Common complaints and solutions

Common complaints and solutions
(I) Difficult to start engine
Reasons and charactors	solutions
1.check the fuel system
a: fuel specification is selected wrong	a:select the right specification diesel
b: there is no diesel in eingine	b:fill diesel
c: there is air in diesel tube and oil-injection pump	c:remove the air from diesel system and tighten the tube connection parts
d: there is water included in diesel	d:change diesel
e:the oil tube or filter is blocked	e:remove and clean oil tube and filter or change filter element
f:there is no oil supply from oil delivery pump、injection pump or the diesel-supply angle of advance is not right.	f:check and repair oil delivery pump、injection pump 、 diesel-supply diesel-supply angle of advance
g:no or a little oil injected , or oil-injection pressure low,poor atomization,damage of oil-injection pressure-adjuster spring, oil-injection blocked	g:wash and grind oil-injection component、adjust the pressure of oil-injection
h:leakage of oil-injection outlet valve、damge of spring,plunger and barrel assembly damage	h:change oil-injection pump、spring or plunger and barrel assembly
2.poor pressure of air cylinder
a,valve distance too small	a,adjust the distance of air cylinder
b,air leakage of air valve	b,change valve spring or grind valve
c,air leakage between air cylinder cover and its washer	c,change air cylinder washer
d,breakage,cementation of piston, and entrance is overlaped	d,remove cementation,change piston,adjust the piston entrance place
e,air cylinder or piston broken	e:change air cylinder and piston
3.check electrical system
a, battery power isn't enough	a,recharge the battery
b,electrical lines connected not right	b,fasten the electrical lines
c, switch of sarting motor failure	c, repair starting motor switch or change starting motor
d,sarting motor gear not inlayed into flywheel	d,check and inlay motor gear into flywheel.
(II) Poor engine efficiency
Reasons and charactors	solutions
1.air filter blocked	clean air filter core, or change it accordingly
2,not press the accelerator to the floor	press the accelerator to the floor
3,exhaust pipe blocked	remove the dust from exhaust pipe
4,air came entered diesel tube	remove the air and tight tube connection parts
5,oil-injection blocked,oil outlet valve failure or the high-pressure oil tube screw loose	tight or adjust
6,diesel is not enough or its quality poor	fill enough diesel, select right-specification diesel
7,oil-supply diesel-supply angle of advance not right	adjust the diesel-supply angle of advance
8,the atomization of oil-injection poor	adjust the oil-injection pressure
9,air valve distance is not right	adjust air valve distance
10,compressing pressure of air cylinder insufficient	refer to "poor pressure of air cylinder"in [(I )difficult to sart engine]
11,oil-injection timing incorrect	adjust gear in accordance to its code.no
12.oil-injection work abnormal	adjust or change oil-injection pump

(III) smoke evacuation abnormal
Reasons and charactors	solutions
1.emit white smoke
a,water entered into air cylinder	a,check and remove the problem
b,water entered into diesel	b,change the diesel
c,oil-injection pressure insufficient	c,adjust oil-injection pressure
2,emit blue smoke
a,engine oil flee,piston fixed incorrectly,blokced or grind too much	a,adjust or change piston
2,the distance between valve and guid tube too big	b,change air valve
3,valve oil seal breakage	c,change oil seal
3,emit black smoke
a,engine overload	a,reduce load
b,diesel supply too late	b,adjust the oil-suplly diesel-supply angle of advance
c,diesl supply too much	c,adjust oil-injection or speed adjuster
d,air filter or exhaust pipe is blocked	d,remove the dust from air filter and exhaust pipe or change the filter core
e,valve distance incorrect,poor valve sealing	e,adjust valve distance;grind valve
f,oil-injection timing incorrect	f,adjust oil-injection gear in accordance to its marked no.

(IV) engine overheated
Reasons and charactors	solutions
1,cooling water is insufficient or polluted	fullfill or change the cooling water
2,cooling system is not smoothl	remove water scale,dust for let pipe smoothly
3,water pump belt is loose	tight the water pump belt
4,water pump working abnormal	repair or change water pump
5, thermostat failure	repair or change thermostat
6,poor lubricate oil quality	change lubricate oil
7,water temperature meter failure	change water temperature meter
8,engine working overload	reduce engine load

(V) abnormal voice happens when engine is running
Reasons and charactors	solutions
1.oil-injection too early,rhythmed knocking voice from air cylinder	adjust the oil-supply angle of advance
2,oil-injection too late,depressing and unsharp voice from air cylinder	adjust the oil-supply angle of advance
3,Due to too big distance between piston and air cylinder, the knocking voice happens from cylinder after engine started. This voice will be reduced when engine is hot	change the piston or cylinder cover
4,due to distance between piston and pin hole too big, voice is light and sharp, specially its very clear during idle speed	change spare parts ,assure the specified distance
5,Due to distance between main bearing and connecting bearing is too big, the knocking voice happens when engine speed reduced suddenly,its heavy and strong	change spare parts ,assure the specified distance
6,the Crankshaft distance too big, can hear the knocking voice like crankshaft shaking back and forth	change crankshaft pushing piece, assure specified distance
7,valve spring broken,pushing-rod bend,valve distance too big, can hear cluttered voice or light rhythmed knocking voice from air cylinder cover	change spare parts ,adjust valve distance
8. top of piston touches air cylinder cover or valve, can hear metal knocking voice around air cylinder when its low speed	adjust the valve distance,port timing or change air cylinder washer
9,gear distance too big coz of grinding, can hear knocking voice in pinionbarrel when speed lowed suddenly	change the gear accordingly

(VI) consumption of engine oil too much
Reasons and charactors	solutions
1. engine oil is too much,engin oil splash too much	drain some engine oil
2,oil leakage in oil outlet bolt, engine oil filter, cylinder cover, oil pan gasket, cylinder cover gasket, back-forth oil seal, engine oil filter washer, echa plug and bock parts	tighten bolt,change washer,change plug and block parts
3,oil return hole of oilring in piston ring is blocked by carbon deposit	remove oil-return hole carbon deposit
4,poor engine oil quality	change engine oil
5,piston ring is grinded and blocked	change piston rong
6,the distance between air cylinder cover and piston too big	change cylinder or piston
7,valve rod oil seal grinded	change valve rod oil seal

(VII) consumption of diesel too much
Reasons and charactors	solutions
1. air filter is blocked	clean air filter or change filter core
2.screw on high-speed limit is not sealed	seal high-speed limit screw
3.oil leakage in diesel pipe	tighten oil-way joint and change oil pipe
4,exhaust pipe is blocked	remove the dust from exhaust pipe
5.Lowest empty -load stable rotating speed too high	adjust lowest empty-load stable rotating speed to specified data
6.poor diesel quality	select and use the specified diesel
7.oil supply Angle of advance is incorrect	adjust oil-supply angle of advance
8.oil-injection Atomization quality is poor	adjust oil-injection starting pressure,check and wash oil nipple
9.valve distance incorrect	adjust valve distance
10. oil-injection pump working abnormal	adjust or change the oil-injection pump
11.air cylinder compressing pressure insufficient	pls refer to 2nd reasons and character of (I) difficult to start engine

(VIII) Lubrication System fault
Reasons and charactors	solutions
1,engine oil pressure too low
a.Oil Pan engine oil pressure insufficient	a.add engine oil up to scale of oil ruler
b.engine oil pipe blocked	b.wash oil-way and blow it by compressed air
c.engine oil filter blocked	c.wash engine oil filter or change filter core
d.engine too hot,engine oil teperature too high,engine oil changed to watery	d.reduce the load,change engine oil,lower engine oil temperature
2,poor quality of engine oil	change the specified engine oil
3,oil-return valve is blocked,oil returned too much in engine oil filter	repair or chagne engine oil filter
4,engine oil pump filter screen is blocked	wash filter screen
5,engine oil pump gear grined or end- face distance too big	adjust or change oil pump gear
6.engine oil pipe is splited or connection get loose	tighten connection part
7, engine pump is failure	repair or change engine oil pump
8,connection-rod bearing and main bearing grinded	change connection bearing and main bearing
9, pressure meter of engine oil broken	chagne oil pressure meter

(VIII) cooling system failure
Reasons and charactors	solutions
1, water temperature too high
a. cooling water is insufficient	a. fullfill the cooling water
b.spring of radiator cover is soft	b.change the spring on radiator cover
c.water pump belt loose or broken	c.tighten water pump belt or chagne water pump belt
d.thermostat invalid	d.change thermostat
e.water pump work abnormal	e.repair or change water pump
f.cooling water scale too much	f.wash cooling water- way for removing the scale
g.radiator is blocked	g.wash radiator pipe for let it smooth
h. water leakage of radiator	h.repair or change radiator
I. water leakage of water pump	i. change washer or seal washer
j. radiator joint soft pipe loose or splited	j. tighten radiator soft joint or change soft pipe
2, water temperature too low
a. thermostat invalid	a.change thermostat
b.. Thermostat selected incorrectly	b.select specified one
c.environment temperature too low	c.fix windbreak

(IX) sarting motor failure
Reasons and charactors	solutions
1, sarting motor not working
a.bad connection of wire	a.clean and tighten joint point
b.battery charging insufficient	b.charge the battery fully
c.bad connection of electric brush	c.clean commutator suface
d.starting power turn-off by itself	d,repair or change starting motor
2,starting motor turn without moving forward weakly
a.bearing bushing block grinded	a.change bearing block
b.bad connection of electrical bush	b.change the surface of commutator
c.commutator is not clean or burned	c.remove the oil dust and polishing by sand cloth
d.back lines Loose Weld	d.weld the loose- lines stably
e.bad connection	e.clean and tighten joint
f.bad connection of switch	f.repair switch
g.battery charge insufficient or volume too low	g.charge battery or change another battery with bigger volume
h.clutch slipping	h.adjust the moment of clutch

(X) generator failure
Reasons and charactors	solutions
1.Not charge completely correct,Charging less ,charging current instability
a.Open the back cover generators one by one with a multimeter or the amount of IC regulator diode	a.change it in time if find broken parts
b.vacuum leaf width is wearing seriously	b..change it in time if find broken parts,leaf width should ≥13mm
c. oil leakage	c.change the oil-leakage parts