before retry.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

During the working of engine, both “oil pressure warning lamp” and the "battery power”
indicator lamps are off.
All indicator lamps are off during normal running of engine.
In event of abnormality, the “horn” will issue warning tone.
 The auxiliary starter shall be used to start the diesel engine under cold temperature. By
running the electric heating flange via relay, the engine can start successfully under -30ºC
environment.

1.9 Running of Diesel Engine

 After start-up, idle the engine for 3 minutes, then increase its speed to 1000 RPM -1200
RPM and apply partial load. Do not have it running under full load until the outlet coolant
temperature is above 60ºC and engine oil temperature is above 50 ºC. Apply load and increase the
speed gradually. Avoid the sudden loading and unloading whenever possible.
 Within the 60h run-in period (or the initial 3,000km mileage) of the diesel engine, it’s
preferable to run the engine under moderate load and it’s not permitted to tow any vehicle.
 Timely slow down while driving on a slope and do not run for a long period under high
torque working condition. It's also inappropriate to run the engine under really low load or speed, as
it will easily lead to the malfunctions such as oil permeation.
 Normally the diesel engine can continuously run with rated output and rated speed. The
diesel engine may not run for more than 20 minutes at the speed 105% the rated speed or the output
110% the rated output. After the unloading, idle the diesel engine for (1~2) min before stop.
 Parameters and checking locations to be observed at all times during operations are as
below:
Oil pressure of main oil-way: 350~550 kPa.
The temperature of engine oil in oil sump is ≤110 ºC.
Coolant outlet temperature is no more than 95 ºC.
Exhaust temperature after turbine: ≤600 ºC.
Check the exhaust fume color, to estimate the performances of the injectors and the load of the
engine. In the case of serious black or white fume, stop and check the engine.
Notice to check the diesel engine for presence of water, gas, and oil leakages. If any, stop the

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

engine for troubleshooting.

 The operator shall understand the following characteristics of the engine:
A. Low fuel consumption at the maximum torque. Increase in engine speed will result in that in fuel

consumption.

B. Maximum torque occurs in the engine speed range of 1200 r/min -17000 r/min.

C. Engine output increases with engine speed. Rated output is achieved at rated speed.

 Precautions for running under cold environments;

A. Fuel: Choose diesel of different trademarks depending on the environmental temperature in
winter.
B. Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons.
C. Coolant: Add antifreeze additive into the cooling system and choose the coolant of different
trademarks depending on the ambient temperature.
D. Start: The auxiliary starter can be adopted if necessary in winter. After the start of the diesel
engine, wait for the oil pressure and water temperature to turn normal before running at high speed
under loaded condition.
E. Battery: Before the approach of the cold season, make sure to check the level and viscosity
of electrolyte and unit voltage of the battery. If the diesel engine is not to be used for a long time and
is under extremely low temperature, disassemble the battery and store in a warm indoor place.
F. Stop: To stop the engine under cold weathers, unload the engine, idle the engine for 1~2min,
and wait for the water temperature and oil temperature to cool down before stop. Please be noted that
it’s disallowed to drain the coolant containing antifreeze additive after the stop of the engine. If the
coolant contains no antifreeze additive, make sure to open the water drainage valves or water plugs
on the engine block, oil cooler cover, radiator, and water inlet pipe to fully drain the coolant, in order
to prevent the frozen cracking of the engine.

1.10 Stop of Diesel Engine

 Avoid the stop of engine under full load. Before stopping the engine, reduce the load,
lower the speed, and run for 3~5min at idling or low-load working condition. This is intended to
cool down the piston, cylinder head, bushing, shaft sleeve, and turbocharger for a sufficient time, in
order to prevent the cylinder scuffing and bushing scratch, which is really important. This is really

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

important for a turbocharged diesel engine. The bearings and oil seals in the turbocharger are
subject to the influence of the high temperature exhaust gas. This heat is carried away by the
circulating engine oil during the running of the diesel engine. If the diesel engine is stopped
suddenly, the turbocharger temperature will increase remarkably to cause overheating, which will
lead to seizure of bearings or failure of oil seals.
 Rotate the key switch to position “OFF” or press the stop button to stop the running of
engine, till the flywheel stops rotation or the speed indication on the instrument panel is zero.
 If the diesel engine circulating water is not added with antifreeze, ensure to drain the
coolant after stop in cold days, in order to prevent the frozen damage of diesel engine. The water
drainage valve is located beneath the oil cooler. Rotate the water drainage valve switch to drain the
water from diesel engine. At the same time, disassemble the water drainage plug from the radiator
to drain the coolant from the radiator.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Chapter II Maintenance Guide

2.1 Fuel, Lubricating Oil, Coolant, and Auxiliary Materials for Diesel Engine

2.1.1 Fuel
Summer: 0# diesel (GB252)
Winter: Generally -10# light diesel (GB252). However, choose -20# diesel for -20ºC
environmental temperature and -35# diesel for -30ºC environmental temperature.
The fuel used must conform to the requirements in Table C.6 of Appendix C to national
standard GB 17691-2005 (revised after June, 2008).

2.1.2 Engine lubricating oil

The user must purchase Baudouin special parts and special engine oil (grade CF-4 15W-40), in
order to guarantee the good running of equipment and prolong the service life.
Choose the viscosity of Baudouin special engine oil based on the temperature, with reference
to Table 2-1.
Table 2-1 Correspondence of Viscosity to Ambient Temperature
Applicable environmental
SAE viscosity grade
temperature (ºC)
15W-40 -20-40
Note:
1) Before starting the diesel engine, ensure to check the engine oil level within oil sump.

2) Do not check the oil level while the diesel engine is running.

3) It’s prohibited to mix the Baudouin special engine oil with any other manufacturer's oil.

For the added volumes of engine oil and numbers of filters of Baudouin Power engines, see
Table 2-2.
Table 2-2 Added Volumes of Engine Oil and Numbers of Filters of Baudouin Power Engines
Number of filters
Added volume of Oil filter Diesel filter
Model
engine oil (L) Fine Centrifugal Coarse
Fine filter
filter filter filter
12M26 90~113 6 2 1 1
Remark:
1) The added volumes listed in the table are only for reference. Actual added
volumes shall be decided with the oil dipstick.
2) If the vehicle is equipped a highly-cold-resistant filter or

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

moisture-removing filter as developed by Baudouin Power, they shall also be

replaced when the fuel is replaced.
Remark:
1) The added volumes listed in the table are only for reference. Actual added volumes shall be

decided with the oil dipstick.

2) If the vehicle is equipped a highly-cold-resistant filter or moisture-removing filter as developed by

Baudouin Power, they shall also be replaced when the fuel is replaced.

2.1.3 Engine coolant

The freezing point specification for Baudouin special coolant includes -25ºC, -35ºC, and
-40ºC. Please choose Baudouin special coolant of different freezing points based on the local
environmental temperature in such manner that the freezing point is less than local air temperature
by approximately 10ºC, with reference to Table 2-3.
Table 2-3 Baudouin Special Heavy-Duty Engine Coolant
Variety Product category Packing specification
HEC-II-25
Heavy-duty
HEC-II-35 4kg, 10kg
engine coolant
HEC-II-40

Note:
1) Make sure to periodically check the coolant and, to prevent the corrosion and damage, timely

replace depending on actual situation.

2) It’s prohibited to use water or low quality coolant as the engine coolant.

2.1.4 Auxiliary materials

Table 2-4 Auxiliary Materials Used for Diesel Engines
SN. Name Color Purpose and location
Applied on flat and smooth metal surfaces to
prevent seize
1 Molykote Pulver Black
For example, applied onto outer surfaces of
cylinder liners
Lubrication before the lubricating oil pressure
Molykote builds up.
2 Dark grey
G-N-Uplus For example, applied onto the intake valve
stem

Table 2-5 Reference Table for Sealant Application of Diesel Engine

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Service Manual of 12M26 Series Diesel Engine for Land Power Generators

List of locations for

Mark Main use
application of sealant Supplement
Flywheel cover bolt
Camshaft thrust plate bolt
Camshaft timing gear bolt
Bolt, intermediate idler
Bolt, front end cover
Bolt, engine oil filter base
It’s applied onto the Oil cooler bolt
Loctite threads to prevent being Screw plug, control valve,
Alternatively, the
242 vibrated to looseness, engine oil cooler,
thread
with moderate strength. Bolt, fuel return pipe fixing
pre-application
device, fuel pump,
sealant
Air compressor shaft end
DriLoc204 can
thread
be pre-applied.
Strainer bolt
Bolts of sensor and harness
fixing device
Applied onto outer
threads for locking,
Loctite
sealing, preventing Auxiliary bolt, cylinder head
262
vibration from causing
looseness
Loctite Preventing looseness,
Cup plug, oil drain hole
271 fixing
Loctite For sealing between
Other cup plugs
277 element and bore
Loctite Sealing cylinder head
Push rod -cylinder head
270 top
Loctite It’s applied onto shining Interface between cylinder
518 metal surfaces for block and crankcase
(modifie sealing purpose. Plates connecting engine
d from body front end face to front
Loctite end cover, and connecting
510) engine body rear end face to
flywheel cover
Interface between engine oil
filter base and crankcase
Interface between water
pump rear cover and engine
body front end face
Interface between flywheel
cover and its connecting plate
Interface between cylinder
block and engine oil cooler
cover
Interface between cylinder
block and engine oil filler
pipe

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

2.2 Daily maintenance

2.2.1 Daily service

 Check the coolant level, engine oil level, and fuel level. Check the lubricating points for
grease insufficiency;
 Check for oil, coolant or air leakage;
 Check the attachments and accessories for loose connection or fixing;
 Check the fan and the belts for excessive or insufficient tension;
 Check the engine oil pressure;
 Check the coolant temperature;
 Check whether the temperature, color, sound and vibration of exhaust gas are normal, and
whether the engine speed remains steady;

2.2.2 Daily Maintenance

 Check the oil level.
Do not start the engine if engine oil level is above the H mark or below the L mark of the oil
dipstick.
After the diesel engine is stopped, wait for at least 5min and then check the oil level, in order
to enable the engine oil to flow into the oil sump sufficiently. The oil amount difference between
lower marking and upper marking of oil dipstick is 23L.

Figure 2-1 Oil dipstick

 Check the fuel level.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

 Check for presence of water, gas, and oil leakages.

The whole engine shall be free of water, air, and oil leakage.
Check the fan. Figure:
Visually check the blades of fan for presence of damage and check connecting bolts for secure
fastening.

Fan

Figure 2-2 Check the fan

 Check the belt. Photo:

The belt is automatically tensioned by belt tensioner. Check the tension of belt by
pushing the belt with hand.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Belt tensioner

Figure 2-3 Check the belt

 Check whether exhaust gas has a normal color.

The normal color of exhaust gas is light grey. Upon detection of change in color, check
and solve the cause.
 Check for normal sound.
 Check for normal engine speed and normal vibration.

2.3 Level-specific maintenance

In addition to the daily maintenance items, fulfill the following items:
 Replace diesel engine oil. As shown in Figure 2-4.

Before replacing old engine oil, remove the drain plug at the bottom of oil pan, and drain
the old engine oil. Then tighten the drain plug;
Add fresh engine oil until the oil level meets the requirement. Then tighten the filler cap.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Oil dipstick
Engine oil filler port

Drain
plug

Figure 2-4 Filler Port, Drain Plug and Filter of Engine Oil
 Replace engine oil filter or filter element.
Replace the engine oil filter. Steps:
A. Disassemble the used oil filter;
B. Fill the new filter completely with clean engine oil.
C. Before installing new engine oil filter, apply engine oil onto the rubber gasket.
D. After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal.
E. Start the diesel engine and check for presence of oil leakage.
 Check and adjust the clearances of intake and exhaust valves.
Check and adjust the intake and exhaust valves clearances. Steps:
A. Under the cold status of diesel engine, turn the engine (along the rotation direction of
engine) to the compression top dead center of 1st/6th cylinder. In such case, the notch on the
flywheel is aligned with the pointer on the flywheel cover.
B. Disassemble the valve rocker cover from the cylinder head and judge whether the 1st or
6th cylinder is at compression stroke (there is a gap between exhaust valve and rocker for the
cylinder under the compression stroke).

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Valve clearance is 0.3

Figure 2-5 Adjustment of valve clearance

C. Using the feeler gauges, check the clearance between Valve Bridge top and valve rocker
arm (Table 2-1). If the clearance is too large or too small, adjust the adjustment bolt on the rocker to
meet the above-mentioned clearance requirement.

Adjustment
bolt

Figure 2-6 Clearances of intake valves Figure 2-7 Clearances of exhaust

under cold status - 0.4mm valves under cold status - 0.3mm

D. After the checking of A1 or A6 cylinder, turn the engine for 360º to adjust the A6 or A1
cylinder to working stroke and then check and adjust the remaining valves on the A side.
Table 2-6 Adjustable Valves of Cylinders in the Compression Stroke

A1 cylinder A2 A3 A4 A5 A6 cylinder
cylinder cylinder cylinder cylinder
A1 cylinder Intake and Intake Exhaust Intake Exhaust Non-adjustable
compression exhaust valves valve valve valve valve
stroke
A6 cylinder Non-adjustable Exhaust Intake Exhaust Intake Intake and
compression valve valve valve valve exhaust valves
stroke
After the checking of B1 cylinder or B6 cylinder, turn the engine for 360º to adjust the B6 or
B1 cylinder to working stroke and then check and adjust the remaining valves on the B side.

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Table 2-7 Adjustable Valves of Cylinders in the Compression Stroke

B1 cylinder B2 B3 B4 B5 B6 cylinder
cylinder cylinder cylinder cylinder
B1 cylinder Intake and Intake Exhaust Intake Exhaust Non-adjustable
compression exhaust valves valve valve valve valve
stroke
B6 cylinder Non-adjustable Exhaust Intake Exhaust Intake Intake and
compression valve valve valve valve exhaust valves
stroke

 Replacement of fuel filter element

Replace the fuel filter. Steps:
A. Remove the old fuel filter element. Remove the water collector installed on the primary
filter if it is reusable.
B. Lubrication seal.
C. Screw the filter by hand, till the seal comes into contact with the port.
D. Continue to screw the filter by hand, till the filter is securely installed (for approximately
3/4 turn).
E. Bleed the air, till there is no presence of air bubble.
F. Conduct the leakage test.
 Check the intake system
Check the intake hose for presence of aging or cracking and check the clamps for presence of
looseness. When necessary, tighten or replace parts to ensure air-tightness of intake system.

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Intake pipe

Exhaust pipe

Figure 2-8 Intake and exhaust pipe

 Check the air filter element.

The maximum intake resistance of diesel engine is 7kPa; Check the maximum intake
resistance only when the diesel engine is running at rated speed under full load. When the intake
resistance reaches the maximum permissible limit, clean or replace the filter element as per the
manufacturer’s instructions.
Caution: It’s absolutely prohibited to run the engine without the air filter, otherwise
the ingress of dusts and impurities into the diesel engine will lead to earlier wear of engine.
Disassemble the filter element from the air filter and flap lightly the end face to fall off the
dust or blow backward (from inside to outside) by compressed air.

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Figure 2-9 Cleaning of Air Filter Element

Caution: Do not blow through the filter paper,

Do not clean the filter paper by water or oil, or
Do not clap or knock the filter element forcibly.

2.4 Maintenance for Long-Term Storage of Diesel Engine

 Cleaning diesel engine;

 Protection measures:

○ After the engine warm-up, drain the engine oil, clean engine oil filter, and add anti-rusting
oil;
○ Drain the fuel and add anti-rust oil mixture;
○ Drain the coolant and add coolant with anti-rust agent;
○ Start the engine and idle for 15~25min.
○ Fully drain the engine oil, fuel and coolant;
○ Take protection measures for other portions.
 Protection during storage:

○ Plug with caps or wrap with plastic film for all oil, gas, and water inlets and outlets and
seal up the entire diesel engine with weather anti-rusting film.
If the transport is required, the external package shall be supplemented.

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Chapter III Typical Malfunctions and Troubleshooting of Diesel Engine

12M26 series diesel engine is designed and manufactured under strict quality assurance
system and each delivered diesel engine passed the specified tests. In addition, the diesel engine is a
kind of high precision machinery and the long-term guarantee of its functionality is closely related
to the normal maintenances. The causes leading to earlier failure of diesel engine are generally as
below:
 Operations against rules or improper management and operations.
 Failure to fulfill maintenance as specified or even repair instead of maintenance.
 Poorly manufactured parts, especially the counterfeit products procured due to temptation
of cheap prices, which will greatly shorten the service life of diesel engine.
 Inappropriate trademark of fuel or lubricating oil or disqualified fuel or lubricating oil.

3.1 Diagnostic method

The common diagnosis methods for malfunctions of diesel engine are generally as below:
 Observation method: Judge the malfunction situation by observing the malfunction
symptom, such as exhaust smoke of diesel engine (Figure 3-1).
 Listening diagnosis method: Judge the characteristic and extent of the malfunction portion
by listenin2g as per the abnormal sound of diesel engine (Figure 3-2).

Figure 3-1 Observation method Figure 3-2 Listening diagnosis

method

 Cylinder interruption method: Interrupt the working of certain cylinder to judge whether
the malfunction occurs in such cylinder. Generally, the cylinder interruption method is to cut off the
fuel supply to the suspiciously malfunctioned cylinder and compare the status changes of the diesel
engine before and after the interruption of cylinder, in order to narrow the scope for further
determination of the malfunction location or cause.

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Comparison method: For some assemblies or parts, the replacement method is adopted to
determine the presence of malfunction.
Note:
1. Judging the malfunction cause of diesel engine is a really precise work. Before the
cause is basically identified, do not disassemble the diesel engine casually, or it will not only
eliminate the malfunction, but also lead to more serious malfunction due to improper
assembly after disassembly. 2. The servicing of critical components particularly the high
pressure oil pump and the turbocharger shall be performed by experienced personnel using
dedicated instruments. Persons who are inexperienced or have no such instruments may not
remove or adjust them.

3.2 General malfunction causes and troubleshooting of diesel engine

3.2.1 Start failure of diesel engine

Cause Troubleshooting
If the starter motor fails, firstly exclude the malfunctions
(1) Working failure of starter motor
of electric circuits.
(2) Low air temperature Take the auxiliary starter measure.
Bleed the air, check sealing performance of connectors,
(3) Air content in fuel system
and repair accordingly.
(4) Blockage of fuel delivery pumps
inlet filter screen or fuel lines (such Check and remove dirt and check fuel cleanliness.
as hoses).
(5) Malfunction of fuel injection Check plunger and fuel outlet valve and repair or replace
pump damaged parts.
(6) Damage or leakage of valve or
Check and adjust
fuel supply pipes
(7) Damage and leakage of high
Repair and replace
pressure fuel pipes
(8) Malfunction of fuel injector Check atomization state of fuel injector.
(9) Insufficient compression Check sealing performance of valves and cylinder gasket,
pressure of cylinder check wear of piston rings, and repair or replace.

3.2.2 Stop of engine shortly after start

Cause Troubleshooting
Check the sealing performance of fuel pipes and
(1) Air content in fuel system. connectors, check and ensure the tightening of bleeder
screw, and bleed the remained air.

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Disassemble the filter body, remove internal contaminant

(2) Blockage of fuel filter.
and water, and when necessary replace filter element.
(3) Poor fuel quality and high water
Clean filter and replace fuel
content
(4) Working failure of fuel delivery Check piston and valve of fuel delivery pump, clean, and
pump repair

(5) Low regulated idling speed Re-adjust

3.2.3 Low power

Cause Troubleshooting
Check air filter and intake pipe and clean or
(1) Intake blockage (blockage of air filter)
replace filter element.
Check valve timing, check exhaust pipeline for
(2) Over-high exhaust backpressure
blockage, and adjust and repair
(3) Insufficient pressure of turbocharger
Check and solve leaks at pipeline connections.
system
(4) Abnormal working of turbocharger Replace assembly
(4-1) Blockage of air compressor or
Clean or replace
turbine runner by dirt
(4-2) Failure of floating bearing Replace
(4-3) Carbon deposit and oil sludge at back
Clean
gap of turbine and compressor
(5) Damage and air leakage of inter-cooler Replace or repair
Check sealing performance of fuel pipes and
connectors, check the contamination degree of
(6) Leakage or blockage of fuel pipeline
filter, repair the fuel pipeline or dredge the
blockage dirt, and replace filter element.
Clean fuel tank, filtration parts and fuel pipes, and
(7) Poor fuel quality
replace fuel
(8) Excessive wear of fuel injection pump
Repair or replace
or speed regulator
(9) Damaged diaphragm of fuel injection
Replace or repair
pump smoking limiter
(10) Damage and air leakage of smoking
Replace
limiter air pipe
(11) ) Poor atomization of fuel injector Check fuel injection pressure and carbon deposit of
nozzle fuel injector nozzle and adjust and repair
(12) Incorrect valve or fuel supply timing Check and adjust
(13) Under-low high-speed adjustment of Check speed regulation characteristic and adjust
speed regulator accordingly
(14) Over-high oil level of oil sump Check oil dipstick and drain excessive engine oil
Check compression pressure during warm-up and
(15) Air leakage of cylinder gasket
replace damaged cylinder gasket

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(16) Wear and breakage of piston rings and

Replace worn parts or overhaul the engine
excessive gap of bearing shells
(17) Wear or scuffing of cylinder sleeve or
Repair or replace
piston

3.2.4 Excessive fuel consumption

Cause Troubleshooting
Check the air filter and intake pipeline and
(1) Blockage of intake pipe
clean accordingly
(2) Over-high exhaust backpressure Check exhaust pipeline and clean accordingly
(3) Poor fuel quality Replace with specified fuel
(4) Blockage of fuel pipeline Check and repair.
(5) Leakage of fuel pipeline Check and repair.
(6) Poor atomization of fuel injector nozzle Check and adjust or repair
Adjust valve clearance and fuel supply advance
(7) Incorrect valve or fuel supply timing
angle as per specification
(8) Air leakage of cylinder gasket Check compression pressure
(9) Excessive gap of bearing shells. The
Check and overhaul
overhaul is required for the engine.
Replace cylinder sleeve, piston, and piston
(10) Expanding of piston
rings
(11) Insufficient pressure of turbocharger
Check and solve leaks at pipeline connections.
system
(12) Abnormal working of turbocharger Check and replace
(13) Damage or air leakage of inter-cooler Replace or repair

3.2.5 Black exhaust gas

Cause Troubleshooting
(1) Blockage of intake pipe or excessive
Clean
exhaust backpressure
(2) Poor fuel quality Clean and replace
(3) Incorrect valve or fuel supply timing Adjust as per specification
(4) Poor atomization of fuel injector nozzle Check, repair, or replace
(5) Excessive fuel volume of fuel injection
Check and adjust
pump

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

(6) Insufficient pressure of turbocharger

Check and solve leaks at pipeline connections.
system
(7) Abnormal working of turbocharger Check and replace assembly
(8) Damage and air leakage of inter-cooler Replace or repair
(9) Incorrect application point of smoking
Re-adjust
limiter

3.2.6 White or blue exhaust gas

Cause Troubleshooting

(1) Poor fuel quality and high water content Replace fuel
Check working temperature of thermostat and
(2) Under-low coolant temperature replace when necessary.

(3) Wear of turbocharger seal rings Check and replace

(4) Wear of turbocharger thrust bearing Check and replace

(5) Blockage of turbocharger oil return pipe Clean or repair

(6) Poor atomization of fuel injector nozzle Check and repair

(7) Incorrect valve or fuel supply timing Check and adjust

(8) Low compression pressure, incomplete Check piston rings, cylinder sleeve, and
combustion, and piston expanding cylinder gasket and repair accordingly
(9) Improper run-in of piston rings and Continue the run-in
cylinder sleeves
(10) Non-staggered openings of piston rings Adjust and reassemble

(11) Failure of piston oil rings Replace

(12) Large fit clearance between piston and Repair and replace
cylinder sleeve

3.2.7 Deposit of engine oil at air inlet port and air inlet pipe of turbocharger

Cause Troubleshooting

(1) Turbocharger sealing failure Repair or replace turbocharger

(2) Failure of fuel-air separator Replace
(3) Over-high oil sump level and excessively Check and drain engine oil as appropriate to
added engine oil meet the required level

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3.2.8 Unstable speed

Cause Troubleshooting
(1) Poor fuel quality, with water or paraffin
Replace fuel
content
Check sealing performance of fuel pipes and
(2) Air ingress of fuel suction pipe
connectors and bleed air
(3) Abnormal working of speed regulator
(mechanical pump) counterweight and speed Check and adjust
regulation spring
(4) Non-uniform fuel supply Check and adjust
(5) Unstable atomization of fuel injector nozzle Check and repair
Check and clean air compressor runner, dredge
(6) Vibration of turbocharger blockage, and remove carbon deposit from
exhaust passage
(7) Damage of turbocharger bearing Replace

3.2.9 Engine oil pressure too low

Cause Troubleshooting

(1) Under-low oil sump level or oil shortage Add oil to the specified level of oil dipstick.
Replace with specified engine oil and choose
(2) Inappropriate engine oil trademark
an appropriate oil trademark
(3) Over-high water temperature of cooling
Check the cooling system for normal working.
system and over-high engine oil temperature
(4) Excessive resistance of engine oil filter Replace with new filter element

(5) Blockage of oil cooler Check and clean

(6) Check strainer, engine oil pipeline, and Check and clean air compressor runner, dredge
connector gaskets for presence of blockage and blockage, and remove carbon deposit from
cracking exhaust passage
Check oil pipes and connectors and repair or
(7) Leakage of oil pump inlet pipe
replace
(8) Malfunction of main oil-way pressure
Check valve and clean and repair
regulator valve
(9) Blockage of main oil-way Check and clean
(10) Excessive gap of bearing shells or damage
Check and replace
of bearing shell
(11) Excessive wear of parts. The overhaul is Check the working condition of engine and
required. overhaul
(12) Leakage of diesel into engine oil Check for presence of diesel odor and measure

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

and ensure that the flashing point of engine oil

is no less than that of new oil

3.2.10 High coolant temperature

Cause Troubleshooting

(1) Under-low level in water tank Check for water leaks and add water
(2) Blockage of water tank radiator fins Clean water tank radiator fins
(3) Loose water pump belt Adjust tension as per specification
(4) Damage of water pump gasket and wear of
Check and repair or replace
water pump impellor
Check water pipes, connectors, and gaskets
(5) Damage of water pipe and ingress of air
and replace damaged parts
(6) Thermostat malfunction Replace
(7) Blockage of water tank Check water tank and clean or repair
Check oil level and oil leaks, repair, and add
(8) Under-low oil sump level or oil shortage
oil

3.2.11 Excessive wear of parts

Cause Troubleshooting
Check and replace with qualified filter
(1) Disqualified or damaged air filter element
element.
Check intake pipe, gasket, and connecting pipe
(2) Short-circuit of intake system.
sleeve and repair or replace
(3) Failure for timely replacement of oil filter
Replace as per specification
element
Check oil level and oil leaks, repair, and add
(4) Under-low oil sump level or oil shortage
oil
(5) Inappropriate engine oil trademark Replace with specified oil
(6) Use of disqualified engine oil Use qualified oil trademark
(7) Blockage of oil-way Clean oil-way
(8) Breakage or wear of piston ring Replace damaged parts
(9) Wear or scuffing of cylinder sleeve or Disassemble and check piston and cylinder
piston sleeve and repair or replace
(10) Non between crankshaft and driven shaft Check mounting bracket and repair
(11) Excessive wear of parts. The overhaul is
Check current mileage and determine overhaul
required.

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3.2.12 Excessive noise

Cause Troubleshooting

(1) Poor fuel quality Replace fuel

(2) Under-low coolant temperature Check thermostat and replace when necessary.
(3) Incorrect valve or fuel supply timing Check, repair, and adjust
(4) Poor atomization of fuel injector nozzle Check, repair, and adjust
(5) Excessive fuel volume of fuel injection
Check and adjust
pump
Check for damage, check state of connecting
(6) Wear of shock absorber
bolts, and replace damaged parts
(7) Air leakage or improper adjustment of
Disassemble and check valves and adjust
valve
(8) Excessive gear backlash or broken teeth Check and replace damaged parts
(9) Wear or scuffing of cylinder sleeve or
Check and repair or replace
piston
(10) Bending or breakage of push rod and
Replace
breakage of rocker arm
(11) Breakage or wear of piston ring Check and replace damaged parts

3.2.13 Working failure of starter motor

Cause Troubleshooting

(1) Burnt fuse Replace fuse

(2) Poor contact of connecting wires Clean circuits and tighten wiring posts
(3) Insufficiently charged battery Check and charge or replace battery
(4) Short-circuit of starter motor Check and repair motor or replace assembly
Clean electric brush surfaces or replace electric
(5) Poor contact of electric brush
brush

3.2.14 Weak starter motor

Cause Troubleshooting

(1) Insufficiently charged battery Charge or replace battery.

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

(2) Wear of bearing bushing Replace assembly

Clean electric brush surfaces or replace
(3) Poor contact of electric brush
electric brush
Remove oil dirt and polish with sand
(4) Dirty or burnt commutator
paper or replace assembly
(5) Loose weld of wire ends Re-weld
(6) Poor contact of switch Check and repair switch
Adjust working moment of clutch or
(7) Slip of friction clutch
replace assembly

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Chapter IV Dismantling and Assembling of Engine

4.1 Overview
During dismantling and assembling of diesel engine, please follow operating instructions in
this manual strictly and pay attention to operation steps containing danger and safety marks, so as
to ensure personal safety and avoid accidents.
For the reason that the diesel engine is dismantled in reverse installation procedures, only one
item is selected for instruction in this maintenance manual unless otherwise specified herein.
Tightening torque of special bolts will be specified in relevant installation procedures, and
unless otherwise specified herein, please refer to Chapter V, Tightening Torque of Standard Bolts.

4.1.1 Danger signs

This sign is a “safety warning sign” for industrial purposes,

此标志为世界公认的警告标志。在本手册中，该标志
which stresses the importance of the following information. Please
用于强调以下信息的重要性。确定您了解危险情况所带来
make sure that you know what potential risks are and how to ward off
的后果以及避免危险发生的方法。违反警告信息的行为可
such risks.
能导致财产损失、人身伤害，甚至人员伤亡。
This warning sign indicates a potential danger, which, if not
warded off, may lead to severe injury, death or major property loss.
我们常见的危险标志通常用于一般警告。在本手册中
The common hazard signs are always used for general warning..
，警告信息按照可能导致危险后果的级别分为不同的类型
In this manual, warnings are divided into three different
（轻伤、重伤以及死亡）。
types(moderate injury, serious injury and death) according to the level
此警告标志表明一种潜在危险情况，若未能避免该情
of dangerous consequences
Warning 况的发生，可能导致重伤甚至死亡或者较大大的财产损失
This warning sign indicates a potential danger, which, if not
。
warded此警告标志表明一种潜在危险情况，若未能避免该情
off, may lead to slight injury or property loss. It is also used to
Notice 况的发生，可能导致轻伤或者财产损失。此警告标志同样
warn against dangerous operations.
用于危险操作的警告。

The instructions herein are provided to explain how to correctly operate and install the engine.
Simply reading through this document will not prevent risks from happening. But only through
adequate understanding can these instructions will be correctly applied.
The warning information provided herein may not cover all possible situations! If you decide
to use a procedure or a method that is not recommended, please make sure that such operation will
not bring harm to yourself, any other person or the equipment.

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4.1.2 Safety signs

Table 4-1 Safety signs

Picture Definition
Wear hand protectors

Wear ear protectors

Wear eye protectors

Wear a head protector

Wear foot protectors

Wear protective mask

Wear protective clothing

No fire

No smoking

No use of mobile phone

Danger: Battery acid liquor

Danger: Live cables and contacts

Combustibles

Keep away from suspended heavy objects!

Fire extinguisher available at a nearby position

During use of the diesel engine, many potential dangers occur without any signs. Hence, this
manual cannot give warning instructions for all kinds of potential danger. If the procedures taken
by you are not recommended ones, please ensure the same procedures are safe to operate and do
not result in any damage to property.

4.1.3 Tools
Table 4-2 Tools

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

Picture Definition

2.5mm hex wrench

5mm hex wrench

8mm socket

Slotted screwdriver

Special tool

10mm flat hexagon wrench

Should any method or tool used is not recommended in this manual, the user must first ensure
personal safety, and avoid jeopardizing the life of the user or other personnel, as well as guarantee
that the use, maintenance or repairing method will not cause damage risks or jeopardize personal
safety.

4.1.4 Precautions for health protection

The following "Precautions for health protection" are to reduce pollution risks.
a) Avoid the long-term repeated touch of used engine oil.
b) If possible, please wear the protective clothing and water-proof gloves.
c) Never place any oil-immersed rag into your pocket.
d) Guard your clothing, especially the underwear, against the oil contamination.
e) Wash your working clothing frequently. Throw away oil-immersed clothing and shoes that
can’t be cleaned.
f) In event of cuts or injuries, please immediately take the emergency treatment.
g) Make sure to apply to apply the protective paste before operations, which will make the
removal of oil easier if your skin is contaminated by mineral oil.
h) Use soap and hot water or use liquid soap and fingernail brush to wash hands, in order to
completely remove oil dirt. If the naturally secreted grease on your skin is removed during the
hand-washing, a product with wool fat content can replace this naturally secreted grease to
help moisturize the skin.

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i) Do not clean the skin by gasoline, kerosene, fuel, thinner, or solvent.

j) Upon detection of skin irritation, please immediately seek for medical treatment.
k) If possible, deoil the parts before the handling of parts.
l) Please use goggles or face mask whenever your eyes are endangered. Make sure to prepare
the eye flushing fluid at all accessible places.
m) During the repair of diesel engine, never splash oil or other liquid onto the ground. In
event of accidental leakage of hydrocarbon or other liquid, take all necessary measures to
quarantine this area to keep clean the environment and guard personnel against injuries.
n) The handling, storage, and recovery of hydrocarbon, ethylene, glycol, and petroleum must
abide by the safety and environmental standards of the country in which the operations are
fulfilled.
4.1.5 Environmental protection measures
Please observe relevant environmental protection laws and regulations with respect to disposal
of waste oil and hydrocarbons. For details, consult local officials.

4.1.6 Precautions for dismantling and assembling of diesel engine

Most accidents in connection with use, maintenance and service of diesel engine are resulted
from failure to observe safety rules and basic precautions. So, you should know risks you face and
take corresponding preventive measures to avoid occurrence of accidents. To conduct operation,
maintenance and service of the diesel engine, you should be trained, and have relevant skill and use
appropriate tools.
Failure to follow relevant instructions given in this manual may result in serious accidents,
even endangering the operator's life. Baudouin Power Co., Ltd. cannot foresee all potential risks.
Similarly, guidelines and instructions specified in this manual are not exhaustive.
Before proceeding with maintenance or repairing, a signboard containing "Don't Use" or a
similar sign should be placed on the starter switch.
Before use of the barring rod, necessary preventive measures should be taken.
Ensure that the maintenance site and surrounding environment are suitable for safe operation.
Ensure the maintenance workshop or area around the diesel engine is clean and neat.
Before working, please take off your ring, necklace and watch. Please wear a suitable working

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 Service Manual of 12M26 Series Diesel Engine for Land Power Generators

uniform.
Before working, please check whether corresponding protection equipment (goggles, gloves,
shoes, masks, working uniform, helmet, etc.) are within effective life.
Do not use faulty or unsuitable tools.
Stop the diesel engine during maintenance or service.

4.2 Cylinder head subassembly

4.2.1 Cylinder head

The cylinder head is located on the upper portion of the cylinder block and works with piston
head to form the combustion chamber. The parts connected with the cylinder head include intake
pipe, exhaust pipe, water outlet pipe, fuel injector, cylinder head cover, cylinder head gasket, and
some parts of valve mechanism.

4.2.2 Dismantling procedures

The connected parts of cylinder head should be disassembled first before disassembling the
cylinder head. The detailed disassembling procedure is indicated in sequence.
1) Disassemble the turbocharger and connecting pipeline. Please refer to the disassembling
instructions of intake and exhaust system for details.
2) For details about dismantling of the fuel injection pump, see the Instructions for
Dismantling of ;
3) Disassemble the thermostat and water outlet pipe.
4) Disassemble the lifting rings;
5) Disassemble the fuel injector return pipe, cylinder head cover and the cylinder head cover
gasket.
6) Disassemble the fuel injector and related parts. Refer to dissembling instructions of fuel
system for details.
7) Disassemble the lubricating oil pipes of cylinder head.
8) Disassemble the intake and exhaust pipe and related parts. Refer to the disassembling
instruction of intake and exhaust system for details.
9) Disassemble the rocker arm assembly and push rod. Refer to disassembling instruction of
valve mechanism for details.

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10) Disassemble the cylinder head and the cylinder head gasket.
11) Disassemble the inner and outer springs of valves, spring upper and lower seats of intake
and exhaust valves, valve collets, and valves. Refer to disassembling instruction of valve
mechanism for details.
12) Disassemble the valve stem sealing sleeve.

4.2.3 Assembling procedures

The assembling procedure is in reverse order of the disassembling procedure.

4.2.4 Disassembling, checking, repair, and assembling essentials

4.2.4.1 Water outlet pipe

[Disassembling]
Loosen the water outlet pipe bolts in turn, take out the water outlet pipe assembly, and
disassemble the seal gaskets from cylinder head, as shown in the figure.
[Checking and repair]
1) Before disassembling, check the water outlet pipe for presence of water leakage and
observe the water outlet pipe for presence of cracking and corrosion. If the cracking is present,
replace water outlet pipe as necessary. For the corrosion that influences the reliability, analyze the
cause and replace with new water outlet pipe.
2) If the water leak occurs at connectors, replace connector and tighten and then observe for
presence of water leakage.
[Assembling]
1) Add O-ring and connect three segments of water outlet pipe together.
2) Place the rubber seal ring neatly at the water outlet port of cylinder head.
3) Fix three segments of water outlet pipe onto the cylinder head by hexagon flange bolt.

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Hexagon head screw Washer

plug

Thermostat
bracket
Thermostat
bolt
Connecting Thermostat
pipe
bracket
O-RING
Hexagon
Hexagon flange bolt
flange
Hexagon flange bolt
bolt
Rubber ring Water outlet Connecting
pipe pipe

Figure 4-1 Assembling of water outlet pipe

4.2.4.2 Engine lifting rings

[Disassembling]
Loosen and take out the lifting rings in turn.
[Checking and repair]
Check the front and rear lifting ring for cracking and other failure and check the threads of
rings for presence of failure. Upon detection of such failure, replace with new parts.
[Assembling]
The engine lifting rings are of M22 threads and the tightening torque is (660±5N·m).

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Lifting rings

Figure 4-2 Assembling of engine rings

4.2.4.3 Cylinder head cover

[Disassembling]
Loosen the cylinder head cover bolts in turn and vertically take out the cylinder head cover
and cylinder head cover gasket, as shown in the figure.
[Checking and repair]
1) Observe the cylinder head cover for presence of cracking and other damage. Upon detection
of cracking, replace with new cylinder head cover.
2) Upon detection of oil permeation or leakage at cylinder head cover gasket, check the
cylinder head gasket for failure and replace with new cylinder head cover gasket.
[Assembling]
1) The cylinder head cover gaskets can be used only once. Replace with new ones in event of
repair. Before installing cylinder head cover gaskets, check and ensure that new cylinder head cover
gaskets are free of manufacturing and operation defects and damages.

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2) Wipe clean the top face of cylinder head and assemble cylinder head gaskets correctly in
turn.
3) Apply oil to the rubber O-rings, install O-rings into grooves of cylinder head cover, wipe
clean the cylinder head cover, and assemble the cylinder head cover onto the cylinder head in
correct sequence.
4) Install and tighten the cylinder head cover bolts.
Rubber O-ring

Hexagon socket bolt

Cylinder head cover

Cylinder head cover

gasket

Figure 4-3 Assembling of Cylinder Head Cover

4.2.4.4 Lubricating oil pipes of cylinder head

[Disassembling]
Loosen and take out the hollow fastening bolts of the lubricating oil inlet pipe from the
cylinder block and cylinder head oil pipes respectively and take out the lubricating oil inlet pipe.
Loosen the fastening flange bolts of pipe clamps and take out the bolts and pipe clamps. Loosen
and take out the hollow fastening bolts from the cylinder head in turn and take out the lubricating
oil pipes of cylinder head.
[Checking and repair]
Check the oil pipes for presence of oil permeation and leakage. Upon detection of oil
permeation or leakage, judge the failure state and replace with new lubricating oil pipes or sealing

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gaskets.
[Assembling]
The assembling procedure is in reverse sequence of the disassembling procedure.

Hollow bolt

Lubricating oil pipe

Flange bolt
Hollow bolt
Pipe clamp
Oil inlet pipe

Hollow bolt

Figure 4-4 Assembling of cylinder head lubricating oil pipes

4.2.4.5 Cylinder head

[Disassembling]
1) Loosen auxiliary bolts of cylinder head and take out clamping blocks.
2) Loosen the cylinder cover main bolts.
3) Before disassembling the cylinder head, ensure that the fuel injectors are disassembled,
otherwise the heads of fuel injectors will be easily damaged during the placement of cylinder head.
4) Disassemble the cylinder head and place the disassembled cylinder head on a paper board,
in order to prevent wearing the top surface of combustion chamber and other sealing surfaces. If the
disassembling of multiple cylinder heads is required, mark the cylinder heads with cylinder
numbers to ease the problem analysis.
5) Disassemble the cylinder head gasket. If the disassembling of multiple cylinder head
gaskets is required, mark the cylinder numbers on the cylinder head gaskets to ease the problem
analysis.

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6) Dismantle the intake and exhaust valves by referring to Instructions for Dismantling of
Valve Mechanism;
7) Disassemble the valve stem sealing sleeve.

Cylinder head main bolt Cylinder head auxiliary bolt

Cylinder head subassembly Washer

Clamping block

End block

Figure 4-5 Assembling of cylinder head

[Checking and repair]

(1) Cylinder head
Before dismantling of the cylinder head, first inspect whether there is water leakage, oil
leakage, gas leakage and other signs, as well as other abnormal phenomena, so as to accurately
locate position where the problem occurs, and accurately analyze the problem.
Clean the cylinder head, and clean the surfaces of the combustion chamber, valve seat, intake
and exhaust valves, intake and exhaust ports, and remove the carbon deposit and varnish, as well as
inspect surface conditions.
①Appearance inspection
Inspect discoloration and crack of the cylinder head carefully, and in case of crack, carry out
penetrant inspection.
②Valve sinkage

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The valve sinkage is the vertical distance from the bottom surface of the valve to the bottom
surface of the cylinder head, and the difference between the valve sinkage measurement value and
the required valve sinkage value can reflect degree of wear of the valve and valve seat. It is
possible to use depth micrometer to measure the valve sinkage as shown in Figure;

Figure 4-6 Depth Micrometer

For the required valve sinkage value, refer to the Table 1, and if the valve singkage exceeds
the permissible range, it is required to replace the cylinder head with a new one to ensure reliability
of the engine. If the valve sinkage does not exceed the permissible value, dismantle the valve for
inspection and then inspect the sealing surface of the valve seat ring. Check whether there is
apparent wear and abnormal damage to the valve and the sealing surface of the valve seat ring.
Table 4-3 Valve Sinkage Values
Required Valve Sinkage
Values (mm)
Intake 0.6~1.1
Exhaust 1.2~1.7
③Clearance between exhaust valve rod and valve guide
The inside diameter of the valve guide is the contact surface between the valve guide and the
valve, and if the clearance between exhaust valve rod and valve guide exceeds the permissible
value due to wear, it will result in influence on guiding effect of the valve, reducing reliability of
the diesel engine operation. The inside diameter of the valve guide can be measured by use of an
inside micrometer, as shown in Figure. The outside diameter of the valve guide can be measured by
use of an outside micrometer. The permissible range is (0.04~0.07) mm for the clearance between
intake valve stem and valve guide pipe and is (0.06~0.09) mm for the clearance between exhaust
valve stem and valve guide pipe. If out of the permissible range, replace the cylinder head to ensure
the working reliability of the diesel engine.

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Figure 4-7 Inside Micrometer

④Cylinder head gasket

In case of gas leakage, water leakage, fuel leakage and other problems at the cylinder head
gasket, it is required to inspect the cylinder head gasket and replace it wherever necessary.
Inspect whether there is visible damage to the cylinder head gasket and analyze the cause.
Regardless of problems at the cylinder head gasket, it should be replaced with a new one after
being dismantled.
[Assembling]
(1) Cylinder head gasket assembly

Figure 4-8 Cylinder head gasket

①The cylinder head gasket can be used once only, and in case that it is returned for repairing,
it must be replaced with a new one.
②Wipe clean the top plane of cylinder block and place the cylinder head gasket as per the
corresponding pin holes.
③Inspect whether the cylinder head gasket is assembled properly.
(2) Attach the cylinder head gasket and then install the cylinder head to the cylinder block.
①Wipe clean the cylinder head carefully and ensure that there is not dust, debris, sand and
other contaminants, and then further wipe clean the bottom surface of the cylinder head.
②Inspect whether there is foreign bodies in the cylinder, and the cylinder head gasket is clean.

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③Use the guide rods to screw them into the cylinder head bolt holes.
④ The cylinder head gasket shall be free of distortion, deformation, and damage.
(3) Loosen the cylinder cover main bolts.
①Apply an appropriate amount of lubricating oil to the threads and support faces of cylinder
head main bolts.
(4) Add the clamping blocks and circular washers, loosely install the cylinder head auxiliary
bolts, and assemble end plates on two ends of cylinder block.
① Apply an appropriate amount of lubricating oil to the threads and support faces of cylinder
head auxiliary bolts.
(5) Tighten the main and auxiliary bolts of cylinder head.
Tighten the main and auxiliary bolts of cylinder head by 5 steps.
Step 1: Tighten the M16 main bolts to 80N.m and tighten the M20 auxiliary bolts to 80N.m.
Step 2: Tighten the M16 main bolts to 45°±5° and tighten the M20 auxiliary bolts to 45°±5°.
Step 3: Tighten the M16 main bolts to 45°±5° and tighten the M20 auxiliary bolts to 45°±5°.
Step 4: Tighten the M20 auxiliary bolts to 45°±5° and tighten the M20 main bolts to 40°±5°.
The main bolts can be reused for 3 times.

Figure 4-9 Torque wrench

Figure 4-10 Tightening sequence for cylinder head bolts

(6) Assemble the valve stem sealing sleeves.

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Figure 4-11 Valve stem sealing sleeve

[Disassembling]
To disassemble the valve stem sealing sleeve, use the special tooling or use pliers to clamp the
outer walls of valve stem sealing sleeve and rotate upward to lift out the valve stem sealing sleeve.
[Checking and repair]
Before disassembling, observe the rubber lips of valve stem sealing sleeve for presence of
damage. Once being disassembled, replace with new valve stem sealing sleeve.
[Assembling]
① The valve stem sealing sleeve can be only used once. Make sure to replace with new one in
event of repair.
② Check the valve stem sealing sleeve for presence of defect and check valve stem sealing
sleeve spring for intactness.
③Install valve stem sealing sleeve on valve guide pipe.
④Apply lubricating oil to the lips of valve stem sealing sleeve.
⑤ Use valve stem sealing sleeve assembling tool and rubber hammer to install the valve stem
sealing sleeve.

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4.3 Engine Block Group

4.3.1 Flywheel cover

4.3.1.1 Parts

Figure 4-12 Disassembling diagram of flywheel cover

Table 4-4 List of flywheel cover

ADJUSTMENT POINTER
POINTER PLATE
Hexagon socket cylindrical head screw
Hexagon socket cylindrical head screw

SENSOR

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4.3.1.2 Disassembling
It’s in reverse to the installation sequence

4.3.1.3 Dismantle
It’s in reverse to the installation sequence

4.3.1.4 Checking
Check for completeness of parts against the table of parts. Check the statuses of rear end plate,
flywheel cover, and cylinder block and ensure that all junction surfaces are free of burrs, oil dirt,
and knocking damages.

4.3.1.5 Assembling
1) Fix the cover plate to the flywheel cover by three M10×35 hexagon head bolts.
2) Fix two adjustment pointers to the flywheel cover by M4×8 hexagon socket cylindrical
head screws.
3) Fix two pointer plates to the flywheel cover by M6×12 hexagon socket cylindrical head
screws.
4) Attach washers to hexagon head screws and install these screws to flywheel cover.
5) Apply clean oil to the rear oil seal and use the oil seal press-in tooling to press it into the
rear oil seal seat.

4.3.1.6 Installation
1) Deoil the junction surface between cylinder block and flywheel housing and wipe them
clean. Then apply the Kingbond sealant 596 to the junction surface of rear end plate.
2) Install the guide bar and knock in the slotted pin into cylinder block. Install the flywheel
housing onto the cylinder block and tighten by 14 M14×80 hexagon head bolts.
3) Apply sealant 596 onto the oil seal seat, install the oil seal seat onto the flywheel housing,
and tighten by 6 hexagon head bolts.

4.3.1.7 Tightening torque specification

Table 4-5 Tightening torque specification
Bolt size Tightening torque /N.m
M4 2.7

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M6 9.5
M8 32
M10 64
M12 110
M14 180

4.3.1.8 Special tools

Oil seal pressing tooling, oil seal alignment tooling, copper hammer, flywheel housing guide
bar, and flywheel housing hoist.

4.3.2 Cylinder block

4.3.2.1 Parts

Figure 4-13 Diagram of cylinder block parts

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Figure 4-14 Diagram of cylinder block parts

Table 4-6 List of cylinder block parts

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4.3.2.2 Dismantle
It’s in reverse to the installation sequence of diesel engine.

4.3.2.3 Checking
1) Check all machined surfaces of cylinder block. All machined surfaces shall be free of burrs,
oil dirt, and knocking damage.
2) Check all water lines and oil lines of cylinder block. All water lines and oil lines shall be
free of burrs, chippings, and flashes.
3) The tappet holes shall be free of burrs, with qualified chamfers.
4) Check the chamfers of cylinder sleeve bore openings. There shall be free of sharp edges and
knocking damage.

4.3.2.4 Assembling
Main bearing bolt and main bearing cover auxiliary bolt:
1) Before assembling the main bearing bolts and auxiliary bolts, apply lubricating oil to the
threads and carrying surfaces. Tighten the main bearing bolts in sequence of
B4-A4-B2-A2-B6-A6-B3-A3-B5-A5-B1-A1-B7-A7. Tighten the auxiliary bolts of main bearing
cap in sequence of 4-2-6-3-5-1-7.
2) Pre-tighten the main bearing bolts in sequence to 80N.m.
3) Pre-tighten the auxiliary bolts of main bearing cap on the side A in sequence to 80N.m.
4) Pre-tighten the auxiliary bolts of main bearing cap on the side B in sequence to 80N.m.
5) Tighten the main bearing bolts alternatively and uniformly in sequence by two steps.
Manual tightening: 200N.m for first step and (575±50) N.m for second step.

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Automatic tightening: 200N.m for first step and (575±25) N.m for second step.
6) Pre-tighten the auxiliary bolts of main bearing cap uniformly on the side A in sequence to
(270±20) N.m.
7) Pre-tighten the auxiliary bolts of main bearing cap uniformly on the side B in sequence to
(270±20) N.m.

Figure 4-15 Tightening Sequence of Main Bearing Bolts

4.3.3 Oil sump and piston cooling nozzle parts

Structure of parts

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Figure 4-16 Diagram of oil sump parts

Table 4-9 Diagram of oil sump parts list

SN. Name SN. Name

1 Oil sump 9 Washer
2 Oil dipstick tube 10 Hexagon head screw plug
3 Pipe connector 11 Magnetic hexagon head screw
plug
4 Washer 12 Washer
5 Hexagon socket cylindrical head 13 Hexagon head screw plug
screw
6 Hexagon socket cylindrical head 14 Washer
screw
7 Hexagon head screw plug 15 Rubber O-ring
8 Fuel inlet elbow 16 Cover plate

4.3.3.1 Disassembling
I. Disassembling of oil sump
1) Prior to dismantling of the oil sump, empty the oil. Place the container containing oil

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beneath the oil drainage plug of the oil sump, and use a screw plug wrench to loosen the oil
drainage plug to empty oil.
2) Disassemble the oil dipstick assembly. Notice not to damage the oil dipstick during
disassembling.
3) Disassemble the bolts of the junction surface between oil sump and cylinder block by a
wrench and then separate the cylinder block from oil sump by equipment such as overhead
traveling crane (Notice to remove the silicone sealant at all times during separation and do not hoist
the cylinder block too high).
4) After the separation of oil sump, check the levelness and check for damage.
II. Disassembling of piston cooling nozzle
Loosen the hollow bolts of piston cooling nozzle and take out the piston cooling nozzle.

4.3.3.2 Installation
I. Installation of oil sump
1) Clean the oil sump and ensure that the inside of oil sump is clean without foreign material
or dust.
2) Install all screw plugs on the external surface of oil sump and all internal devices (such as
strainer). During the installation, tighten strictly as per the specified tightening torques to ensure the
normal operations after installation.
3) Apply silicone sealant to the gaps of junction surfaces among front end cap, cylinder block,
and oil sump. The silicone sealant shall be applied uniformly without any interruption.
4) Install the oil sump assembly onto the cylinder block by hexagon socket head bolts (Before
installation, check the inside of cylinder block for presence of foreign material, turn the crankshaft
for 360º along the rotation direction of flywheel, and check the crankshaft crank arm and oil pump
gears for presence of interference with the oil sump. If present, handle accordingly. Tighten the
fastening bolts of oil sump to (60~66) N.m in a symmetric manner.)
5) Space with seal ring and screw the magnetic plug assembly (Wipe clean the magnetic plug
assembly before installation).
II. Installation of piston cooling nozzle
Insert the locating pin of piston cooling nozzle into pin hole and tighten the hollow bolt.

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Tightening torque is 40N.m.

4.3.3.3 Torque specification

Tightening torque for hexagon socket cylindrical head screws: 60~66N.m
Tightening torque for hollow bolts of piston cooling nozzle: 40N.m

4.4 Crank Connecting Rod Mechanism

4.4.1 Crankshaft and flywheel subassembly

4.4.1.1 Parts
The crankshaft and flywheel subassembly is mainly composed of crankshaft, flywheel, timing
gear, crankshaft pulley, and shock absorber which is mainly functioned to convert the reciprocating
motion of piston to rotating motion to output torque, drive the accessories (including valve timing
mechanism and water pump), and store energy and overcome rotating resistance for uniform
running of crankshaft system. The flywheel ring gear installed on the outer ring of flywheel
engages with the gear of starter motor to start the diesel engine.

4.4.1.2 Disassembling
1) The thermal assembling apparatus is required for the assembling between crankshaft gear
and crankshaft and between flywheel and flywheel ring gear, with thermal assembling temperature
requirement. Therefore, do not disassemble these parts, except the special cases. The crankshaft and
the counterweight are of split type. Never disassemble the counterweight, except the special cases.
2) Check the journals and oil-ways. The main journal and the connecting rod journal shall be
free of damages. Check and ensure there is no cracking, deformation, or discoloration around the
oil orifices of the bushing.
3) All parts dismantled should be put by category as required.

4.4.1.3 Assembling
1) Keep the oil-ways clean, without blockage of oil dirt or chipping. Wipe clean the main
journal and connecting rod journal, guard the bushings against the scratch by impurities, and notice
to check the status of bushings. Assemble the main bushings and connecting bushings as per the
cylinder numbers, without any error.

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Figure 4-17 Crankshaft assembly

2) Check the junction surface between crankshaft and flywheel and ensure that the junction
surface is free of burr, oil dirt, and damage.
3) Knock the locating pin into the front pinhole of crankshaft to the end and tighten the
flywheel bolts as per the following requirements.
12M26: 300N.m for first step and (700±35) N.m for second step.

Figure 4-18 Tightening sequence

4) Face outward the beveled end of flywheel ring gear.

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Figure 4-19 Flywheel assembly

5) Rotate for several turns, check the axial clearance, and ensure the flexible rotation of
crankshaft without obstruction. Ensure that the axial clearance of the crankshaft is 0.1~0.346.
6) Check the junction surface between crankshaft pulley and crankshaft. The junction surface
shall be free of burr, oil dirt, and damage. Pass 6 M14×75 and 2 M14×65 hexagon flange bolts
through the turning flange and crankshaft pulley and tighten these bolts onto the crankshaft in
diagonal manner.
Tightening torque for fastening bolts of crankshaft pulley: 220N.m.
7) Install the shock absorber onto the crankshaft pulley by 6 M12×30 hexagon flange bolts and
tighten the shock absorber bolts in diagonal manner in turn after coming into contact with the shock
absorber.
Required tightening torque for shock absorber bolts: 140N.m.

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Figure 4-20 Crankshaft and pulley subassembly

1. M16×75 Hexagon head bolts with flange 2. M14×65 Hexagon head bolts with flange 3.
Crankshaft pulley 4. Shock absorber 5. M12×30 Hexagon head bolts with flange 6. Turning device

4.4.2 Piston and connecting rod

4.4.2.1 Parts
The piston and connecting rod subassembly is functioned to convert the reciprocating motion
of piston to rotating motion of crankshaft and at the same time convert the force applied onto the
piston to the output torque of crankshaft. The main parts include piston, connecting rod body,
piston rings, piston pin, connecting rod bolts, connecting rod cap, connecting rod bearing shell, and
retainer rings.

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4.4.2.2 Breakdown
Trapezoidal
barrel-face ring Taper-face ring
Coil spring
loaded oil
control ring Piston
Piston pin
Retainer ring
for hole

Connecting
rod body
Connecting
rod upper
bearing shell

Connecting rod
lower bearing shell
Connecting Connecting rod
rod bolt cap

Figure 4-21 Breakdown diagram of piston and connecting rod

4.4.2.3 Disassembling
1) Disassembling of piston and connecting rod subassembly
Carefully remove the carbon deposit from the cylinder top and do not damage the inside of
cylinder. Turn to place the piston at bottom dead center and disassemble the connecting rod bolts
and connecting rod bearing pressure cap. Then, turn to the top dead center and knock out the piston
by the wooden hammer. Operate carefully to prevent the large end of connecting rod from blocking
the cylinder block. Arrange the bearing shell and connecting rod caps as per original sequence.
2) Disassemble the retainer ring for hole, the piston pin, and connecting rod body.
Use a pair of internal circlip pliers to dismantle the circlips on both sides of the piston
carefully, and push out the piston pin to remove the connecting rod body. Assign numbers to the
piston pin and connecting rod body, and put them in numerical sequence.
3) Disassembling of piston rings
Use a pair of piston ring pliers to dismantle the 1st & 2nd gas rings and oil ring respectively,
and mark them.

4.4.2.4 Checking
1) Check and ensure that the large and small ends of connecting rod are free of burrs and
knocking damage and check and ensure that there is no cracking, deformation, and discoloration

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around the oil orifices of small end bearing shell.

2) Mark one end of the connecting rod bolt with the cylinder number, and the end of the
piston toward the flywheel with the cylinder number.
3) Inspect whether the piston surface and inner cavity, piston ring, and piston pin surfaces are
free from burr, oil stains and collision.
4) For one same engine, the weight group marking “G” shall be consistent for both pistons
and connecting rods.
5) The fitting numbers must be consistent for the connecting rod body and connecting rod
cap.

4.4.2.5 Assembling
1) Use a pair of internal circlip pliers to install one circlip onto the piston circlip groove, and
turn the circlip to have it inserted completely. The rough side of the circlip should be inward.
2) Insert the piston pin into piston pin hole. After the piston pin is protruded from the piston,
insert the small end of connecting rod into piston, and then insert the piston pin through small end
of connecting rod. Notice: The punching marking at large end of connecting rod shall be opposite
to the dimensional marking of the piston head.
3) Install the retainer ring for hole on the other side and rotate the retainer ring to ensure
complete installation. The rough side of the circlip should be inward.
4) Put the assembled parts of the piston connecting rod aside in sequence of the cylinder
numbers, and use a pair of piston ring pliers to mount the oil ring, taper-face ring and trapezoidal
barrel-face ring into the piston ring groove in sequence. The "TOP" end of the piston ring should be
upward, and the ring should be turned flexibly in the ring groove.
5) Adjust direction of opening end of rings: the first ring is installed in such a manner that its
opening end is deflected from the centerline of the piston pin by 30°, and the second ring is
installed in such a manner that its opening end is staggered from the opening end of the first ring by
120°, and the oil ring is installed in such a manner that its opening end is staggered from the
opening end of the first ring and the second ring by 120°, respectively, and is at position where the
perpendicular bisector of the piston pin centerline is placed. As shown in the figure below.

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1st gas ring 2nd gas ring

Horizontal direction
of piston pin

Oil ring
Figure 4-22 Opening direction of piston ring

6) Ensure that the piston rings are installed parallelly in the ring grooves, without any
distortion.
7) Check and ensure the consistent fitting numbers for the connecting rod body and
connecting rod cap and then install the upper connecting rod bearing shell.
8) The bearing shell shall be free of damage. If necessary, replace with new one.

4.4.2.6 Installation
Hoist the cylinder block and place it on the overturning device, ensure to face upward the
observation hole of cylinder block, and prevent the collision of cylinder block. Stamp the cylinder
number on the connecting rod bolt hole side and stamp the cylinder number on cylinder end facing
side of the piston head. For one same engine, the weight group marking “G” shall be consistent for
both pistons and connecting rods. Wipe clean the inner walls of cylinder sleeve, crank arm of
crankshaft, and piston and connecting rod subassembly and apply clean oil. Adjust the opening
angles of piston rings, apply clean oil to the portions above piston skirt, and attach guide sleeve
onto the piston. Turn to the top dead center of each cylinder, place the connecting rod and piston
subassembly into tooling, and lower it into the cylinder as per the corresponding cylinder number.
Slowly press down the piston and at the same time drag the large end of connecting rod onto the

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crank arm. Before assembling, notice to face the oil orifice of piston towards the nozzle. While
lowering the connecting rod, prevent collision with nozzle and crank arm. After the assembling,
ensure that the opening of connecting rod bolt faces towards the observation hole. The cylinder
numbers and fitting numbers shall be consistent and no swap is allowed. Install the connecting rod
bearing shells, pre-tighten by connecting rod bolts, tighten the bolts in vertically symmetric
manner, and add the paint sealing. Check the opening clearance. The axial clearance of connecting
rod: 0.2～0.346 mm. Turn to check the crankshaft for flexible rotation, check the cylinder sleeve
for scuffing, check nozzles for collision with pistons, and wipe clean the lubricating oil on the top
face of cylinder block.

4.4.2.7 Torque specification

Install the connecting rod bolts and tighten uniformly and alternatively by three steps: 70N.m
for first step, 200N.m for second step, and 350±30N•m for third step. Apply lubricating oil to the
threads and carrying surfaces of connecting rod bolts.

4.4.2.8 Special tools

1. Hole retainer ring pliers – For installation of retainer ring for piston pinhole
2. Piston ring installation pliers – For disassembling or installation of piston rings

Figure 4-23 Piston ring installation pliers

3. Guide sleeve – Piston
4. Micrometer – For measurement of outside diameters for pistons and piston pins.

Figure 4-24 Micrometer

5. Feeler gauge – For measurement of piston ring closed gap and the gap at ring groove
and shaft connections during assembling.

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Figure 4-25 Feeler gauge

4.5 Valve mechanism

4.5.1 Rocker arm

4.5.1.1 Rocker overview

The rocker is actually a double armed lever (as shown in the Figure 4-26) and is functioned to
change the direction of the force transmitted from the push rod and apply it to the valve stem end to
drive the valves. For M26, the end connected with connecting rod is a ball pin and the other face is
a circular face. These two ends are functioned to apply the force along the valve axis to the
maximum extent.

Exhaust rocker arm Sleeve

Rocker arm
Intake rocker arm
shaft

Valve bridge
Self-plugging rivet

Rocker
arm seat

Figure 4-26 Rocker arm assembly

4.5.1.2 Checking before disassembling of rocker

1) Check the rocker for deformation, breakage, and serious cracking.

2) Turn the crankshaft, and observe whether the rocker arm is turned flexibly.

3) Measure clearance of individual valves, and inspect change in clearance of the valves.

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4.5.1.3 Disassembling of rocker

Open the rocker cover. After the checking, loosen the screws of rocker seat, lightly take out
the rocker, and add the markings to prevent the confusion among the rockers of different cylinders.

4.5.1.4 Checking of rocker

1) Clean the rocker arm, observe appearance of the rocker arm, and determine whether there
is crack and other defects.
2) Observe the bores of rockers for presence of wear and scratch.
3) Check the contact surface between rocker and valve bridge and check the ball pin for wear.
4) Inspect whether individual oil passages are unobstructed or not.

4.5.1.5 Installation of rocker

1) Loosely install the rocker seat to the cylinder head by hexagon bolts, with the bosses of
rockshaft seat face-to-face.
2) Assemble the self-plugging rivets on two ends of rockshaft.
3) Attach intake and exhaust rockers onto rockshaft, attach the sleeve, install to the rockshaft
seat, and ensure that the axial clearance of rocker sleeve is 0.4~0.6.
4) Tighten the bolts of rockshaft seat to 54N.m.
5) Turn to the top dead center of each cylinder and adjust the valve clearance. The intake
valve clearance is 0.3mm and the exhaust valve clearance is 0.3mm.
The tooling and auxiliary materials used for the installation of rocker are listed in Table below.
Table 4-10 Table of tooling and auxiliary materials for installation of rocker
Installation Number/model/specification Auxiliary
Tooling name
procedures of tooling material
Allen wrench
d 8
Torque wrench
Double offset ring spanner
17ⅹ18
Straight screwdriver
200ⅹ1.2ⅹ8
e Feeler gauge
150
Dial indicator
0~5-0.01
Magnetic stand

4.5.1.6 Checking after installation of rocker

1) Turn the crankshaft, and observe whether the rocker arm is turned flexibly.

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2) Check and adjust the clearances of intake and exhaust valves.

3) Check the phase angles for opening of intake valve and closing of exhaust valve for 1st
cylinder and record.
Valve timing of M26 diesel engine:
Opening of intake valve: (34±5) º prior to top dead center.
Closing of intake valve: (40±5) º after bottom dead center.
Opening of exhaust valve: (70±5) º prior to bottom dead center.
Closing of exhaust valve: (34±5) º after top dead center.

4.5.2 Camshaft

4.5.2.1 Overview of camshaft

The M26 camshaft mainly includes the main journal and intake and exhaust cams, as shown in
Figure 4-27, and is mainly functioned to open and close the valves as per the preset working
sequence and valve timing and ensure the sufficient lift for the valves. The cams are subject to the
periodic impact load during the intermittent openings of the valves so that the cams require
wear-resistant surfaces and the camshaft requires sufficient toughness and stiffness. The M26
adopts full-support mode to prevent the deformation of camshaft from influencing the valve timing.

Intake and exhaust cams 12M26 camshaft

Main bearing journal

Figure 4-27 12M26 camshaft

4.5.2.2 Checking before disassembling of camshaft

Rotate the camshaft and check the camshaft for flexible motion without obstruction.
Use a dial indicator to inspect whether the camshaft is subject to axial float, as shown in table
4-11.
Table 4-11 Camshaft axial float
Product Axial clearance Axial clearance Difference
M26 before after0.1~0.25
assembling
disassembling
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4.5.2.3 Disassembling of camshaft

On the working bench for installation and dismantling of the engine, turn the crankshaft to
enable the camshaft timing gear to be at the top dead center of the 1st cylinder. Disassemble the
camshaft timing gear, camshaft bushing, and camshaft and guard the camshaft against collision.

4.5.2.4 Checking after disassembling of camshaft

1) Check the cam surfaces in contact with tappets for presence of wear and check the main
journals for presence of seizure and wear.
2) Measure the circular run-out of camshaft main journal, as shown in Table 4-12.

Table 4-12 Circular run-out of main journal

Cam Permissible circular Measured
2nd main bearing journal run-out (max)
0.06 value
3rd main bearing journal 0.08
4th main bearing journal 0.10
5th main bearing journal 0.08
6th main bearing journal 0.06

4.5.2.5 Installation of camshaft

After dismantling, inspect the camshaft and timing gear. If wear occurs or a big deviation in
other parameters is produced, it is required to repair them, or have them replaced with a new
camshaft and/ or timing gear.
1) Wipe clean the camshaft bore, inspect whether the camshaft bushing is collided, and apply
adequate amount of lubricating oil onto it. Apply an appropriate amount of lubricating oil into the
camshaft bushing by an oil pot, without any oil flow or drip.
2) Install the camshaft, wipe clean the camshaft, check the camshaft for collision damage,
connect the camshaft and camshaft guide sleeve together, and apply an appropriate amount of
lubricating oil. Carefully insert the camshaft and camshaft guide sleeve into the camshaft bushing.
3) Install the camshaft bushing, apply thread sealant 242 to three threads of M8 hexagon
socket head screws, attach the washers, and then tighten the screws, with the oil groove of thrust
plate facing towards the oil sump (forward direction of engine).
4) Rotate the camshaft for several turns. If the camshaft rotates flexibly without obstruction,

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measure the axial clearance of camshaft and ensure that the axial clearance is 0.1~0.25mm. Install
the camshaft cover plate flange on the flywheel end.
The tooling and auxiliary materials used for the installation of camshaft are listed in Table
4-13.
Table 4-13 Table of tooling and auxiliary materials for installation of camshaft
Installation Number/model/specification Tooling name Auxiliary material
procedures of tooling
a Lubricating oil, towel,
brush, and oil pot
b Camshaft guide sleeve Lubricating oil, towel,
brush, and oil pot
c Allen wrench 6 Thread sealant 242
d 0~5-0.01 Dial indicator
Magnetic stand

4.5.2.6 Checking after installation of camshaft

1) Check the axial clearance, rotate the camshaft for several turns, and observe for flexible
rotation, without any obstruction.
2) If the camshaft rotates flexibly without obstruction, measure the axial clearance of
camshaft and ensure that the axial clearance is (0.1~0.25) mm.

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4.5.3 Timing gear

4.5.3.1 Gear train diagram

Fuel injection
pump gear

Intermediate
gear

Camshaft gear

Crankshaft gear

Figure 4-28 Diagram of gear train

4.5.3.2 Disassembling
1) Complete the disassembling of front accessories (including water pump and pulley) and
the front end cover plate.
2) Inspect the mark on the mounting bolt of the camshaft timing gear and confirm whether
the bolt turns or not. Disassemble six M10 fastening bolts from the camshaft.
3) Disassemble the subassembly of camshaft timing gear and fuel injection intermediate gear

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and then disassemble six M10 connecting bolts between camshaft gear and fuel injection pump
intermediate gear to separate them.
4) Inspect the mark on the mounting bolt of the injection pump gear and confirm whether the
bolt turns or not. Disassemble the 6 hexagon flange bolts on the oil pump gear and thus disassemble
the fuel injection pump gear.

4.5.3.3 Checking
1) Check the fastening bolts for good threads and check the bolt shanks for presence of shear
trace.
2) All fitting surfaces shall be free of burrs, oil dirt, knocking damage, and non-metal
adhesions and all oil-ways shall be free of obstruction, burr, flash, and chipping.
3) The gears shall be free of cracking, broken teeth, and large area of tooth face pitting.

4.5.3.4 Installation
1) Complete the installation of engine oil pump and crankshaft in turn. The engine oil pump
gears and the crankshaft timing gears are installed along with the engine oil pump and crankshaft
onto the diesel engine.
2) Assemble the camshaft gear and fuel injection pump intermediate gear together by six
M10 hexagon flange bolts and align the markings “N” of camshaft gear and fuel injection pump
intermediate gear, as shown in the figure:

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Figure 4-29 Installation of gear

3) Rotate the crankshaft to place the marking “.” of crankshaft gear with respect to the
vertical plane, install the camshaft gear subassembly onto the camshaft, and align the marking “N”
of camshaft gear with the marking “.” of crankshaft gear, as shown in the figure:

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Figure 4-30 Installation of gear

Tighten the camshaft gear and camshaft by six M10 hexagon head bolts. Check the backlash
between crankshaft gear and camshaft gear. The backlash range is 0.09~0.15.
4) Place the high pressure fuel pump on the fuel pump bracket above the cylinder block and
assemble the drive shaft subassembly together. Connect one end of drive shaft subassembly to the
high pressure fuel pump and pass the other end through the flange hole on cylinder block and
pre-tighten it onto the cylinder block by hexagon socket bolts through the flange. Turn the engine to
the firing top dead center of 1st cylinder, align the marking “N” of fuel injection pump gear with
marking “.” of intermediate gear, and rotate the fuel pump gear onto the drive shaft. Adjust the fuel
supply advance angle to the required value and tighten the connecting hexagon socket cylindrical
head screws of the fuel injection pump gear. Check and ensure that the backlash between
intermediate gear and fuel pump gear is 0.08~0.125.
5) The water pump gears are installed along with the water pump assembly onto the front
cover plate.

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Figure 4-31 Installation of gear

4.5.3.5 Torque specification

Intermediate gear bolts: Apply sealant uniformly to the threads and tighten to (75±5) N.m.
Camshaft gear bolts: Apply sealant uniformly to the threads and tighten to (70±5) N.m.
Fuel injection pump gear bolts: Apply sealant uniformly to the threads and tighten to (65±5)
N.m.

4.5.3.6 Special tools

Feeler gauge or lead wire – For measurement of gear backlash.

4.6 Intake and exhaust system

4.6.1 Intake and Exhaust Systems

4.6.1.1 Introduction of intake and exhaust system

1. The air filtered by the air filter is supplied to the turbocharger.
2. The turbocharged air outputted from the turbocharger flows through the inter-cooler.
3. The air outputted from the inter-cooler is supplied to the intake pipe and then to the intake
valve.

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Figure 4-32 Intake diagrammatic sketch

4. The combusted exhaust gas is supplied to the exhaust pipe via exhaust valve.
5. The exhaust gas is supplied to the turbine of turbocharger via exhaust pipe.
6. The exhaust gas is exhausted from the outlet port of turbocharger.

4.6.1.2 Check the air filter element.

The maximum resistance of diesel engine is 7kPa; Check the maximum intake resistance only
when the diesel engine is running at rated speed under full load. When the intake resistance reaches
the permissible limit, clean or replaces the filter element as per the manufacturer’s instructions.
Disassemble the filter element from the air filter and flap lightly the end face to fall off the
dust or blow backward (from inside to outside) by compressed air.
Caution: Do not blow through the filter paper
Do not clean the filter paper by water or oil
Do not clap and knock the filter element forcibly

4.6.1.3 Check the intake system

Check the intake hose for aging, cracking, and loose hoop and when necessary tighten or
replace parts to ensure the airtightness of intake system.

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4.6.2 Turbocharging system

4.6.2.1 Maintenance
To ensure the reliable and normal running of turbocharger and engine, the maintenance in line

1) Daily maintenance
2) Inspect whether the connecting pipe between the turbocharger and the engine is loosened
or not, and if any, eliminate the problem.
3) Inspect whether the turbocharger is subject to air leakage or oil leakage, and if any, it is
required to timely eliminate the problem in time.
4) Inspect whether the fastening screws of the turbocharger are loosened or not, and if any, it
is required to eliminate the problem in time.
5)
 Periodic maintenance
1)
By lightly turning the air compressor impeller with hand, rotation of the impeller by more than
1 turn indicates that it is in normal condition. If the impeller stops immediately, it indicates that the
bearing is worn abnormally or collision or jamming between the rotating part and the stationary
part occurs, it is required to analyze cause and carry out troubleshooting.
2)
Enable the dial indicator probe to be against the air compressor end, and push and pull the
rotator shaft, and measure and record difference indicated on the dial indicator, as shown in Figure
1. The rotor displacement should be within 0.088mm~0.118mm, and in case of exceeding this
range, it indicates that the thrust bearing plate or thrust plate and bearing body are worn, and it is
required to analyze cause and eliminate the problem.

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Figure 4-33 Diagram for measurement of axial clearance

3) Inspection of axial clearance of the air compressor impeller
Press the air compressor impeller by hand in axial direction, and use a plug gauge to measure
the minimum and maximum clearance between the air compressor impeller and air compressor
scroll, shown as following figure: This value should be within 0.4mm~0.8mm, and in case of

Note: The measurement should be carried out in cold state of the turbocharger.

Figure 4-34 Diagram for measurement of radial clearance

 Re-disassembling and re-
During the disassembling or assembling of turbocharger, upon detection of non-solvable
malfunction or unavailable disassembling or assembling condition, hand over to the production or
service department for handling.
1) Disassemble the fastening screws on the compressor volute, shake the compressor volute
lightly along the perimeter of impellor, and hammer the volute outward uniformly by a rubber

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hammer. It’s prohibited to collide the impellor blades with the housing or loosen the shaft end nut.
2) Wipe away the oil dirt from the impellor passage and housing inner chamber by gasoline.
3) While reinstalling the compressor volute, tighten the fastening screws to the specified
15N.m.
4) If the disassembling of shaft system parts is required, please disassemble by professional
or contracted supplier.

4.6.2.2 Function and operation descriptions

The turbocharger system increases the intake volume by compressed air. It utilizes the inertia
force of the engine exhaust gas to drive the turbine within the turbine chamber. The turbine drives
the impellor on the same shaft and the impellor compresses the air supplied from the air filter
pipeline and conveys the compressed air into the cylinder so that the pressure and density of the air
are increased to consume more fuel and accordingly increase the fuel volume, adjust the engine
speed, and improve the engine power output.
To guarantee the normal working of turbocharger, after the installation of turbocharger on the
engine, all fastening screws must be tightened. Then, lightly operate the impellor by hand and
check it for flexible rotation. Start the operations only after all things are normal.
Operation instructions:
1) The turbocharger must be correctly installed to face the engine oil outlet of the
intermediate body downward. Under special cases, the engine oil outlet can be inclined, provided
that the inclination angle is no higher than 30º.
2) The lubricating oil of turbocharger can be directly supplied by the engine oil line (or
forcibly supplied independently). A fine filter can be installed on the upstream of turbocharger so
that the oil is free of impurities in particle size of >15um. To ensure the reliable working of
bearings, the lubrication is of great importance.
3) The oil inlet pipe shall be larger than Ø13mm in inside diameter and shall be arranged as
close as possible to the outlet of engine oil pump. Generally, it’s prohibited to apply sealant to the
connection between oil inlet pipe and turbocharger; otherwise the measure shall be taken to prevent
the ingress of sealant into turbocharger pipeline. The oil return pipe shall be larger than Ø26mm in
inside diameter and shall be fitted with reducing connector to gradually incline to the oil level of

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crankcase.
4) The capacity of the diesel engine intake pipe shall be as large as possible, in order to
reduce the intake pressure pulsation. The air filter must have appropriate capacity to prevent the
excessive inlet pressure loss of the compressor.
5) The sectional area of the exhaust pipeline must be basically consistent with the total
sectional area of the cylinder exhaust port. The sectional area of the turbine housing outlet pipeline
shall be large, otherwise it will impair the turbocharging effect. All inlet and outlet pipelines must
be carefully arranged to prevent the sudden change of sectional area and ensure good airflow
performance.
6) During the installation, ensure that there is no foreign material falling into the turbocharger
and the engine exhaust pipe system is free of foreign material, otherwise the turbocharger will be
damaged. After the installation of turbocharger on the engine, all fastening screws must be
tightened. Then, lightly operate the impellor by hand and check it for flexible rotation. Start the
operations only after all things are normal.
7) The engine shall be generally fitted with the instruments for measurement of turbine
upstream exhaust gas temperature, turbocharged air pressure, lubricating oil temperature,
lubricating oil pressure, and turbocharger speed and shall also be fitted with warning devices for
high oil temperature and low oil pressure.
8) The engine shall be fitted with air filter and intake muffler.
9) The crankcase ventilator pipe shall not be connected with the inlet of turbocharger. If
connected, an effective oil-gas separator shall be fitted on the inlet.

4.6.2.3 Malfunction diagnosis

For the malfunction detection and diagnosis, if the engine is malfunctioned, the turbocharger
and the engine will have low power output. In event of such problem, firstly check all engine parts
for malfunction. Then, perform the malfunction analysis for the turbocharger depending on
different symptoms occurred.

4.6.2.4 General malfunctions and troubleshooting of turbocharger

If the engine performance fluctuates remarkably due to turbocharger cause, replace the entire
turbocharger or return it to the manufacturer for repair. The general malfunctions and the

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troubleshooting are listed in Table 4-14.

Table 4-14 General malfunctions and troubleshooting of turbocharger
SN. Symptom Cause Troubleshooting
1. Blockage of air filter and reduced intake
Clean the air filter.
volume
2. Excessive oil dirt of compressor impellor
and volute inner chamber, reduce compressor Clean the impellor and
Reduced efficiency, and reduced turbocharging volute inner walls
engine pressure
1 power or 3. Over-high backpressure due to deformation Take corresponding
black or blockage of turbine downstream exhaust measure to solve
exhaust gas pipe problem
4. Reduced turbocharging pressure due to air Take corresponding
leakage of compressor outlet pipeline or measure to solve
turbine inlet pipeline problem
5. Wear of floating bearing Replace
1. Damage or seizure of bearing due to Clean oil line or replace
insufficient oil supply, oil inlet pipeline oil
blockage, or dirty oil or bearing
2. Elasticity loss, wear, sintering, or breakage
Replace
of seal rings
Inflexible 3. Excessive accumulation of oil dirt and
rotation, formation of carbon deposit due to serious Replace parts and clean
slight leakage at seal rings during operation.
friction 4. Accumulation of oil dirt and friction with
2 Clean the impellor and
sound, or impellor arc due to excessive oil mist ingress
compressor volute inner
even no of compressor impellor and volute during
chamber
rotation of operation.
rotor 5. Serious wear of thrust bearing plate Replace
6. Ingress of foreign material and collision or Remove foreign material
wear with rotor and housing and clean intake passage
7. Carbon deposit on turbine back Clean
Check installation
8. Deformation of turbocharger
location
1. Sealing failure due to serious wear of seal
Replace
ring and groove
2. Wear of shaft bushing or ring groove at
Oil leakage
turbine shaft Replace
of
Due to wear of floating bearing
3 turbocharger
Take corresponding
and blue
3. Blockage or deformation of return pipe measure to solve
exhaust gas
problem
4. Low speed oil drainage due to over-long Reduce the low-speed
no-load idling time of engine idling time
Abnormal Replace damaged parts
1. Bending and deformation of turbocharger
4 noise or and verify the dynamic
rotor shaft or deformation of blades
vibration of balance

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turbocharger 2. Eliminated gap and friction between

Replace bearing or entire
impeller outer arc and housing
turbocharger
Due to damage of bearing
3. Deteriorated dynamic balance precision due Clean and verify
to carbon deposit of rotor dynamic balance
Take corresponding
4. Partial leakage of pipeline connected with
measure to solve
turbocharger
problem
1. Oil flow to blade or turbine side
Repair or replace oil
Due to blockage or deformation of oil return
pipe.
White pipe
5
exhaust gas
2. Excessive wear of seal ring due to Disassemble and repair
excessive wear of bearing turbocharger

4.6.2.5 Main data and technical specification

The main data of J135A series turbocharger are listed in Table 4-15.
Table 4-15 Main specification of J135A series turbocharger
SN. Name Parameter Unit Remark
Turbocharger overall
1 0.56~0.60
efficiency
Compressor impellor
2 Φ122 mm
diameter
At engine rated
3 Rated speed 75000 r/min
power
Maximum permissible
4 82500 r/min
speed
5 Rated compression ratio 3.3
Flow in standard
region
6 Rated flow 0.74 kg/s
P0=1.00×105P
at0=25℃
Turbine inlet
7 ≤700 ℃
temperature
8 Turbine outlet pressure ≤3 kPa
9 Oil inlet pressure 0.2~0.4 MPa
Minimum permissible
10 ≥0.15 MPa
oil supply pressure
11 Temperature at oil inlet ≥40 ℃
12 Temperature at oil outlet ＜120 ℃
13 Overall dimensions Φ440×350 mm×mm
14 Mass 42±1 kg
15 Model of lubricating oil 40CD+
The fit clearances of J135A series turbocharger are listed in Table 4-16.
Table 4-16 Table of fit clearances of J135A series turbocharger

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Name Clearance Unit

Front clearance of compressor 0.505~1.075 in axial direction
mm
impellor 0.467~0.995 in normal direction
Back clearance of compressor
0.59~0.98 mm
impellor
0.801~1.319 in axial direction
Front clearance of turbine impellor mm
0.538~0.886 in normal direction
Back clearance of turbine impellor 0.74~1.148 mm
Axial run-out of rotor 0.088~0.118 mm
Radial clearance between impellor
0.4~0.8 mm
and compressor housing
Radial clearance between turbine
0.5~0.9 mm
impellor and turbine casing

4.6.3 Turbocharger

4.6.3.1 Parts
Diagram of turbocharger parts:

Figure 4-35 Diagram of J135A turbocharger

Table 4-17 List of turbocharger
SN. Name SN. Name SN. Name
1 Turbine casing 10 Nut washer 19 Bearing body
2 Screw plug 11 Back plate screw 20 M8 bolt
3 O-ring 12 Oil baffle plate 21 Washer
Compressor
4 Heat insulating cover 13 22 Thrust bearing plate
impellor

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Turbine end clamping band

5 14 Turbine shaft 23 Spacing sleeve
assembly
6 Volute pressure plate 15 Shaft end nut 24 Thrust plate
7 Compressor back plate 16 Oil slinger 25 Floating bearing
Floating bearing retainer
8 Compressor volute 17 Shaft sleeve 26
ring
9 Rubber O-ring 18 Seal ring 27 Process plug

4.6.3.2 Checking
(1) Check the turbine rotor and compressor impellor for good contact and check the rotor for
normal rotation.
(2) Check the rotor condition.
Axial rotation of rotor: wear limit at 0.09mm
Radial rotation of rotor: wear limit at 0.17mm

4.6.3.3 Disassembling
The installation angle of turbine seat and the installation angles of bearing seat and compressor
seat depend on the installation condition of the engine. Add markings before the start of
disassembling.
1) Disassemble the compressor seat.
(1) Disassemble the flat hexagon head bolts and compressor side plate.
(2) Disassemble the compressor seat.
Note:
(1) Apply liquid sealant to the compressor surface for installation of bearing seat.
(2) While disassembling the compressor seat, take cautions to prevent damaging the compressor
impellor.
2) Disassemble the compressor impellor.
(1) Disassemble the shaft end clamping plate by a socket wrench (10mm) on the turbine end of
turbine shaft.
Notice: Notice the loosening direction, as the shaft end nut is of left-hand thread.
(2) Disassemble the compressor impellor.
3) Disassemble the turbine seat.
(1) Loosen the hexagon nut and turbine end metal plate.
(2) Disassemble the turbine seat.

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4) Take out the turbine shaft.

(1) Hold the thermal shield lightly by hand and withdraw the turbine shaft.
Notice: If it’s difficult to withdraw the turbine shaft, lightly knock the compressor end by a wood
hammer.
(2) Take out the thermal shield.
5) Disassemble the sealing plate.
(1) Loosen the T-shaped torque screws by a torque adjustable screwdriver.
(2) While disassembling the sealing plate, notice that the installation surfaces of sealing plate and
bearing seat are applied with liquid sealant.
(3) Take out the engine oil slinger from the sealing plate.
6) Disassemble the sliding bearing and thrust bushing.
(1) Loosen the M3 T-shaped torque screws of thrust bearings by a torque adjustable screwdriver.
(2) Knock out the thrust bearing and thrust bushing by a copper bar.
7) Disassemble the floating bearing.
(1) Take out the retainer ring from the bearing seat by a thrust ring pliers.
(2) Take out the floating bearing from the bearing seat.
8) Disassemble the seal ring.
(1) Take out the turbine end seal ring from the turbine shaft.
(2) Take out the compressor end seal ring (small) and the compressor end seal ring (large) from the
engine oil slinger.

4.6.3.4 Cleaning
1) Checking before cleaning
Before cleaning, visually observe every part and check for trace of seizure, wear, foreign material,
and carbon deposit. Check and judge the problem cause by self, especially at the occurrence of
problem.
Table 4-18 Main checking items
Checking point Checking location
Adhesion of carbon chipping 1) Turbine shaft 1, turbine end seal ring, and turbine
rear end face
2) Installation location of thermal shield disc 20 and
inside of bearing chamber 15

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Lubricating oil status 1) Turbine shaft 1, journal location, and thrust bearing
(such as wear, seizure, and oil slinger 2
discoloration) 2) Floating bearing 5 and thrust bearing 6
3) Bearing chamber 15 and bearing fixing ring inner
walls
Oil leakage status 1) Inner walls of turbine chamber 11
2) Inner walls of turbine chamber 11 and installation
location of thermal shield disc 20
3) Turbine shaft 1, turbine end seal ring, and turbine
rear end cap
4) Inner walls of compression chamber 7
5) Rear end of compression blade 18
Surface of sealing disc 4 and the sealing insertion
2) Cleaning procedure
segment
Table 4.19 Cleaning procedure
Parts Tools and cleanser Procedures
Tools 1) Boil the turbocharger in a barrel and
1) Bucket (500*500) do not scrape the carbon chipping by a
2) Heat source sharp blade.
Steam or gas 2) Immerse it within the detergent, till
3) Brush the carbon chipping and other deposits are
Cleanser softened.
Standard carbon chipping 3) Remove the softened deposits by a
detergent plastic scrape or a hard brush.
4) Guard the bearing surfaces and seal
ring grooves on the turbine shaft against
a) Turbine shaft damage.
5) The residual deposits on the turbine
shaft due to incomplete cleaning will lead
to unbalance of turbine shaft.
Ensure the thorough clean and do not use
a metal brush.

b) Turbine chamber Tools 1) Boil the turbocharger in a barrel.

The same as above 2) Immerse it within the detergent, till
Detergent the carbon chipping and other deposits are
softened.
The same as above 3) Remove the deposits by a plastic
scrape or a hard brush.

c) Blade and chamber Tools 1) Immerse within a barrel, till the

1) Bucket (500*800) deposits are softened.
2) Brush 2) Remove the deposits by a plastic
Detergent scrape or a hard brush and do not use a
metal brush.

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d) Others 1) Clean other parts by diesel.

2) Blow the lubricating oil ways by compressed air.
3) Take special cautions not to damage or corrode the parts.

4.6.3.5 Checking
1) Compressor seat Check the compressor seat for contact trace with compressor impellor,
for surface damage, and for indentation or cracking at junction surface. Upon detection of such
problem, replace the parts.
2) Turbine seat Check it for the contact trace with turbine rotor and check it for the falloff,
thermal deformation, and cracking due to surface oxidizing annealing of castings.
Upon detection of such problem, replace with new parts
3) Compressor impellor
Check for contact trace, fragment, corrosion, and deformation. Upon detection of such
problem, replace with new parts
4) Turbine shaft
(1) Check the turbine rotor for contact trace, fragment, thermal discoloration, and deformation.
Check for bending of shaft, for thermal
discoloration and abnormal wear at shaft journal,
and for surface damage and wear at seal ring
grooves. Upon detection of such problem, replace
with new parts
(2) Measure the outside diameter of turbine
shaft and width of seal ring groove (E). If out of
wear limit, replace with new turbine shaft.
Figure 4-36 Measurement drawing

(3) Measure the wear extent of turbine shaft. If beyond the 0.011mm, replace with new turbine
shaft.
5) Thermal shield 20
Check thermal shield for contact trace, thermal deformation, and wear. Upon detection of
damage, replace with new parts.

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Figure 4-37 Schematic diagram

6) Thrust bearing, engine oil slinger, and thrust bearing

Check every part for wear, surface damage, and discoloration. Upon detection of any
above-mentioned damage, replace with new parts, even if they are still within the wear limit.
(1) Thrust bushing
Measure the distance (K) between the groves of thrust bushing.
If out of wear limit, replace with new parts.
(2) Engine oil slinger
Measure the widths (G1) and (G2) of seal ring grooves. If beyond wear limit, replace with
new parts.
Wear limit RHF5………G1:1.31mm, G2:1.11mm RHB51………G1:1.31mm, G2:1.11mm
RHB31………G1:1.04mm, G2:0.84mm
(3) Thrust bearing
Measure the width (J) of thrust bearing. If beyond the wear limit, replace with new parts.
Wear limit RHF5…………3.98mm RHB51………3.98mm RHB31………3.58mm
7) Floating bearing
(1) Check the floating bearings for abnormal wear, discoloration, and surface damage. Upon
detection of such defect, replace with new parts.
(2) Measure the outside diameter (C) and inside diameter (D). If either is beyond the wear
limit, replace with new part.
Wear limit
RHF5…………Outer diameter (D):12.31mm
Inner diameter (C):8.04mm
RHB51…………Outer diameter (D):12.31mm

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Inner diameter (C):8.04mm

RHB31…………Outer diameter (D):9.93mm
Inner diameter (C):6.29mm
8) Bearing seat 15
(1) Check the surfaces of bearing seat castings for oxidizing falloff, deterioration, indentation,
and cracking. Upon detection of such defect, replace with new parts.
(2) Check the retainer ring 16 for breakage and cracking. Upon detection of such defect,
replace with new parts.
(3) Check the locations (B) and (F) in the bearing seat, as shown in the figure below. If the
wear exceeds any limit, replace with new parts.

Figure 4-38 Measurement drawing

Wear limit for inside diameter (B) of bearing seat
RHF5…………12.42mm RHB51………12.42mm RHB31………10.01mm
Insertion position (F) of seal ring on turbine side
RHF5…………15.05mm RHB51………15.05mm RHB31………11.03mm
Compressor end
9) Seal plate 4
(1) Check the contact trace of seal plate and check it for surface defect, indentation, and
cracking. Upon detection of such defect, replace with new parts.

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(2) Check the installation dimensions (H1 and H2) of seal ring on the compressor side. If
beyond wear limit, replace with new seal ring.

Figure 4-39 Measurement drawing

Wear limit RHF5………H1:12.45mm, H2:10.05mm RHB51………H1:12.45mm,
H2:10.05mm RHB31………H1:10.04mm, H2:8.01mm
10) Seal ring
New seal ring.
11) Check the pressure plate and bolts for deformation. Upon detection of such defect, replace
with new parts. Replace with new M3 torque screws.

4.6.3.6 Assembling
1) Before the assembling of turbocharger, prepare the common tools, special tools, liquid
gasket sealant, and solid sealant.
2) During the assembling, replace the following parts: One turbine end seal ring
One compressor end seal ring (large)
One compressor end seal ring (small)
Three M3 screws
Four M3 screws
Assembling:

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(1) Install the floating bearing.

1) Install the inner retainer ring into bearing seat by pliers.
2) Install the floating bearing to the bearing seat.
3) Install the outer retainer ring into bearing seat by pliers.
Note:
1) The joint of retainer ring shall follow the location shown in right figure. The round
edge of retainer ring shall face towards the bearing.
2) Before assembling, add lubricating oil to the place of floating bearing.
(2) Install the turbine shaft.
1) Attach the seal ring onto the turbine shaft.
2) Install the thermal shield to the turbine end bearing seat.
3) Apply lubricating oil to the turbine shaft journal and install from the turbine end of bearing
seat.
Notice: Operate carefully to prevent the turbine shaft from damaging the floating
bearing. After the centering of turbine shaft, the joint of seal ring shall be at the oil inlet side.
(3) Install the thrust bearing.
1) Attach the thrust bearing onto the turbine shaft.
2) Apply lubricating oil to the bearing face of thrust bearing and install the thrust bearing into
the bearing seat.
3) Apply the sealant to the threads of M3 screws and then fix the thrust bearing to the
specified torque by a torque wrench. Tightening torque: 1.3±0.1N·m (13±1kgf·cm)
(4) Install the seal plate.
1) Attach the seal ring onto the oil slinger 2.
2) Install the oil slinger 2 into sealing plate 4.
Notice: The joint of the seal ring shall be installed as per the above figure.
3) Apply liquid gasket sealant to the installation face of sealing plate and to the bearing bore
of compressor end. Sealant application thickness: 0.1-0.2mm.
4) Install the sealing plate 4 to the bearing bore 15.
5) Apply the sealant to the threads of screws and fix the sealing plate to the specified torque
by a torque wrench. Tightening torque: 1.3±0.1N·m (13±1kgf·cm)

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(5) Install the compressor impellor

1) Attach the compressor impellor 18 to the turbine shaft 1.
2) Fix the turbine end of turbine shaft 1 by a 10mm socket and tighten the shaft end nut 19.
Notice: The shaft end is of left-hand thread. Notice the disassembling direction during
tightening. Tightening torque: 2.0±0.2N·m (20±2kgf·cm)
(6) Install the turbine chamber.
1) Align the marking of bearing chamber 15 added during disassembling with the marking of
turbine chamber 11 and install.
Notice: For replacement of parts, please check the locations of engine oil inlet and outlet
and the location of exhaust gas inlet before assembling.
2) Install the turbine support plate and tighten the M8 12 hexagon head bolts.
Tightening torque: 285±10N·m (28±1kgf·cm)
(7) Install the compressor chamber.
1) Apply liquid gasket sealant to bearing chamber 15 and compressor end flange.
Notice: Refer to (4) 3) for the application locations. Sealant application thickness: 0.1~0.2mm
2) Check the marking on the compressor chamber and install the compressor chamber 7 onto
the bearing seat 15.
Notice: During replacement of parts, determine the locations of oil inlet and exhaust port and
reinstall the parts.
3) Install the compressor support plate and tighten the M8 hexagon head bolts.
Tightening torque: 48±15N·m (4.7±0.5kgf·cm)
(8) Perform the rotor running test.
If the running of rotor fails to meet the specification, it should be caused by an assembling
error or the use of incorrect parts. Ensure to reassemble the parts.
Maintenance criterion of rotor during axial running RHF5………0.03~0.06mm
RHB51………0.03~0.06mm RHB31………0.022~0.053mm
Maintenance criterion of rotor during radial running RHF5………0.08~0.13mm
RHB51………0.08~0.13mm RHB31………0.061~0.093mm

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4.6.3.7 Installation instruction of turbocharger

Handling after assembling
Strictly abide by the following installation instruction while installing the turbocharger to the
engine or during the handling after reinstallation. Take special cautions to prevent the falling of
foreign material into turbocharger.

4.6.3.7.1 Lubrication System

1) Before installing the turbocharger to the engine port, add new engine oil through oil filler
port and rotate the turbine shaft by hand to lubricate the floating bearings and thrust bearings.
2) Flush the oil inlet and return pipes. Check for cracking, dust, and foreign material.
3) Properly connect the oil return pipe to prevent oil leakage.

4.6.3.7.2 Intake system

1) Check the intake pipe for presence of oil dirt and dust.
2) Properly connect the intake pipe and air filter to prevent air leakage.

4.6.3.7.3 Exhaust system

1) Check the exhaust system for presence of foreign material.
2) The bolts and nuts used for the exhaust system are made of heat-resistant steel. Do not use
common bolts or nuts. Apply the anti-lubricant while tightening the bolts or nuts.
3) Properly connect the exhaust pipe to prevent the air leakage from the joint.

4.7 Fuel system

4.7.1 Fuel System

Composition diagram of fuel system:

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2
3

6 8
7

Figure 4-40 Composition diagram of fuel system

1-Fuel injector; 2-Gear fuel delivery pump; 3-Fuel injection pump; 4-Manual fuel delivery
pump; 5-Fuel cutoff solenoid valve; 6-Fuel strainer; 7-Fuel strainer; 8-Fuel tank

4.7.1.1 Precautions for maintenance services

During the maintenance services for related parts of fuel system, pay special attention to the
cleanliness of parts. During the disassembling and installation of parts, including high and low
pressure fuel pipes, fuel filter, fuel injection pump, and fuel injector, take proper protection
measures to prevent the ingress of dirt into the fuel line from blocking and wearing the high
precision parts, including fuel injector nozzle, fuel injector needle valve, and fuel injection pump
plunger, and from causing abnormal working of system.

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4.7.1.2 Functional description

The fuel system is functioned to inject the fuel of fixed volume into the cylinder at the fixed
timing so that the fuel is combusted to power the running of diesel engine. The functions of the
system parts are as below:
Fuel strainer – It’s functioned to filter away the impurities of large particle size from the fuel
and separate the water content from the fuel.
Fuel delivery pump – It generates a negative pressure to suck the fuel from fuel tank into fuel
strainer, deliver the fuel to itself via low pressure fuel pipe, and then pump
the fuel filtered by the fuel strainer into the fuel fine filter.
Fuel fine filter – It’s functioned to filter away the impurities of small particle size from the
fuel.
Low pressure fuel pipe – It conveys the low pressure fuel among the fuel tank, fuel strainer,
fuel delivery pump, fuel fine filter, and fuel injection pump.
Fuel injection pump – It compresses the low pressure fuel transmitted from the low pressure
fuel pipeline to high pressure fuel as per the powering sequence of diesel
engine and transmits the fuel to the fuel injectors via high pressure fuel
pipeline.
High pressure fuel pipe – It conveys the high pressure fuel between fuel injection pump and
fuel injectors.
Fuel injectors – They are functioned to spray high pressure fuel into cylinders as per the
powering sequence of diesel engine.

4.7.1.3 Function Inspection

Please refer to the relevant contents of 3.16 and 3.19 for the daily checking of fuel system.

4.7.2 Fuel filter

Layout of fuel filter

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Fuel coarse
filter

Fuel fine filter

Figure 4-41 Layout of fuel filter

4.7.2.1 Parts

Manual
pump
Fuel coarse filter

Fuel inlet
Fuel outlet

Fuel outlet

Fuel inlet

Fuel fine filter

Bleeder plug

Figure 4-42 Diagram of fuel filter parts

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Water drainage valve

Figure 4-43 Fuel filter water drainage valve

4.7.2.2 Breakdown

Figure 4-44 Diagram of fuel filter parts

Table 4-19 List of fuel filter

1 Fuel filter bracket 10 Hexagon socket head screws

2 Fuel coarse filter 11 Combination washer
3 Fuel fine filter 12 Combination washer
4 Manual pump 13 Hollow bolt
5 Hexagon flange bolt 14 Hollow bolt
6 Wave spring washer 15 Hexagon flange bolt
7 Hexagon nut 16 Strainer - Manual pump fuel pipe
17 Manual pump - Fine filter fuel
8 Hexagon bolt
pipe
9 Spring washer

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4.7.2.3 Checking
Check the water level in the water collector of fuel strainer and drain the water once every 100
hours. Replace the fuel filter element once every 400 hours.

4.7.2.4 Assembling
1) Disassemble the fuel strainer element and fuel fine filter element by an appropriate wrench
and clean the filter seats.
2) Apply engine oil to the new filter element seal gasket.
3) Install the filter element in place by hand in such manner that the seal ring comes into
contact with the sealing surface of filter seat.
4) Tighten the filter element by 3/4~1 turn by an appropriate wrench.
5) Loosen the bleeder plug of fuel strainer and pump the fuel by the manual pump on the fuel
strainer, till the fuel flows out from the bleeder plug.
6) Loosen the hollow bolt at the fuel outlet of fuel fine filter, pump the fuel by the manual
pump on the fuel delivery pump, till the fuel flows out from the loosened hollow bolt, and then
tighten the hollow bolt.

4.7.3 Fuel pump

4.7.3.1 Parts

Fuel inlet pipe connector bolt

Fuel return pipe connector bolt

Lubricant inlet pipe connector bolt

Fuel injection pump body

Lubricant return pipe connector bolt bolt

Fuel inlet pipe connector bolt Electromagnetic actuator

Figure 4-45 Diagram of fuel injection pump assembly parts

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4.7.3.2 Breakdown
P10 fuel injection pump is an enhanced inline fuel injection pump, featuring small volume and
high fuel supply and carrying capacity. It’s mainly composed of pump body, pumping system, fuel
volume control mechanism, and drive mechanism.

4.7.3.2.1 Pump body:

P10 pump is an suspended flange full-enclosed fuel injection pump made of die cast aluminum
alloy, with full-enclosed pump body, bracket installation, and cylinder bore spacing at 40, featuring
high strength and stiffness and high carrying capacity against high pump end pressure. When the
forced lubrication is adopted, the pump body is fitted with lubricating oil inlet and return orifices.

4.7.3.2.2 Pumping system:

The pumping system of P10 fuel injection pump adopts the suspension structure, in which the
plunger sleeve is suspended within the pump body mounting bore and the plunger, fuel outlet valve
coupling, fuel outlet valve spring, and fuel outlet valve gasket are fixed in the plunger sleeve by
fuel outlet valve fixing seat. The plunger sleeve is fitted with two rubber O-rings to realize low
pressure sealing. The plunger sleeve is designed with kidney-shaped hole so that the rotation of
plunger sleeve can adjust the non-uniform fuel volume among cylinders. The gasket is installed
between plunger sleeve and pump body to adjust the fuel supply pre-travel and fuel supply angle
among cylinders, in order to ensure that the cam profile is working in the best working segment.
The fuel outlet valve coupling is functioned to separate the high pressure fuel pipe and the plunger
chamber at the completion of plunger pumping, in order to prevent the backflow of fuel. The
pressure reduction travel (relief pressure) of fuel outlet valve can guarantee an appropriate residual
pressure of high pressure fuel volume and prevent the secondary and irregular injection. The
plunger sleeve is fitted with fuel return orifices to reduce the fuel leakage. The fuel return orifices
of the plunger sleeve are fitted with baffle screws to prevent the return fuel from impacting the
pump body.

4.7.3.2.3 Fuel volume control mechanism:

The fuel volume is controlled by the pull rod and the plunger control sleeve. The pull rod is
installed within the sleeve of pump body. Driven by the speed regulator, the pull rod drives the

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plunger via the engaged plunger control sleeve to change the relative position between plunger and
the plunger sleeve so that the change extent of the relative position is used to adjust the fuel
volume.

4.7.3.2.4 Drive mechanism:

The drive mechanism is composed of the camshaft subassembly, roller body subassembly,
plunger spring, and upper spring seat. The camshaft of P10 pump is fixed within the camshaft
chamber of pump body by a rolling bearing without inner ring, a double-row taper roller bearing,
and 1~2 intermediate bearings. The cams drive the roller body subassemblies of various cylinders
as per preset sequence to reciprocate the plungers vertically. The plunger springs are functioned to
move downward the plungers driven upward by the camshaft and keep the roller body assemblies
non-separated from the cams.

4.7.3.2.5 Electric speed regulator

The electric speed regulator is mainly composed of electromagnetic actuator, speed controller,
and speed sensor. The electromagnetic actuator is installed on the rear end of fuel pump, the speed
sensor is installed on the flywheel cover, and the speed controller is generally installed within the
control cabinet.

Control battery
Speed controller

Speed sensor
Power
switch

Speed
measurement
flywheel
Electromagneti Test button
c actuator Idling/rated speed
changeover switch Speed tuning potentiometer

Figure 4-46 Structural diagram of electric speed regulator

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4.7.3.3 Disassembling

4.7.3.3.1 Disassembling
Before the disassembling, remove the external dusts and dirt, record the adjustment data, and
disassemble as per the procedure below:
1) Fix the fuel injection pump assembly on special bench or vice bench.
2) Disassemble the electromagnetic actuator.
3) Loosen the fastening nuts of plunger sleeves and take out the plunger sleeves (including the
fuel outlet valve coupling, fuel outlet valve spring, and fuel outlet valve gasket installed within the
plunger sleeve).
4) Loosen the pull rod locating screws, pull the pull rod till the plunger control sleeve is just
beyond the pull rod slot, and take out the plunger by rotating the plunger and pulling upward the
plunger. The disassembled plungers shall be place into corresponding plunger sleeves and no
interchange is allowed.
5) Take out the plunger control sleeve.
6) Rotate the camshaft and, when the roller is at bottom dead center, push down the spring seat
by a metal bar. When the snap ring pops up, take out the snap ring, spring upper seat, plunger
spring, and roller body subassembly.
7) Disassemble the drive end bearing cap, unscrew the intermediate bearing screws, and take
out the camshaft.
8) Push out the disassembled roller body subassemblies from one end of roller pin to the other
end and take out the wire retainer, roller inner ring, and roller.
9) Loosen the fuel outlet valve fastening cap from the plunger sleeve and take out the fuel
outlet valve and O-ring.

4.7.3.3.2 Checking of disassembled parts:

Clean the disassembled parts by clean gasoline and check the wear and damage status of parts.
Replace seriously worn and non-reusable parts and replace all seal gaskets, O-rings, oil seals, and
snap rings of spring upper seat.
1) Plunger coupling
Replace the plunger upon detection of damage, wear, and discoloration in its spiral groove.

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Check the sliding performance of plunger by rotating and sliding downward the plunger. Upon
detection of over-fast rotation or stagnation midway, replace the plunger.
2) Fuel outlet valve coupling
Replace the fuel outlet valve and valve seat upon detection of damage or wear in their working
surfaces.
3) Roller body assembly
Replace the roller upon detection of wear, damage, and surface falloff on its surface.
Replace roller pin and roller inner ring upon detection of wear or damage.
Replace roller body upon detection of wear or damage on its working surface.
4) Replace the camshaft upon detection of defect in taper area, cam surface, contact surface
with intermediate bearing, or thread area.
5) Bearings
Replace the intermediate bearing upon detection of defect and replace the bearings on two
ends of camshaft upon detection of wear.
6) Springs
Replace the plunger spring and fuel outlet valve spring upon detection of damage, rusting, and
non-uniform wear.
7) Fuel supply pull rod and plunger control sleeve
Replace the fuel supply pull rod upon detection of bending or deformation. Replace the
plunger control sleeve upon detection of serious wear at flat insertion part of plunger.
8) Pump body
Replace the pump body upon detection of cracking, wear, or thread damage.

4.7.3.3.3 Disassembling of electric speed regulator

1) Unplug the connecting cable between actuator and controller.
2) Disassemble 7 connecting hexagon socket head screws between actuator and intermediate
body.
3) Drain the lubricating oil from the intermediate body housing.
4) Disassemble the connecting nut or butterfly pin between actuator and toothed bar and
loosen the connection between actuator and oil pump toothed bar.

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4.7.3.4 Assembling

4.7.3.4.1 Installation of fuel injection pump

1) Place the plunder sleeve on special tooling or vice, install the sealing gasket, fuel valve
parts, fuel outlet valve spring, and fuel outlet valve spring seat, screw the fixing seat of fuel outlet
valve, place the plunger into original plunger sleeve, and install the O-ring.
2) Assemble the roller, roller inner ring, wire retainer, and roller body together to the roller
body subassembly.
3) Fix the pump body on special tooling or vice, overturn the pump body, install the roller
body subassemblies into cylinder bores from bottom to top via bearing bores, press the bearings
onto the journals on two ends of camshaft, and secure the snap rings on the speed regulator end.
Pass the camshaft together with intermediate bearings into the camshaft chamber of pump body
from one end and then tighten the fastening screws of intermediate bearings and fastening screws
of front housing.
4) Press the bearings and framework oil seals into bearing caps, attach the O-rings, and install
the bearing caps into the mounting bores of pump body.
5) Turn over the pump body, place the plunger spring and upper spring seat in turn, and install
the snap ring of upper spring seat securely by special tool. Ensure to secure the snap ring, otherwise
it will lead to accident and damage the fuel injection pump.
6) Install the pull rod into the pump body sleeve. The pull rod shall move flexibly, with the
pull rod marking facing upward.
7) Rotate the camshaft. When certain cylinder is at the top dead center, the flat end of plunger
will insert into the flat slot of the plunger control sleeve. While installing the plunger into the roller
body, rotate the plunger control sleeve to ensure the complete engagement of its pull rod. Align the
plunger sleeve installed with pumping subassembly with the plunger, install them together, and
tighten fastening nuts of flange sleeve to 45~50N.m. Tighten the fixing seat of fuel outlet valve by
a torque wrench to 120N.m. Check the pull rod for flexible movement, otherwise check and solve
the cause. Install all other cylinders as per same method.
8) At completion of assembling, the static sliding resistance of the pull rod shall be no higher
than 300g.

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4.7.3.4.2 Installation of electric speed regulator

Perform the wiring and installation as per the figure below.

Auxiliary power supply (10V)

Speed regulation voltage input

SN. Name
1 Speed controller
2 Electromagnetic actuator
Idling when closed
3 Actuator cable
4 Sensor cable
5 Speed sensor
Droop when closed 6 Control battery
7 Fuse
8 Power switch
9 Trimming potentiometer
10 Droop changeover switch
11 Idling/rated speed
High pressure changeover switch
oil pump

Figure 4-47 Connection diagram of electric speed regulator

4.7.3.5 Installation

Fuel injection
pump hub
Fuel injection
pump

M10 Flat washer

Hexagon socket cylindrical head screw

M10×395(Grade 10.9)
Electromagnetic
actuator

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Figure 4-48 Assembly of fuel injection pump

1) Install the fuel injection pump hub onto the fuel pump, with the hub marking facing
upward. Align its marking with that of fuel pump, apply sealant 242 to the threads, and tighten to
(250~300) N.m.
2) At the compression top dead center of cylinder B6, tighten the fuel pump hub with
coupling.
3) Turn the diesel engine to the advance angle. If the advance angle is inappropriate, loosen
the connection between hub and coupling and perform fine tuning.
4) After adjustment, tighten the fuel pump hub together with coupling and fix the fuel pump
onto the cylinder block by M10×95 grade 10.9 bolts.

4.7.3.6 Special tools

Special tooling for snap ring of upper spring seat of fuel pump plunger spring

4.7.3.7 Torque specification

Except the torques specified otherwise in the installation, follow the general tightening torques
for conventional bolts.

4.7.3.8 Troubleshooting
1. Engine Start-up difficult
1) Incorrect fuel supply advance angle while 1) Readjust as per operation manual of diesel
installing fuel pump onto diesel engine engine
2) Air content in fuel system 2) Bleed the air
3) Working failure of fuel delivery pump
A. Air leakage at fuel inlet and outlet pipe A. Replace gaskets and tighten connectors
connectors of fuel delivery pump
B. Failure of fuel delivery pump check valve B. Remove dirt and grind end face of check
valve
C. Wear of fuel delivery pump piston C. Replace piston
D. Blockage of internal filter screen of fuel D. Clean filter screen
delivery pump fuel inlet connector
4) Insufficient starting fuel amount 4) Re-adjust
5) Wear or blockage of plunger coupling 5) Replace plunger coupling
6) Blockage of nozzle or poor atomization 6) Replace nozzle coupling
7) Low opening pressure of nozzle 7) Re-adjust
8) Filter blockage 8) Clean the filter element
9) Insufficient power of electric speed regulator 9) Charge or replace battery
power supply (battery)
10) Poor installation of speed sensor 10) Reinstall speed sensor
11) Broken cable of speed sensor 11) Replace sensor cable

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12) Stagnation between actuator and fuel pump 12) Overhaul

rack linkage
13) Broken actuator cable 13) Replace actuator cable
2. Insufficient horsepower
1) Early or delayed fuel injection timing 1) Re-adjust
2) Insufficient fuel injection volume 2) Readjust and repair
3) Leakage of fuel injector 3) Repair or replace
4) Wear of plunger 4) Replace plunger coupling
5) Poor atomization of nozzle 5) Repair or replace nozzle
3. Unstable engine speed
1) Inappropriate adjustment of controller 1) Adjust differential (stability) and gain
potentiometers on controller
2) Excessive axial clearance of camshaft 2) Readjust clearance
3) Deteriorated fuel supply volume uniformity 3) Adjust and repair
among cylinders
4) High pull rod resistance 4) Overhaul
5) Large error of fuel supply angular interval 5) Re-adjust
among cylinders
6) Excessive lubricating oil level within actuator 6) Overhaul and troubleshooting
4. Engine galloping
1) Low gain setting and poor flexibility of 1) Reset
controller
2) Malfunction of speed controller 2) Replace
3) Mismatch of fuel supply zero position 3) Adjust and Overhaul
between actuator and fuel pump so that the fuel
supply of fuel pump can’t cut off after power-off
of actuator
4) Signal error of engine speed sensor 4) Replace the sensor
5) Blockage of pull rod 5) Overhaul
6) Breakage of plunger spring 6) Replace
Notice: Upon detection of engine galloping,
immediately cut off the fuel line and block the
intake passage of engine to force the stop of
engine.
5. Sudden stop of engine
1) Failure of electric speed regulator power 1) Ensure the continuous power supply for the
supply electric speed regulator
2) Fuel supply interruption 2) Check the fuel volume in fuel tank, the
working status of fuel delivery pump, and the
fuel pipeline.
3) Poor contact of cable or damage of circuit 3) Overhaul and replace
4) Blockage of plunger 4) Replace
5) Seizure of fuel injector nozzle 5) Replace
6) Breakage of plunger spring 6) Replace

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4.8 Cooling System

4.8.1 Cooling circuit

The diesel engine for land power generator only adopts the circulation of heat carrying fluid
within an enclosed circuit.
The major and minor circulations of the cooling system are controlled by the thermostat:
When the temperature of coolant is low, the thermostat closes so that the coolant returns to
water pump via bypass pipeline for cooling circulation, without flowing through the radiator
(Minor circulation of coolant).
When the temperature of coolant is high, the thermostat opens so that the coolant completely
flows through the radiator and then flows into water pump for cooling circulation (Major
circulation of coolant).
Oil cooler

Thermostat Fan

Cylinder block
and cylinder head

Exhaust pipe of
water jackets

Cylinder block
and cylinder head
Water pump Radiator

Oil cooler

Figure 4-49 Schematic diagram of cooling system

4.8.2 Thermostat
 Thermostat subassembly

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Gasket

Thermostat
Thermostat body
Thermostat cover

Figure 4-50 Breakdown diagram of thermostat

 Checking of thermostat

Immerse the automatic thermostat in a water container. After heating, measure the water
temperature and observe the temperatures of thermostat for consistency with the temperatures listed
in the table below.

Thermometer

Thermostat

Figure 4-51 Checking of thermostat

Table 4-20 Inspection item of thermostat

Initial opening Lift height at full opening (ºC)

temperature (ºC)
Hata! Başvuru ≥9.5mm(87℃)
kaynağı
bulunamadı.℃

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4.8.3 Water pump

The 12M26 model adopts two water pump which symmetrically arranged on both sides of
diesel engine and is driven by a poly V-belt. The poly V-belt automatic tensioner is fixed on the
cylinder block by brackets to keep a sufficient tension for poly V-belt.

Lable

Water seal

Vortex
O-ring Impeller chamber
Bearing Water pump body

Pulley assembly

Figure 4-52 Breakdown of water pump

4.8.3.1 Disassembling of water pump

Disassemble the small alternator.
Disassemble the fan, poly V-belt, and pulley.
Disassemble the cooling pump.
Disassemble the thermostat.

4.8.3.2 Precautions
1) Check the bearings of cooling pump for abnormal noise, blockage, swing, and water
leakage.
2) Replace the O-ring of water pump with new one.

4.8.4 Fan
The 12M26 series diesel engine for power generator adopts the steel fan with rigid drive
mode. Depending on the needs of diesel engine for power generator, the reverse fan is adopted to

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guarantee the cooling effect.

4.8.4.1 Parts
The fan parts are as below:

Figure 4-53 Diagram of fan

Table 4-21 List of fan

SN. Chinese name Number of units

1 Fan 1
2 Hexagon bolt 1
3 Standard spring washer 6
4 Flat washer 6

4.8.4.2 Disassembling
14mm open-end wrench
Unscrew six hexagon head bolts and take out the fan.
The installation is in reverse order:
Tighten fix hexagon head bolts in turn. The required tightening torque is as below.

Table 4-22 Bolt tightening torque

Bolt size Rating Tightening torque

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specification
M14 10.9 190N·m

Figure 4-54 Diagram of fan

4.8.4.3 Checking

4.8.4.3.1 Checking of fan

Check the fan rivets for looseness, check the fan blades for bending, and ensure the normal
working of fan.

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Figure 4-55 Checking of fan

4.8.4.3.2 Check the poly V-belt

Visually observe the poly V-belt for cracking and scratch and when necessary replace.

Figure 4-56 Checking of poly V-belt

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4.9 Lubrication System

4.9.1 Lubrication System

Figure 4-57 Diagram of lubrication system

Table 4-23 List of lubrication system
1 Oil sump 2 Drain plug
3 Oil dipstick 4 Strainer
5 Oil pump 6 Pressure limiting valve
7 Oil pipe 8 Oil cooler
9 Centrifugal engine oil filter 10 Filter
11 Pressure regulating valve 12 Oil pipe
13 Oil pipe 14 Piston cooling nozzle
15 Camshaft bushing 16 Main bearing shell
17 Connecting rod bushing 18 Connecting rod bushing

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19 Rocker lubricating oil pipe 20 Oil inlet pipe of fuel injection pump
21 Oil return pipe of fuel injection pump 22 Oil return pipe
23 Turbocharger oil inlet pipe 24 Turbocharger oil return pipe
25 Pressure gauge 26 Pressure sensor
27 Pressure switch

4.9.1.1 Oil line:

The engine is fitted with pressurized lubrication system. The gear oil pump is located on the
bottommost place of the engine. This oil pump is driven by the valve mechanism on the front of
crankshaft. All lubricating points and accessories requiring lubrication are connected by the
pipeline or conduit in the pressurized lubrication system. The splash lubrication mode is adopted to
lubricate the timing gear. The lubricating oil is splashed to the pistons for continuous cooling.

4.9.1.2 Engine oil pump subassembly

Figure 4-58 Diagram of engine oil pump parts

Table 4-24 List of engine oil pump parts
1 Oil pump assembly
2 Bushing
3 Bushing
4 Pin
5 Shaft and gear assembly
6 Shaft and gear assembly
7 Hexagon bolt
8 Drive gear
9 Safety valve
10 Copper gasket
11 Straight pin
12 Rubber O-ring
13 Hexagon socket cylindrical head screw
14 Hexagon socket cylindrical head screw

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During installation, the backlash of engine oil pump with the crankshaft gear is (0.15~0.2)
mm.
The fastening bolts of the engine oil pump are in specification of M12 (grade 10.9). During
installation, apply Loctite 242 to the thread surfaces to prevent vibration looseness and tighten to
110±5N.m.
Notice: After the installation of engine oil pump, check the engine oil pump for smooth
rotation. If the rotation of the engine oil pump is tight, the oil pump will be probably burnt during
running of engine.

4.9.1.3 Adjustment of oil pressure

1) Safety valve
Two safety valves are arranged on the right side of the oil sump and can be maintained by the
access panel of the cylinder 6. When the oil is start under cold status, the above-mentioned valves
can carry the pressure of 10 bar and are functioned to limit the oil pressure of engine circuit.

Figure 4-59 Diagram of safety valves

2) Control valve
The oil pressure control valve is located on the engine oil filter bracket. The oil pressure
control valve is used to keep constant the oil pressure in the circuit and the opening pressure of this
valve is 0.2MPa. In addition, the oil displacement of these valves is the fuel supply volume of the
cooling pump beneath the piston head.

Figure 4-60 Diagram of control valve

4.9.1.4 Centrifugal engine oil filter

This engine is fitted with two centrifugal filters, which are installed near the lubrication

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circuits respectively. The engine oil filter is located on the side face of oil sump.
Replace the centrifugal filter element.
a. Loosen the top nut 5.
b. Take out the intermediate filter cup 1.
Warning: If the nut 4 on the filter cup is loosened,
please disassemble this nut. Tighten it to the fixing seat
during reassembling.
c. Disassemble the filter element 2 and sealing
gasket 3.

Figure 4-61 Diagram of d. Clean the filter cup and fixing seat.

centrifugal engine oil filter e. Install new filter element and use the
sealing gasket 3 attached in new filter
element.
f. Reinstall the filter cup, tighten to 20N.m, and
ensure that the filter cup is free of distortion.

4.9.1.5 Oil filter

Both engine oil filters adopt one-time full-flow filter element. If the engine oil filter is
blocked, the safety device on the filter element is used. This means that the lubrication is
maintained even when the filter element is blocked. Periodically replace these filter elements
during maintenances.
Replace the Oil filter
Replace the filter element during each replacement of engine oil. Before
disassembling the engine oil filter, remove the dirt from its surrounding area.
A one-time engine oil filter element is installed on each side of the engine. Loosen the filter
element by an engine oil filter wrench during replacement.
a. Clean the engine oil filter base.
b. Apply engine oil (instead of lubricating
grease) to the sealing gasket.
c. Tighten the engine oil filter by hand (instead of
tool) and rotate by approximately 3/4 turn.

Figure 4-62 Installation of engine

oil filter

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Check the engine oil level and pre-lubricate the engine. Re-check the oil level and when necessary
add sufficient oil. Ensure that the engine oil filters are free of oil leakage.

4.9.1.6 Engine oil

4.9.1.6.1 Engine oil type

Use CD15W/40 or above engine oil as specified by GB11122.

4.9.1.6.2 Oil capacity:

The capacity of the standard oil tank for 12M26.2 horizontal engine is 113L.

4.9.1.6.3 Replace engine oil

1) After the stop of engine, use the manual pump for the replacement of engine oil.
2) Place the three-way connector to the place shown in figure below.

Pre-lubrication

Drain

Figure 4-63 Diagram of manual oil pump

3) Check whether the three-way valve is placed at the position “Drain” shown in the figure
below.
4) Check whether the pump switch is place at position 1.
5) Place the “Drain” changeover switch of operation box to “ON”, till the engine is fully
drained.
6) At completion of the drainage, place the “Drain” changeover switch of operation box to
“OFF”.
7) Adjust the three-way valve to position “Pre-lubricate".
8) Add engine oil into the engine oil tank.
Notice: Add clean engine oil into diesel engine oil tank, till the oil level reaches the upper

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marking of oil dipstick. Start and idle the engine and check the engine oil filters and drainage
plug for oil leakage. Stop the engine, wait for approximately 5min for the engine oil to return
from upper parts into oil sump, and check the oil level once again. When necessary, add engine
oil, till the engine oil reaches the upper marking of oil dipstick.

4.9.2 Oil cooler

Figure 4-64 Diagram of engine oil cooler parts

Table 4-25 List of engine oil cooler
1 Oil cooler element 2 Rubber O-ring
3 Support block 4 Rubber O-ring
5 Water inlet port cap 6 Hexagon socket cylindrical head
screw
7 Coolant outlet 8 Hexagon socket cylindrical head
screw
9 Hexagon socket cylindrical head 10 Rubber O-ring
screw
11 Seal ring 12 Water drainage valve
13 Flange 14 Gasket
15 Hexagon socket cylindrical head 16 Connecting pipe
screw
17 Fuel inlet bend 18 Rubber O-ring
19 Gasket 20 Hexagon socket cylindrical head

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screw

The engine is fitted with two engine oil cooler, which located on the both sides of the engine.
The engine oil is circulated by cooler and is cooled by engine coolant before being filtered.
Replace the engine oil cooler core:
1) Loosen 4 M8 connecting screws of water inlet pipe on the water inlet port cap of engine oil
cooler by a wrench and disassemble the connecting water pipe. (Drain the coolant from engine
before disassembling)
2) Disassemble 4 bolts of engine oil cooler water inlet and outlet port caps by an Allen wrench
and disassemble the water inlet port cap and the engine oil cooler housing.
3) Clean the water inlet and outlet port caps and the sealing junction surface of engine oil
cooler housing.
4) Disassemble the engine oil cooler core and clean the inside of housing.
5) Replace and install new engine oil cooler core.
6) Reinstall the water inlet and outlet port caps of engine oil cooler and tighten the screws.
7) Reinstall the water inlet pipe of engine oil cooler and tighten the screws.
Note: Apply Loctite sealant 242 to the threads before tightening the bolts.

4.10 Startup system

4.10.1 Start-up system

The starter system is composed of battery (to be provided by the user), starter motor, starter
switch, and wires.

4.10.1.1 Precautions for maintenance services

 Before start of engine

Ensure that there is no person around the engine before start.

Ensure that all protective plates are properly seated.
Ensure that all engine parts are free of contact with any object: Splash danger.
Take necessary protection measures during operations around motion parts.
Never disable the automatic stop circuit.
Above measures are intended to prevent the personal injuries and machine damage.
Before starting a new engine or a recently repaired engine, operate the acceleration and stop

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control levers on the fuel injection pump to ensure flexible motions.

Before start, rotate the crankshaft of diesel engine for several turns. After the rotation without
obstruction is confirmed, place the speed control lever of fuel injection pump in the middle position
and turn on the power switch.
Start the diesel engine only after the safety of the equipment and the environment is ensured.
 Take the necessary measure for emergency cutoff of fuel or air supply, in order to prevent
the initial speed risk.
Check circuit for cleanliness.
Check for non-obstructed exhaust gas in the exhaust pipeline.
If the engine is stopped for ≥24 hours, perform the pre-lubrication before restart. If the engine
is stopped for less than 24 hours, the pre-lubrication is not especially required.
Check the electric supply system.
Check and ensure that all other parts driven by the engine work normally.
 Engine with manual pre-lubrication pump
Ensure that the three-way valve is placed at the position “Pre-Lubrication” as shown in figure
below.
After the stop of engine, pre-lubricate the engine by manual drainage pump.
Ensure that the transmission linkage is already disengaged.
Ensure that all drive parts at neutral position.
Ensure that the accelerator control lever is at position “Idling”.
Rotate the key to position “Start” on the instrument panel to start the engine.
Alternatively, start the engine from the cabinet of the machine room. If the “Start” switch is at
position “ON”, press the “Start” button.

Notice
After the start of diesel engine, idle the engine for 2~3min. The engine oil pressure shall be
no less than 200kPa. If insufficient, stop the engine immediately for checking, in order to prevent
damaging the diesel engine. When the coolant temperature is less than 60 ℃, do not run the
engine at high speed under heavy load suddenly, otherwise it will deteriorate the wear resistance
and reliability of the diesel engine.
Do not idle or run the diesel engine under unloaded condition for a long time.

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4.10.1.2 Function and operation descriptions

12M26 series diesel engine for power generator is started by electric starter motor. Under
normal working condition, the starter motor converts the electric energy stored in the battery into
mechanic energy to drive the running of engine at a speed high enough for successful start of the
engine.

4.10.1.2.1 Startup of Diesel Engine

 Control panel
Turn off the master circuit.
Rotate the key to position “1” to power on the control panel.
“Engine oil pressure warning lamp” automatically turns on for 10s (test of ultimate low engine
oil pressure safety line)
It’s recommended to test the indicator lamps, bulbs, and buttons once (by pressing the touch
button 10 on the control panel).
Rotate the key to position “START” to start the engine and then release the key. The key
automatically returns to position “1”.
At the start of diesel engine, if the diesel engine fails to start within 10s, immediately release
the button and wait for 1min before retry.
If the engine can’t be started by three consecutive attempts, stop the attempt and find out and
solve the malfunction before retry.
During the working of engine, both “oil pressure warning lamp” and the "battery power”
indicator lamps are off.
All indicator lamps are off during normal running of engine.
In event of abnormality, the “horn” will issue warning tone.
When the engine is running.
The adjustment and repair are prohibited during the running of the engine.
For the purpose of safety, all persons and objects shall keep away from motion parts.

Notice
Do not wear loose clothing or wear bracelet or necklace. Otherwise,
such articles will be probably blocked into engine parts.
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4.10.1.2.2 Stop of Diesel Engine

Avoid the stop of engine under full load.
Before stopping the engine, reduce the load and speed and run the engine under idling or
low-load condition for 3~5min to cool down the pistons, cylinder sleeves, bushings, shaft sleeves,
and turbocharger for a sufficient time, in order to prevent the scuffing and bushing scratch.
Rotate the key switch to position “OFF” or press the stop button to stop the running of engine,
till the flywheel stops rotation or the speed indication on the instrument panel is zero.
If the diesel engine circulating water is not added with antifreeze, ensure to drain the coolant
after stop in cold days, in order to prevent the frozen damage of diesel engine. The water drainage
valve is located beneath the oil cooler. Rotate the water drainage valve switch to drain the water
from diesel engine. At the same time, disassemble the water drainage plug from the radiator to
drain the coolant from the radiator.

4.10.1.3 Malfunction diagnosis

1. The starter motor is not working, even when the switch of starter motor is turned on.
Cause Troubleshooting
1 Insufficiently charged battery Check and charge or replace battery
2 Poor contact of connecting wires Look up and tighten wiring posts
3 Burnt fuse Replace fuse
Poor contact of electric brush Clean electric brush surfaces or replace
4
electric brush
5 Short-circuit of starter motor Check and repair motor or replace assembly
2. The drive gear is engaged, but the engine is not running – Weak starter motor
Cause Troubleshooting
1 Insufficiently charged battery Check and charge or replace battery
2 Wear of bearing bushing Replace assembly
3 Loose weld of wire ends Re-weld
4 Poor contact of switch Check and repair switch
3. The drive gear moves forward, but can’t engage with ring gear.
Cause Troubleshooting
1 Insufficient movement distance of Check motor or replace assembly
starter motor gear
2 Tooth collision of starter motor or Replace starter motor or flywheel ring gear
flywheel ring gear

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4. After the start of engine, the starter motor doesn’t stop rotation when the starter motor
switch is turned off.
Cause Troubleshooting
1 Return failure of switch Check and repair switch
2 Return failure of starter motor gear Check and repair motor or replace assembly

4.10.1.4 Main data and technical specification

The DC starter motor is in voltage of 24V, with right-hand rotation direction and 12 teeth. The
circuit diagram of starter motor is shown in figure below. The internal circuit of the starter motor is
already connected.

Figure 4-65 Circuit diagram of starter motor

4.10.2 Starter

4.10.2.1 Overview of starter motor

4.10.2.1.1 Function and basic structure

The starter motor is one of the core parts of vehicle starter system and is functioned to convert
the electric energy of battery to electromagnetic torque and, via the gear and ring gear mechanism,
drive the rotation of engine to start the engine. The starter motor is mainly composed of DC motor,
one-way clutch, starter pinion (or reduction gear train), electromagnetic switch, and starter relay.

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4.10.2.1.2 Model and classification

In accordance with the regulations of the industry standard QC/T73-93 Preparation Method of
Product Model for Automotive Electric Equipment of the People’s Republic of China, the
composition of model number for the automotive starter motor is as below:

Variant code
Design number
Power level
Voltage class
Product code: QD are the initials of the
Chinese Pinyin of “starter motor”

Figure 4-66 Model designation of starter motor

QD denotes starter motor; QDJ denotes reduction starter motor; QDY denotes permanent
magnet starter motor (including the permanent magnet reduction starter motor).
Voltage grade code: 1 denotes 12V and 2 denotes 24V.
Power grade code: As listed in Table 4-26.
Table 4-26 - Power grade code
Power level
1 2 3 4 5 6 7 8 9
code
Power / kW <1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 >8
At present, the starter motor equipped on our products adopts the electromagnetically driven
flexible engagement mode and can be divided by drive gear engagement mode to armature motion
starter motor and shifting fork gear motion starter motor (of which the latter accounts for a high
proportion) and by drive mechanism to direct drive starter motor (Equal speed for starter motor
rotor and starter motor gear) and reduction starter motor (The speed of starter motor gear is less
than rotor speed).

4.10.2.2 Installation specification of starter motor

4.10.2.2.1 Installation of starter motor

Before the assembling of starter motor, check the status of junction surface between starter
motor and flywheel cover. The junction surface shall be free of burr, oil mist, and knocking
damage.

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Screw three M10×25 studs into flywheel cover by stud tooling and tighten the studs (As
shown in Figure 1). Put the ring washer on the starter motor and place the starter motor vertical to
the installation hole, pass the starter motor through the studs and install to the flywheel cover, and
ensure the correct engagement of starter pinion (As shown in Figure 2). Use three M10 type 1
hexagon nuts attached with standard spring washer install the starter motor loosely to the flywheel
cover and tighten the nuts symmetrically to 64N.m~76N.m (As shown in Figure 3) by a 16mm
open-end wrench.

Stud

Flywheel
cover

Figure 4-67 Installation of studs

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Type 1 hexagon
Starter nut
Ring
washer

Standard spring
washer

Figure 4-68 Loose installation of starter motor

Tighten to
64N.m~76N.m
by a 16mm
wrench

Figure 4-69 Tighten bolts as per specification

4.10.2.2.2 Wiring of starter motor

The wiring of starter motor must be correct, secure, and safe. The tightening torques are listed
in the table below.

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Table 4-27ightening torques

Screw Tightening torque Screw Tightening torque
specification (N.m) specification (N.m)

M5 2~2.5 M10 13.5~15.8

M8 8.4~10.5 M12 24.7~27.5

4.10.2.2.3 Disassembling of starter motor

To disassemble the steering pump, disassemble the bolts by a 16mm wrench, take out the nuts
and washers, and lightly knock the housing by a rubber hammer (never knock by a hard object) to
disassemble the starter motor.

4.10.2.3 Common Malfunction Diagnosis and Troubleshooting of Starter

Motor

4.10.2.3.1 Start failure

Symptom 1: The starter motor doesn’t rotate at the time of start, without any sound.
Cause 1: Malfunction of starter switch
Checking: Check the starter master switch and the starter control relay for normal functioning.
Troubleshooting: Replace malfunctioned part.
Cause 2: Burnt starter circuit fuse
Checking: Check the starter circuit fuse.
Troubleshooting: Replace the fuse. If the fuse is burnt once again at the next start, check the
circuit for presence of short-circuit point and solve the short-circuit. If the external circuit is
normal, the starter motor is internally short circuited and needs to be replaced.
Cause 3: Locking of starter circuit.
Checking: Check whether the transmission is at neutral gear and whether the safety switch is
normal.
Troubleshooting: Shift the transmission to neutral gear and ensure the normal safety switch.
Cause 4: Open-circuit of starter motor
Checking: Check the switching motor terminals of starter motor for voltage to ground. If the
voltage to ground is zero at the time of start, the internal circuit of starter motor is open circuited.

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Troubleshooting: Replace starter motor.

Symptom 2: The starter motor is not rotating, but a clear and short “click” sound can be heard.
Cause 1: Low voltage of battery.
Checking: Under the stop state of engine, turn on the headlamp for 1~3min and then measure
the battery voltage. If the measurement is less than 24V, it indicates the low power of battery.
Troubleshooting: Connect an external power supply to charge the battery, or replace the
battery, or start the engine by an external power supply via cables.
Cause 2: Excessive voltage drop at start due to excessive internal resistance of starter circuit.
Checking: Compare the terminal voltage of battery with the terminal voltage to ground of
starter motor. The voltage difference shall be no higher than 1V. Measure the control terminal
voltage and the battery terminal voltage. The voltage difference shall not be higher than 1V.
Troubleshooting: Increase the sectional area of wires to reduce the internal resistance. The
recommended sectional area is at least 1.5 mm2～2mm2.
Cause 3: Occurrence of “tooth collision” symptom (The drive gear of starter motor comes into
contact with end face of flywheel ring gear).
Troubleshooting: Disassemble the starter motor and check the drive gear and flywheel ring
gear end face for excessive wear.
Troubleshooting: Replace the drive gear or isolator of starter motor and replace flywheel ring
gear.
Cause 4: Internal malfunction of starter motor. The possible causes include short-circuit of
armature and excitation winding, surface oxidizing, ablation, or oil dirt of commutator, poor contact
of electromagnetic switch, wear of electric brush, and insufficient pressure of electric brush spring.
Checking: Disassemble the starter motor and test the functioning of starter motor by an
external normal circuit.
Troubleshooting: Disassemble the starter motor for checking and repair by professional repair
personnel of starter motor.
Symptom 3: High noise, abnormal sound, or intermittent running
Cause 1: Abnormal starter motor installation and damaged starter motor gears.
Checking: Disassemble the starter motor, check the starter motor gears and flywheel ring gear,
and analyze for correct installation.

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Troubleshooting: Correctly install the starter motor. If the starter motor gears are damaged,
replace the starter motor.
Cause 2: Excessive depletion of battery.
Checking: Under the stop state of engine, turn on the headlamp for 1~3min and then measure
the battery voltage. If the measurement is less than 24V, it indicates the low power of battery.
Troubleshooting: Connect an external power supply to charge the battery, or replace the
battery, or start the engine by an external power supply via cables.
Cause 3: Turn-to-turn short-circuit of relay coil, poor contact of relay contact, and turn-to-turn
short-circuit of electromagnetic switch coil.
Checking: Replace relay and restart starter motor. If the starter motor can work normally, the
original relay is damaged.
Troubleshooting: Replace with new relay.
Symptom 4: Idling of starter motor.
Cause 1: Deformation of shifting fork or loose shifting fork linkage.
Checking: Disassemble the starter motor, power on the starter motor by an external circuit, and
observe the starter motor gears for presence of protrusion.
Troubleshooting: Replace starter motor.
Cause 2: Serious damage of certain segment due to breakage or excessive wear of ring gear
and slip or damage of one-way clutch.
Checking: Disassemble the starter motor and observe the wear extent of starter motor gear and
flywheel ring gear.
Troubleshooting: Repair by welding or replace the flywheel ring gear. If the starter motor is
still idling, replace the starter motor (The one-way clutch is damaged).
Symptom 5: Constant rotating of starter motor.
Cause 1: Return failure of ignition switch.
Checking: Replace ignition switch and perform start test.
Troubleshooting: Replace ignition switch.
Cause 2: Ablation of relay contact and disqualified breaking voltage of contact.
Checking: Replace starter motor and perform start test.
Troubleshooting: Check, repair, adjust and replace.

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Cause 3: Ablation of starter motor contact or damage of contact coil spring and soft or broken
return spring of drive fork.
Checking: Replace starter motor and perform start test.
Troubleshooting: Replace starter motor.

4.10.2.3.2 Judge malfunction points on vehicle

Check appearance of starter motor for obvious abnormality, such as ablation, looseness,
deformation, and damage.
Firstly, check the battery voltage and all switching voltages.
Start by using the auxiliary starter switch and verify the normal start control system. Operation
method of auxiliary starter: Shift the transmission to neutral gear, place the ignition switch to
“ON”, open the engine hood, and press “Start”. After the engine is started, immediately release the
button to complete the start by using the auxiliary starter.
Replace the starter motor. If the malfunction disappears after the adoption of measure c), the
malfunction exists in the start control circuit. If the malfunction still exists, further judge the
malfunction source by replacement method. Replace the malfunctioned starter motor by a good one
or disassemble the wires of starter motor, connect the battery and starter motor directly by auxiliary
wires, and observe the start effect. If the start is normal, the malfunction exists in the start control
circuit. Otherwise, the starter motor is the malfunction source.

4.10.2.3.3 Malfunction judgment of starter motor parts

Manual rotation of isolator in both directions
Discoloration of drive shaft
Ablation or damage of electromagnetic switch

4.10.2.3.4 Replacement criterion of starter motor parts

The residual length of the worn electric brush is less than half of its original length.

Original length of M90 series electric brush: 18

Original length of M93 series electric brush: 20.5
Original length of M105 series electric brush: 21.5
The wear of armature commutator is higher than 1mm.
The original diameter of M90 series commutator is Ø39.

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The original diameter of M93 series commutator is Ø35.

The original diameter of M105 series commutator is Ø39.
The electromagnetic switch and the starter relay are used continuously for 2 years
(20,000 start cycles).

4.10.2.4 Daily maintenances of starter motor

Check the starter motor for secure installation and wiring.
Remove the surface oil dirt of starter motor.
Check the drive gear and flywheel ring gear.
Remove the surface oil dirt of drive shaft.
Clean the terminals of battery.
The starter motor is a short-time working unit. The start time shall not exceed 15s each time
and the interval between two consecutive starts shall be >30s.
When the temperature is below -5ºC in winter, preheat the engine before start.
To start the diesel engine in winter or under low temperature condition, take the thermal
insulation measure for the battery.
Once the engine is started, Immediately release the starter switch to disengage the starter
motor drive gear from flywheel ring gear.

4.10.3 Malfunction diagnosis and troubleshooting of charging system

4.10.3.1 Charging failure

Malfunction 1: Charging failure
Vehicle Failure detection Troubleshooting
symptom
(1) The a. Check charging ① Check alternator indicator lamp for presence
charging indicator lamp. of voltage to ground. If not, replace indicator
indicator b. Check the lamp or check circuit.
lamp fails to excitation circuit ② If yes, it indicates that the alternator
turn on after for presence of regulator or rotor is malfunctioned. Repair or
turn-on of open-circuit. replace alternator.
key switch.

(2) The a. Low power of ① Use recommended 2~6W lamp bulb or repair
charging indicator lamp or circuit.
indicator loose parallel ② Adjust idling speed of the engine.
lamp fails to excitation resistor.
turn off b. Low idling

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during idling speed of engine.

of engine and
turns off
during
high-speed
running of
engine.
(3) The a. Check whether ① If the alternator indicator lamp terminal
charging the voltage to voltage is really low, it indicates low power of
indicator ground of the excitation line indicator lamp or loose connection
lamp fails to alternator exciting in circuit. Adjust the indicator lamp power or
turn off terminal is within check the circuit connectors and connection
while the 1~3V. points.
engine is ② If the alternator indicator lamp terminal
running. voltage is zero, it indicate the presence of
short-circuit to ground at the excitation circuit
alternator terminal. In such case, check the
circuit.
③ If the alternator indicator lamp terminal
voltage is the battery voltage, it indicates the
presence of malfunction in vehicle excitation
circuit and that the alternator regulator and
excitation tube may be damaged. In such case,
make sure to correct the excitation circuit and
then repair the alternator.
b. Check whether ① If the B+ voltage to ground is zero, check
the voltage to whether both the positive and negative wires
ground of the between alternator and battery are under
alternator output continuity status.
terminal B+ ② If the B+ voltage to ground is significantly
equals to battery below the battery voltage, check the connecting
voltage of points of positive and negative wires between
approximately alternator and battery for presence of looseness or
24V. check the battery for damage.
Recommended measurement method: Jumper
connect one 2W indicator lamp between
alternator output terminal B+ and excitation
terminal D+/L and observe the working status of
indicator lamp.
Troubleshooting:
① The lighting intensity of indicator lamp is
normal, the indicator lamp turns off after the
engine is started, and the alternator output
voltage is 27~28.5V. The vehicle excitation
circuit is malfunctioned and needs checking and
repair.
② The lighting intensity of indicator lamp is
normal, the indicator lamp turns on constantly
after the engine is started, and the alternator
output voltage is 27~28.5V. The alternator

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regulator is malfunctioned and needs to be

replaced.
③ The lighting intensity of indicator lamp is
normal, the indicator lamp turns on constantly
after the engine is started, and the alternator
output voltage is the battery voltage. The
alternator regulator, rectifier bridge, stator, or
internal connection may be malfunctioned and
need repair or replacement.

4.10.3.2 Low charging voltage

Malfunction 2: Low charging voltage
Vehicle Failure detection Troubleshooting
symptom
The battery is Understand The measurement of alternator terminal B+
frequently whether the voltage shall be at 27.8~28.4V. If the voltage is
charged alternator output normal, it indicates that the voltmeter or
insufficiently, power is voltmeter sampling point is malfunctioned and
with low reasonably needs to be repaired or replaced.
charging matched with the
voltage, and electric devices of
its voltage vehicle.
drops a. Check ①It’s recommended that the no-load idling speed
significantly voltmeter for of alternator is higher than 1600RPM.
when being damage. ② When the alternator is working under high
loaded. b. Check the power load condition (for instance, the air
alternator speed. conditioner is switched on), the alternator speed
shall be ≥2000rpm or the voltage shall be
approximately 27V.
c. Check the drive ①Check the quality of belts for alternator and
belt quality and relevant pulley systems and replace any burnt,
tension for ruptured, distorted belt or the belt with tooth
alternator and breakage or the belt dropping to the bottom of
related gear groove.
system. ②Re-tension the alternator and relevant pulley
systems.
★ Notice: For the systems with double drive belt,
replace both belts in event of replacement.
d. Check Tighten if loosened.
alternator pulley.
e. Check wires for ①If the voltage difference is higher than 1V
reasonable use (high voltage drop due to thin wires) under
and measure heavy-load condition, replace the wires.
voltages at if ≤35A, then S ≥6mm2; if ≤70A, then S ≥12mm2
alternator and if ≤100A, then S ≥20mm2; if ≤150A, then S
battery terminals. ≥25mm2
②If the wire or connector has clear temperature

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rise under heavy-load working condition, replace

the wire or connector.
f. Check for ①Grind the wire lugs with oxidized surfaces and
presence of high the housing surface for installation of grounding
temperature due bolt and reinstall.
to looseness, ②Retighten any loose nut and wire lug and
oxidation, or re-insert the connectors.
loose connection ★Notice: Run the reinstalled or re-tightened
at the joint portions for 3~5min when the alternator is under
between wire and heavy-load and then check for the presence of
bolt of charging high temperature.
system.
g. Check the If there is high difference between phase terminal
phase output (W/R/AC) output voltage and normal output, the
voltage of alternator rectifier bridge or stator is malfunction
alternator (This and the checking and replacement shall be
voltage shall be considered.
approximately
one half of B+
output voltage.)
h. Check the The charging current shall drop to approximately
battery for normal 10A after 10min charging. If the charging current
charging. is at 30~90A constantly, the battery is damaged
and needs repair or replacement.

4.10.3.3 High charging voltage

Malfunction 3: High charging voltage
Vehicle Failure detection Troubleshooting
symptom
a. Check The measurement of alternator B+ terminal
voltmeter for voltage generally shall be at 27~28.4V. If the
damage. voltage is normal, it indicates that the calibration
error of voltmeter is high and the voltmeter needs
to be repaired or replaced.
b. Check the ① In event of poor contact or loose connection,
wires and retighten or re-insert the connectors.
connections of the ② In event of short-circuit, re-connect the
The charging system, wires.
voltmeter check the
indicates connection bolts
high voltage for presence of
looseness, loose
connection, and
high temperature,
and check for
presence of
short-circuit
between wires

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and alternator
housing.
c. Check battery ① Observe during the charging of battery
for normal whether the charging current varies greatly within
working status. a short period (from 50A to below 10A). If not,
the replacement of battery as soon as possible
shall be considered.
② Observe the battery surfaces for cleanliness
and dryness and check whether the wiring
terminals and clamps are in good fit. Replace as
soon as possible in event of any damage.
d. Check the If there is high difference between phase terminal
phase terminal (W/R/AC) output voltage and normal output and
output voltage of the voltage drop is high when the alternator is
alternator (This loaded, the alternator rectifier bridge or stator is
voltage shall be malfunctioned and the checking and replacement
approximately shall be considered.
one half of B+
output voltage).
e. The Replace alternator regulator, rotor, or whole
malfunction alternator.
symptom is not
solved after above
checking.

4.10.3.4 Unstable charging voltage

Malfunction 4: Unstable charging voltage
Vehicle Failure detection Troubleshooting
symptom
The a. Loose belt or belt run-out for Tension belts for alternator and
voltmeter alternator or related pulley related pulley systems.
indicates the systems.
charging b. Looseness or poor contact at Check and tighten connections of
during connections of charging circuit charging circuit
normal c. Contamination of collector ring, Remove contaminants or replace
running of excessive wear of electric brush, electric brush or electric brush
engine, but or softening or breakage of spring
the pointer electric brush spring
fluctuates and d. Damage of regulator Replace the regulator.
the reading
can’t be read
(or the
charging
indicator
lamp turns
off
occasionally).

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4.10.3.5 Alternator noise

Malfunction 4: Unstable charging voltage
Vehicle Failure detection Troubleshooting
symptom
a. The fixing bracket of alternator Improve strength of fixing
is deformed or is too close to bracket and adjust installation
There is an other external housings. status.
abnormal b. Looseness or slip of alternator Replace engine belt.
noise during belt
running of c. Loose alternator pulley Tighten pulley.
alternator. d. Oil shortage or damage of Replace alternator bearing
alternator bearings
e. Low noise within alternator The stator coil is short circuited.
Replace it.
f. Speed-dependent squealing This is the noise generated by the
within alternator vibration of stator iron core. If
necessary, replace stator
subassembly.

4.10.4 Generator

4.10.4.1 Basic operation rule of alternator

4.10.4.1.1 Secure installation

The alternator shall be installed on the engine or vehicle correctly, securely, and reliably. The
mounting bolts must match with mounting holes of alternator and must be tightened. The grooves
of the pulley shall be within same plane with those of drive pulley.
★ Recommendation: Immediately tension the belt after 20km mileage or 20min engine
running time for a new vehicle. Periodically check the belt for proper seating within the grooves.
The mounting bracket for the alternator must ensure the necessary strength and stiffness
requirements.

4.10.4.1.2 Appropriate tension of belt

The appropriate belt tension is generally in such manner that the belt deflection is 10~20mm
when a 150N (15kgf) force is applied onto the belt in the middle point between two pulleys (or that
the belt is free of obvious vibration during loaded running). Check the belt tension once every 2
months.

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★ Warning: The loose belt will lead to “speed loss” of the alternator and cause the
malfunctions such as insufficient power generation, battery depletion, stator burnout, and bearing
damage. A new replacement belt must be re-tensioned after 5min running.
Recommendation: Appropriately adjust the adjustment arm to ensure the appropriate belt
tension and tighten all fastening nuts of motor to specified torque.

4.10.4.1.3 Correct and secure wiring

1. Description of alternator wiring terminals. Never connect the terminals incorrectly, in
order to prevent burning the vehicle harnesses and damaging the alternator units.
B+: Positive terminal, to battery and other loads (with battery motor).
B-: Negative output, to circuit (double wire system motor).
E: Negative grounding terminal.
N: Neutral terminal.
W/AC/R: Phase output terminal.
IG/WL/D+/L: Charging indicator lamp terminals (sometimes also with excitation function.
The 2W indicator lamp is recommended. The terminals D+/WL can output ≤1A current.
2. For an alternator without battery application, there are special wiring requirements. Please
refer to the operation instruction of alternator without battery application.
★ Warning: Ensure to periodically check the fastening status for the nuts (bolts) and wiring
plates. Looseness (loose connection) will lead to insufficient power generation and generate electric
spark at loose point to bring about major potential dangers for the operation safety of the vehicle
(especially the high-power motors). It’s prohibited to bind up the output wires of alternator with the
high pressure gas pipe of the vehicle or the engine or the oil pipes.
3. Before the disassembling/assembling of alternator and electric welding of vehicle, ensue to
disconnect the wires of battery and alternator.
★ Special notice: Disconnect the negative wire before positive wire for disassembling and
connect positive wire before negative wire for installation.

4.10.4.2 Disassembling and installation method of alternator

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Generator installation position. 2. Loosen the automatic tensioner and

disassemble the poly V-belt from alternator
pulley.

Generator
Automatic
tensioner

3. Disassemble the M12 and M10

mounting bolts of alternator. 4. The installation sequence for the
alternator is in reverse order of the
disassembling sequence.

★ Notice: The alternator must be disassembled, assembled, and repaired by

professionals. During installation, check all insulation gaskets and sleeves for intactness and
ensure to replace any damaged one. The positive terminal of alternator can’t be short
circuited with the housing; otherwise it’s prohibited to install the alternator onto the vehicle
to prevent causing serious vehicle accidents.

4.10.4.3 Malfunction diagnosis and maintenance of alternator

4.10.4.3.1 Procedure for judgment of alternator malfunction

During the warranty service for the user, firstly test on the vehicle to judge whether the

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alternator is malfunctioned. Tool: Test lamp. The procedure is shown in figure below.
Turn on the power switch of the vehicle and connect the test lamp to the
terminal B+ and E (negative) of the alternator.
No It indicates that there is no voltage at terminal B+ of
Is test lamp ON? alternator and the wire to the positive pole of battery is
Yes malfunctioned.

Connect the wire from

terminal E to terminal D+ of
alternator N
It indicates that the internal electric circuit at
Is test lamp ON? o
terminal D+ of alternator is malfunctioned.

Yes
Start the engine

Yes
Alternator
Is test lamp ON? malfunction

No

Alternator is not
malfunctioned

Flowchart for judgment of alternator malfunction

4.10.4.3.2 Maintenances of alternator

The timely and correct maintenances are effective means to prolong the service life of
alternator and improve the operation efficiency of whole vehicle. Therefore, the systematic and
standardized maintenances are required for the alternator.
Main maintenance items;
Check the wear and slip status of belt.
Check wires for broken ends and damage.
Check all fasteners of alternator and all wiring post nuts of alternator. Check the terminal nuts
of all electric devices for looseness and retighten all fasteners to prevent the vibration of alternator
from causing hitching of bracket and alternator or prevent the loose connecting nuts from causing
flow-through of high current and damage of regulator.

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Timely remove the dusts and oil dirt from alternator.

Periodically check the wear status of alternator carbon brush and slip ring and when necessary
remove the dusts adhered onto the slip ring by sand paper.
Check the fan blades for damage and when necessary replace with new fan.
Maintenance-free for full-sealed heavy-duty bearings.

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Annex A Recommended Torque for Standard Bolts

Recommended Torques for Standard Bolts

Friction
0.125 (zinc plated) 0.14 (polished)
coefficient

Strength grade 6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
Bolt size Recommended torque (N·m)
M4 2.3 2.7 3.8 4.6 2.4 2.9 4.1 4.9
M5 4.7 5.5 8.0 9.5 5.0 6.0 8.5 10
M6 8.0 9.5 13.0 16.0 8.5 10 14.0 17
M8 19 23 32 39 21 25 35 41
M10 39 46 64 77 41 49 69 83
M12 67 80 110 135 72 86 120 145
M14 105 125 180 215 115 135 190 230
M16 165 195 275 330 180 210 295 355
M18 225 270 390 455 245 290 405 485
M20 325 385 540 650 345 410 580 690
M22 435 510 720 870 465 550 780 930
M24 560 660 930 1100 600 710 1000 1200
M27 830 980 1400 1650 890 1050 1500 1800
M30 1100 1350 1850 2250 1200 1450 2000 2400
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 1250 1450 2050 2500 1350 1600 2250 2700

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Annex B Recommended Torque for Hollow Bolts

Recommended Torques for Hollow Bolts

Recommended tightening
Specification Head type
torque (Nm)
M8×1 Hexagon head 7±1
17±2
Hexagon head 13±2 (Copper bolt and small
M10×1
combination washer)
Flange bolt 20±3
Hexagon head 22±3
M12×1.5
Flange bolt 28±3
Hexagon head 27±3
M14×1.5
Flange bolt 32±3
Hexagon head 30±3
M16×1.5
Flange bolt 36±3
Hexagon head and
M18×1.5 60±5
flange bolts

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Appendix C Fit Clearances for Main Parts of Diesel Engine

SN. Item Theoretical
value (mm)
1 Main bearing clearance 0.122~0.202
2 Connecting rod bearing clearance 0.093~0.167
3 Crankshaft endplay 0.1~0.346
4 Connecting rod axial clearance 0.26~0.452
Clearance between connecting rod small end
5 0.031~0.081
and piston pin
Working clearance of piston ring opening in cold state
1st ring 0.45~0.6
6
2nd ring 0.75~1
Oil ring 0.45~0.7
Clearance between piston pin and piston pin
7 0.01~0.024
seat
Clearance between intake valve stem and valve
8 0.04~0.07
guide
Clearance between exhaust valve stem and
9 0.06~0.09
valve guide
Indentation of intake valve bottom with respect
10 0.60~1.10
to cylinder end plane
Indentation of exhaust valve bottom with
11 1.20~1.70
respect to cylinder end plane
Protrusion of cylinder sleeve shoulder with
0.07~0.13
respect to top plane of cylinder block
12
Indentation of cylinder sleeve shoulder with
0.39~0.5
respect to top plane of cylinder block
13 Camshaft axial clearance 0.1~0.25
14 Camshaft bearing clearance 0.055~0.128
15 Camshaft bearing clearance (thrust bearing) 0.06~0.119
16 Clearance between tappet and tappet hole 0.025~0.066
Clearance between outside diameter of
cylinder sleeve and cylinder sleeve bore of 0.014~0.079
engine block (upper portion)
17
Clearance between outside diameter of
cylinder sleeve and cylinder sleeve bore of 0.03~0.095
engine block (lower portion)
18 Clearance between rocker sleeve and rockshaft 0.017~0.043

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0.3±0.03
19 Valve clearance Intake/exhaust (cold state)
/0.3±0.03
20 Axial clearance of rocker 0.4~0.6
Backlash between crankshaft gear and
21 0.09~0.20
camshaft gear
Backlash between camshaft gear and fresh
22 0.09~0.15
water pump gear
Backlash between fuel injection pump
23 0.08~0.125
intermediate gear and fuel injection pump gear
Backlash between crankshaft gear and engine
24 0.20~0.25
oil pump gear
25 Protrusion of fuel injector 1.87~2.68

Clearance between crankshaft speed sensor and

26 0.5~1.5
flywheel

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