RA4LT Series Diesel Engine

Operation & Maintenance Manual

Please read this manual carefully before using the engine.
 Content

Preface ............................................................................................................................................ 4
Important considerations in use................................................................................................... 5
SAFETY WARNING ...................................................................................................................... 6
SAFETY SIGNS ............................................................................................................................. 7
Chapter 1 Main Technical Specifications and Parameters of Diesel Engine ........................ 8
1. Main Technical Specifications ............................................................................................ 8
2. Main Technical Data ................................................................................................................ 9
Chapter 2 Operation of Diesel Engine ................................................................................... 12
1. Fuel .......................................................................................................................................... 12
2. Lubricating Oil .................................................................................................................... 14
3. Coolant .................................................................................................................................... 15
4. Diesel Engine startup steps ............................................................................................ 16
5. Running-in of Diesel Engine ............................................................................................ 18
6. Precautions during Operation of Diesel Engine......................................................... 19
7. Shutdown and Inspection of Diesel Engine................................................................... 20
Chapter 3 Regular Inspection and Technical Maintenance ................................................... 21
1. Fuel Supply System .............................................................................................................. 21
2. Lubricating System .............................................................................................................. 24
3. Cooling system ...................................................................................................................... 27
4. Air Intake System ................................................................................................................ 28

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5. Battery .................................................................................................................................... 28
6. Usage and Technical Maintenance in Winter................................................................. 29
7. Regular Technical Maintenance .......................................................................................... 32
Chapter 4 Common Fault Analysis and Elimination Approaches for Diesel Engine .......... 35
1. Difficult Startup of Diesel Engine ............................................................................ 35
2. Unstable Minimum No-load Steady Speed (Idle Speed)............................................. 37
3. Unstable Speed of Diesel Engine .................................................................................. 38
4. Diesel Engine Power shortage ........................................................................................ 38
5. Exhaust Smoke Abnormal .................................................................................................... 39
6. Diesel Engine Overheated ................................................................................................ 40
7. Abnormal Sound during Operation of Diesel Engine................................................. 41
8. Excessive Lubricating Oil Consumption ...................................................................... 42
9. Excessive Fuel Consumption ............................................................................................ 43
10. Malfunctioned Lubricating System ................................................................................ 44
11. Malfunctioned Cooling System ........................................................................................ 45
12. Malfunctioned Starter ...................................................................................................... 46
13. Malfunctioned Alternator ................................................................................................ 46
Chapter 5 Preservation of Diesel Engine ................................................................................. 48
Chapter 6 Lifting, Installation and Depreservation of Diesel Engine.................................... 50

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3
 Preface
Thanks for your choosing “FMT” diesel engine. The Instruction is
prepared for your understanding its operation and maintenance. For the
sake of safety of person and property, please read it carefully before
using.
The mark “ ” in the Instruction shows that personal injury or
other damages may be caused, please obey the instruction strictly.
The instruction marked with “Notice” in the Instruction shows that
personal injury or slight damages on gadget may be caused, please
follow the operation procedure carefully.

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 Important considerations in use
1. In order to guarantee the safety of person and property, please read the Instruction carefully
before using and operate and maintain diesel engine according to the regulations in the
Instruction strictly.
2. Diesel engine’s startup, running-in, operation, shutdown shall be carried out properly
according to the Instruction
3. Operators shall pay attention to the safety warning marks. Do not close to the area with
safety warning during the operation of diesel engine.
4. In order to prolong the life of starter and battery, the continuous starting time of starter shall
not exceed 15 seconds. If restart is required, turn the ignition key to “OFF” and restart after
1 or 2 minutes.
5. Do not remove air filter during operation. The air filter shall be cleaned as required. The
upper and lower gasket rings for filter element shall be fit up for sealing in re-installation.
When the filter is connected with hose, clamp shall be used to prevent the hose from
loosing due to shake of diesel engine. Strictly prohibit not-filtered dusty air from entering
into cylinder.
6. Oil supply system is the important system of diesel engine. The parts and components
thereof shall not be removed or adjusted without permission, which shall be carried out in
the technical service station authorized by FMT Group.
7. When the running-in period comes to an end, please carry out maintenance in the service
station as required.

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 SAFETY WARNING
1 、 When diesel engine is running, don’t touch fan, pulley, belts and other region
where rotating parts are exposed, to avoid damaging rotating parts.
2 、 Operators should not open radiator cap at once when diesel engine in hot
condition. To avoid being scalded by the high temperature vapor.
3 、 When the diesel engine is in hot condition, don’t touch the high temperature parts like
exhaust pipe, to avoid being scalded.
4、It is forbidden to fill cold water into the engine when diesel engine temperature is too high
and short of water.
5 、 Diesel engine would exhaust harmful gases like carbon dioxide and carbon black in
operating condition, be sure it is effective ventilation when used.
6、Must consider the influence of waste gas, smoke, noise to the surroundings, personnel and
goods.

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 SAFETY SIGNS
Pay attention to these marks when running the engines:
Table 1
Mark Warning specifications Pasting place
1. Keep away from rotating parts when engine Paste in
is running in order to avoid being hurt; advanced cover
2. When engine is running or stopping for 30 shell in the front
minutes, keep away from exhaust pipe, of diesel
turbocharger, silencer and do not open engine.
cooling water tank to avoid being scalded.

Watch out for cutting your finger by Revolute Paste in fan

Joint blades.

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 Chapter 1 Main Technical Specifications and Parameters of Diesel Engine
1.Main Technical Specifications
The parameters listed in this book are values in standard environment (atmospheric pressure: 100Kpa, inlet
temperature: 298K, dry air pressure: 99Kpa, partial pressure of water vapor: 1Kpa, relative humidity: 30%).In
addition, the specific value of the product is subject to change base on engines’ various upgrade. Please always
follow the actual engine parameters.
Table 2
Table 2 (continued)
Model No. RA4LT
four-cylinder in-line,direct injection,
Model
water cooling, four-stroke,turbocharged
bore×stroke (mm) 102×115
Total Piston Displacement L 3.8
Rated Power/Speed kW/r/min 60/1500
Adjustable rate % 5
Cylinders Working Sequence 1-3-4-2
Min. Fuel Consumption Rate (g/Kw.h) ≤ 225
Crankshaft Rotating Direction Clockwise（from the front view of diesel engine）

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 Lubricating Way Pressure & splash combined
Cooling Way Forced circulating water cooled
Oil capacity (L) 6.8
Net Weight (kg) 330±20

2. Main Technical Data

1).Valve Clearance
Table 3
Cold state 0.30～0.35mm
Intake Valve
Hot state 0.25～0.30mm
Cold state 0.35～0.40 mm
Exhaust Valve
Hot state 0.30～0.35mm
2). Temperature and Pressure Ranges of Diesel Engine under Normal Situation
Table 4
Max Water Temperature ≤ 95℃
Oil Pressure 196-588kPa
Oil Pressure at Min. No-load
≥ 78kPa
Speed

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3). Tightening Torque of Main Bolts
Table 5
Type RA4LT Series N·m(kgf·m)
160~200
Bolts for Cylinder Head
（16~20）
200~240
Bolts for Main Bearing
（20~24）
100~140
Bolts for Connecting Rod
（10~14）
100~140
Bolts for Flywheel
（10~14）
70~110
Bolts for Flywheel Housing
（7~11）
200~230
Bolts for Crankshaft Pulley
（20~23）

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 4). Tightening Torque of General Bolts and Nuts (For Reference)
Table 6
Nominal Diameter of Bolt mm
Strength Class of Bolt 6 8 10 12 14 16 18 20
Tightening Torque N.m
5.6 5~7 12~15 25~31 44~54 69~88 108~137 147~186 206~265
6.6 6~8 14~18 29~39 49~64 83~98 127~157 176~216 245~314
8.8 9~12 22~29 44~58 76~102 121~162 189~252 260~347 369~492
10.9 13~14 29~35 64~76 108~127 176~206 274~323 372~441 529~637
12.9 15~20 37~50 74~88 128~171 204~273 319~425 489~565 622~830

5). Recommended Value of Tightening Torque of Screw Plug

Table 7
Thread Size NPT1/8 NPT1/4 NPT3/8 NPT1/2 NPT3/4 NPT1

Tightening Torque N.m 8～14 24～34 47～68 68～95 88～102

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 Chapter 2 Operation of Diesel Engine
1. Fuel
In order to guarantee the reliability of supply system, we recommend to use the the clean
diesel produced by regular fuel company. In the country or region where there is a special request
about environment protection, please use the request fuel which suitable for environment
regulations. The fuel holder should be clean and exclusively used. The fuel must be precipitated
for at least 48 hours, and please fill the upper part of the fuel into the fuel tank.
The selected diesel brand is related to ambient temperature. When the temperature is low,
the paraffin wax will be separated from diesel fuel. Then diesel fuel viscosity will decrease.
Engine will be startup difficult with black smoke. On the other hand, if the diesel fuel for winter be
used in summer, its viscosity will decrease due to high temperature. Fuel pipeline lubrication will
be poor. Fuel injection pump and injector will be broken. Engine will be lack of power with white
smoke due to delay of startup.
Please select diesel fuel base on below conditions:
Table 8
Ambient Temp. T≥5℃ -10℃≤T＜5℃ -20≤T＜-10 T＞-20℃

No. 0 No. -10 light No. -20 light No. -35 light
Diesel Brand to be used
diesel diesel diesel diesel

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 Notice:
(1) Before fill the fuel, please check the fuel tank and pre-filter’s bottom level, make
sure to remove the excessive water in time since excessive water will cause engine
can’t start.
(2) Do not running the engine until fuel tank run out of fuel. Otherwise, air will be into
the fuel pipeline, engine will stop due to fuel supply is not stable.

Please fill diesel in the Compliant service station. The failure of engine caused
by low-grade diesel will make you lose the guarantee of quality assurance.

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2. Lubricating Oil
Diesel engine shall use the lubricating oil at CF level or above
The viscosity grade of selected oil is related to ambient temperature. The lubricant viscosity
will change when ambient temperature change. It will lead engine difficult to achieve start speed
or lubrication not good working. Engine difficult to startup or be damage. Therefore, the engine
which work at different seasons,regions and ambient temperature, different grade of lubricant
should be used.
Table 9
Ambient
Lubricating Oil Brand Corresponding SAE Number
Temp.
＞-10℃ 15W/40 CF-4 level 15W/40 CF-4 level
-20℃～-5℃ 10W/30 CF-4 level 10W/30 CF-4 level
＞-20℃ 5W/30 CF-4 level 5W/30 CF-4 level

1).It is not allowed to use mixture oil from different brands or different
manufacturers;

2). The oil to be filled is not allowed to contain foreign article or water.

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3. Coolant
Diesel engine shall use antifreeze coolant fluid (which may use alcohol and glycerin mixture
or glycol). It has the necessary performance of antifreeze, anticorrosion, antiscale and increasing
boiling point.
Use antifreeze fluid or clean soft water which with less mineral composition and little scale
deposit. The cooling system will not be clogged easily and affect heat dissipation.
 Notice:
1).Constantly use coolant fluid and pay attention to the continuity of the usage. Please
notice that coolant fluid has not only the function of antifreeze but also the roles of anticorrosion,
antiboiling and antiscale.
2). Select coolant fluid with different freezing point based on the air temperature of the
region where the engine to be used. The freezing point shall be at least 10℃ lower than the min.
temperature of this region so as to avoid malfunctioning.
3). Purchase qualified product and do not buy inferior one so as to avoid damages on engine
and cause unnecessary loss.
4). Different brands of coolant fluid are not allowed to be used together so as to prevent
chemical reaction and destroy the comprehensive performance of anticorrosion.
5). Do not add hard water, such as well water, tap water; once the coolant fluid is found to
have any suspended or deposited matter, or has been stunk, it is demonstrated that it has been
reacted chemically and deteriorated and malfunctioned; at this time, the cooling system should be
cleaned in time and the coolant fluid should be replaced completely.
6). Glycol coolant fluid is poisonous, which shall be prevented from being contacted or
inhaled; in case of skin contact, wash with water immediately and completely; furthermore,

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anticorrosive additive of nitrite in this coolant fluid has carcinogenicity so that the waste is not
allowed to poured randomly to avoid environment pollution.

4. Diesel Engine startup steps

Preparation and Inspection before First
Startup:
1).Fill lubricating oil into oil pan till reaching Upper mark
upper mark on dipstick.
2). Add coolant fluid till reaching water tank filler,
and then cover the filler cap. Lower mark
3).Fill clean diesel into the tank, check the
pipeline and exhaust the inside air.
4).Check the connections between battery and
electrical system is correct and firm.
5).Check the pipelines and joint locaion whether
there is oil and water leakage points.
6).Check the belt for its tensioning force and if
any other abnormal. Attention:when measuring the oil level, the
engine must be placed horizontally with the engine
in a cold state.

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Preparation and Inspection before Daily Startup.
Place the engine on flat ground and keep engine in safety conditions
1).Pull out dipstick.
2).Wipe the dipstick with clean cloth, then insert it again down to the bottom.
3).Pull out the dipstick again and check the oil level.
4).Check the oil level and confirm whether it is between upper and lower mark on the dipstick;
5).If it is below the lower mark, add required grade oil.
 Notice：
1).The oil level check shall be carried out after engine shutdown for 15～20min
2). Check radiator coolant and add properly if required.
3). Check oil tank and add properly if required.
4). Check the pipeline/hose/joints whether there is leakage points.
5). The engine should be under the no load condition.

Starting procedure of cold engine (ambient temp is higher than 0℃):

1. Switch on with the key and check each electrical instrument is in normal indication.
2. Turn the ignition key to “ON”.(If equipped with a pre-heater, then turn the ignition key to “ON” till
the preheating indicator light is off.）.
3.After the heating indicator disappear, turn on the engine start button to start the engine;

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Warming up and inspection after startup:
1). Diesel engine shall be running at idling speed for 3～5min after startup for warming up, but
cold engine shall be prevented from running at idling speed for long time.
2). The followings shall be checked during warming up:
(1). Oil pressure (the alarm light is off after warming up)
(2). Oil pressure (the alarm light is off after warming up)
(3). Pay attention to abnormal sound of engine; if any abnormal sound is heard, check the
engine immediately and eliminate the fault in time.
(4). he color of the exhaust.
Table 10
The color of the exhaust Combustion state notes
No color or little blue Normal Good combustion state
Black smoke Abnormal Not good combustion state
White smoke Abnormal Not good combustion state

5. Running-in of Diesel Engine

The diesel engine must be run in before use, through which the surfaces of moving parts of
the engine can reach good matching so as to avoid abnormal abrasion and damage. Its service
life, reliability and economics shall depend on the quality of initial running-in to the great extent,
please run it in strictly according to the specification.
The running in of diesel engine can be carried out together with end application. The
running-in time is 40~60hours. When it is running-in, engine load should not be higher than the
70% of the rated load and engine speed should not be higher than the 80% of rated speed. It is

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not allowed that engine running at idle speed for long time. After running-in finished, the engine
should be taken mandatory maintenance (follow details in Chapter III, 7th). It is been
recommended that the mandatory wearing-in maintenance in professional service stations.
(1). Diesel engine is not allowed to work when coolant is “boiling”, it’s not allowed to work for
long time if water temperature is too low or too high.
(2). Diesel engine is not allowed to run at idle speed for more than 10min.

6. Precautions during Operation of Diesel Engine

During diesel engine running, user must pay attention for below points:
1). Oil Pressure
During diesel engine running, if the alarm light of oil pressure is twinkled repeatedly, it shows
the oil pressure is relatively low and the engine should be shut down for inspection.
2). Coolant Temperature
(1). The indication of water thermometer exceeds 100℃ or the indicator light is on, it shows
the engine is overheated. Keep engine running at speed lower then 1000rpm for 5 min,
then shutdown the engine for inspection.
(2). If water temperature can’t reach to normal value, it shows that the engine is over-cooled.
It will cause parts abrasion ahead of schedule. Please add cover to the radiator.
3). Engine Noise
If the engine and related parts has any abnormal sound, it shows that engine runs abnormally
or the moving part has abnormal friction; thus the engine should be shut down for inspection.
4). Exhaust Smoke Color
If big volume of white or black smoke rise from the engine, it shows the inside combustion is

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abnormal and the engine should be shut down for inspection.

 Notice：
(1). Do not stop overheated engine instantly.
(2). Diesel engine is not allowed to work under overload for long time

7. Shutdown and Inspection of Diesel Engine

1).Before stopping the diesel engine, ensure that the engine is at no load status.
2).Diesel engine shall be operated at low speed for 3-5 minutes before shutdown in order to
keep engine cooled down completely, during this period, user can check the engine such as
abnormal noise, oil pressure, fuel/oil/coolant leakage.
3).Turn the key switch to “OFF” and disconnect the battery (if equipped).
When the ambient temperature is below 0℃, if the coolant is not antifreeze, drain the water
in radiator completely, to avoid engine cylinder, water pump and radiator damage. If antifreeze
coolant at proper temperature is used, the drainage is not required.

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 Chapter 3 Regular Inspection and Technical Maintenance
Because the working environment of most non-road machinery is bad, the status of
deterioration is determined by the using time and the using state. If user ignore the degradation
and performance degradation, engine structure and performance will be reduced correspondingly.
It will lead an irrecoverable damage to the engine. If user want the engine work in a good
condition at a long time, please follow the below technical requirements strictly.

1. Fuel Supply System

The fuel pump and nozzle for injection is precise parts so that the water or impurities in the
fuel will cause the piston or injector to be damaged and make the filter dirty or blocked. Thus
unclean fuel will reduce the service life of the pump and the injector. Please carry out regular
inspection according to the following.
1). Pre-filter(oil/water seperator) &Fuel Tank Drainage
Drain the water in oil-water separator and fuel tank
regularly (every time when filling fuel). If the indicator light (if
provided) on oil-water separator is on during working, shut
down engine properly and drain the water.
(1). Stop engine at safe place.
(2). Place a vessel under drain plug of oil-water
separator or fuel tank.
(3). Screw of the drain plug 4 or 5 turns to drain the
water inside. In order to avoid the plug from
dropping, do not screw it off extremely.

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 (4). After drainage, screw up the plug and check without leakage.
(5). Carry out air for fuel system (refer to Exhaust in Fuel System).
(6). When start the engine with oil-water separator, check whether the drain plug is leaked
and whether the indicator light of the separator is off.

 Notice:
If frequent drainage is required, please drain the water in fuel tank at the technical
service station.
If the engine is not equipped with oil-water separator, consult the manufacturer to
add or add oil-water separator by yourself;
2). Replacement of Diesel Filter
I Replacement Cycle
The replacement cycle for the diesel filter: Every 12 months or cumulative work at 320 hours
when engine with guaranteed fuel. If the fuel with much impurities and water, reduce the
replacement cycle properly.
II Replacement Procedure
(1). Screw off the diesel filter with proper tool.
(2). Wipe the joint face of the filter seat clean, fill the new filers with clean diesel fuel.
(3). Screw on filter seat till there is slight resistance, and then screw up more 2/3 circle till
tightened.
(4). Exhaust the gas in fuel pipes（Exhaust in Fuel System）
(5). Start up engine and check for the leakage.
3).Exhaust air in fuel system

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 Air entering into the fuel system will lead to difficult startup of engine and other failures. During
use or maintenance, If the fuel tank is emptied during maintenance, please exhaust the air in the
fuel system after refilling of fuel.
Procedure of Exhaust in Fuel System
(1). Loosen the bleed screw ①
(2). Press the fuel transfer pump ② up
and down with force till no bubbles
could be seen in the fuel exhausted
from the bleed screw ①.
(3). Tighten the bleed screw ①
(4). Press the transfer pump ② up and
down with force till the resistance is
increase suddenly.
(5). If the engine is not operated stably
after startup, increase to the highest
throttle two or three times.
 Notice：
1). The piston type fuel transfer pump, mounted on the side of injection pump, is driven by the
eccentric wheel on the camshaft of the injection pump. When diesel engine stop running, if fuel
pumping or air exhausting is required, pump fuel with manual pump and then tighten the nut on
manual lever. The joint of fuel suction pipe is set at the bottom of the transfer pump; and inside
the joint bolt, there is a small sieve which is mounted at the front portion of the fuel pipeline.It
filters most of the impurities. Hence do not throw this small sieve away in usual inspection;

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furthermore, this sieve shall be cleaned frequently, otherwise the fuel pipeline will be blocked
resulting in abnormal operation of diesel engine.
2).The engine installed with a single- or double-grade spin-on filter, it with bleed screw on the top.
The filter element shall be cleaned or replaced regularly. To avoid mess up inside of the filter body
when doing maintenance; especially, the seal at every portion shall be noticed when in
assembling. In order to guarantee diesel engine to get clean fuel,it is suggested that users or
supporting manufacturers should install a primary oil-water separator or a fuel filter with less
resistance before the filter.
3).Injection pump is the heart of diesel engine, so the engine performance depends on the pump.
The pump has been adjusted properly before delivery and sealed with lead already. Do not
unseal. Maintenance and adjustment is required to be carried out on special test stand by
professional people.

2. Lubricating System
If no maintaining to the engine lubrication system, it will greatly affect the service life of the
engine.
Please replace lubricating oil and the filter in accordance with the specified maintenance cycle.
Replace lubricating oil and the filter
following below steps to change lubricating oil and oil filter.
The warning light for oil pressure is on during operation of the engine indicating filter blocked.
Replace it immediately regardless of the specified maintenance cycle.
1).Replacement Cycle
Lubricating oil: 6 months or the accumulative work 100 hours

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 Oil filter: 6 months or the accumulative work 100 hours
2).Replace lubricating oil
(1). The engine in normal temperature.
(2). Stop engine on horizontal plane with parking brake
(3). Stop the engine. Cut off the power and wait at least 10 to 15 minutes
(4). Use a large oil pan (about 8 liters) to catch the oil outlet of the engine oil sump
(5). Open the refueling port cover (on the top cylinder cover of the engine).
(6). Unscrew the oil drain plug on the oil sump and drain the oil thoroughly.If you need to
change the oil filter, you can remove the oil filter and replace it with the above steps. See
"change the oil filter" section.
(7). wash the drain screw plug and install it together with the gasket, then tighten it with a
wrench(tightening torque of drain screw plug: 54-59n •m(5.5-6.0kg•m), be careful not to
overexert).
(8). Add the required oil and cover the filler cap.
Oil filling capacity：
Oil gauge’s upper grade(when change oil filter element)
Oil gauge’s middle grade(when not change oil filter element)
Note: use the recommended engine oil (see chapter 2 "lubricating oil" for details)
(9). Start the engine and check whether there is oil leakage around the drain plug and oil filter.
(10). Run the engine for 3-5 minutes and then shut down.After 10 minutes, check the oil level
to meet the requirements.
(11). Proper disposal of waste oil
 Notice：

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a).The used oil must not be poured into the ground, ditches or rivers.Disposal should be carried
out at properly equipped dumps. We suggest that the engine oil be replaced by the service centre.
Be sure to follow the rules when dealing with waste oil. Make sure local regulations are in place
first (regulations on environmental pollution vary from country to country).
b).long-term and frequent contact with oil can cause serious skin diseases, including dermatitis
and cancer.
c).Avoid contact with skin as much as possible and wash thoroughly after contact.
d).Keep out of reach of children.
e).It is illegal to pollute sewers, waterways and land. Approved waste collection equipment is to
be used, including sites in the city where waste oil and filters can be properly treated and
garages.If in doubt, seek advice from local authorities.
Be careful not to burn yourself when the engine oil is hot.
3). Change engine oil filter
Used oil filter should be handled with appropriate device in the garbage dump. We advice that
changing oil filter in the service station.
(1). Engine should be placed on a flat road in the safe condition
(2). Using the filter wrench to loosen the filter. (according to the type of engine, you may
need a special cap-type wrench. If you have some question, you can inquire FMT Group
maintenance station.) then you can use the filter wrench unscrew the filter.
Attention: be ware of hand burns by hot oil.
(3). Use a cloth to wipe the mounting surface of the filter cleanly.
(4). Hand tight until the packing contacts the sealing face and tighten filter 2/3 turn.
(5). Start engine, check for the surrounding of filter whether oil leaks, then adjust it if it is
necessary.

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 (6). Turn off the engine, check for the oil height level, make it meet the requirement.

3. Cooling system
1). Check for drive belt
(1).Check belt if any cracks, wear or oil/water adsorption. Replace it if necessary. The belt is
not allowed to contact the bottom of the groove.
(2).Pressing the middle of the two pulley belt to check for the offset of the belt. When the fan belt
exceeds the prescribed value of the offset, replace the fan belt, and adjust the fan belt tension
as below table
Table 11 Belt Deviation： Unit：mm
Driving belt Deviation of used belt Deviation of new belt
Limit Deviation after adjustment
Fan belt 12-13 8-9 7-8
Pressure applied 98N（10kg）
2). Engine cooling fluid
Check coolant level height
After the engine is cooled, please check the coolant level in the radiator. If the coolant position
is low, add coolant to the radiator cover.
Notice:
If the cooling system requires frequent supplement of coolant fluid, please make a
check in maintenance service center.

Replacement of Coolant Fluid in Engine

27
 (1). Open both drain plug and radiator cap.
(2). Open the drain valve on the engine block.
(3). Drain the coolant and tighten the drain valve on the cylinder block.
(4). Add coolant to the radiator
(5). Keep the engine running for about a minute to clear the air.
(6). Stop the machine and wait for it to cool down, check the coolant and, in case of shortage,
supplement the coolant to the radiator.

4. Air Intake System

The working condition of the intake system greatly affects the service life and performance of
the engine.
Dirty air filter elements can cause insufficient intake of air into the engine, resulting in engine
power loss and ultimately engine failure, shortening the service life of the engine.
For the air filter of diesel engine, please follow the "regular technical maintenance" to maintain
the air filter.

5. Battery
1) The surface of battery shall be kept clean and dry. Any corrosive liquid shall be washed
away with alkaline water.
2) The joint of battery shall be ensured clean and firm.
3) If engine not work for more than 30days, please cut off the battery to be negative “-” (or
cut off the power switch) to avoid leakage.

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 ....................................................................................................................................................................
NOTICE：
Do not let the battery near to fireworks or electric spark since the hydrogen released during
the reaction of battery would explode. Do not let battery fluid contact skin, eyes, textile, or
paintwork. After touch the battery by hand, do not rub eyes with this hand and clean it completely.
Once the acid fluid contacts eyes, skin or clothes, wash with clean water for at least 15 minutes
immediately and go to see a doctor in time.

6. Usage and Technical Maintenance in Winter

When the temperature is below 5℃ in winter, the diesel fuel may be frozen due to low
temperature of diesel engine body and increased viscosity of lubricating oil, which results in
difficult startup of the engine. Hence it is better be carried out comprehensive technical
maintenance before entering into winter and the followings shall be noticed in usage:
Fuel
1) Choice of the fuel
(1). Select proper fuel as appropriate (Refer to the section of “Fuel” in Chapter 2 for details).
(2). Please go to service station to make sure you use the right fuel.
2) The supply of fuel and eliminate water
(1). Pay attention to the supply of fuel.
(2). Pay attention to loose the drain plug of the fuel tank to exhaust the deposited water content
before startup.
 Notice：
(1). If the liquid surface of Fuel tank is low, it will increase the cubage of air. So that it will

29
 increase the amount of air in the fuel tank.
(2). Damp amassment may cause the fuel tank rust, and it may lead engine start difficult or
engine malfunction.
Coolant Fluid
When the temperature decreases below 0℃, the water in the cooling system shall be drained
after shutdown. In order to avoid draining and filling water repeatedly, we recommend to use
antifreeze coolant fluid (refer to the section of “Coolant Fluid” in Chapter 2 for details).
 Notice：
(1). Carbinol base antifreeze is not recommended because it will affect the non-metal material
in the cooling system and decrease the boiling point of the coolant fluid.
(2). High silicate antifreeze is not recommended because it will lead to serious deposits.
(3). Please use antifreeze as the proper proportion recommended by related manufacturer.
Lubricating Oil
When the temperature decreases, the viscosity of the oil increases resulting in difficult startup
of the engine, and the viscosity affects the stability of the engine; hence it is very important to
select lubricating oil with appropriate viscosity based on the temperature. (Refer to the section of
“Lubricating Oil” in Chapter 2 for details)
Battery
The battery capacity decreases pending on the temperature and its discharge rate reduces
rapidly. Therefore it is proposed to check the battery in chartered service station before winter and
replace it if necessary.
1) Pay attention to charge the battery fully in cold winter.
(1). Cold startup requires a large current consumption, thus comparing to normal temperature,

30
 more time is needed for recharge after startup.
(2). The electrolyte of undercharged battery has low specific density so that it is easy to be iced
up and damaged
2) Pay attention to cold-proof for battery in winter.
3) Refill distilled water to battery shortly after starting the engine. If it is done after the engine
begins to work, the supplemented water can not mix with the original electrolyte and the
unmixed water may stay in the upper layer and cause ice.
Engine Startup in Winter
The followings shall be paid attention to in starting the engine below 0℃：
(1). Preheated before starting the engine.
(2). If the first start is not succeed, please wait 30 seconds to restore power to the battery
and then re-warm start.
(3). Please make sure each starting time must not exceed 15 second to protect the starter.
(4). When starting, if the starter pinion and flywheel collidere peatedly, it indicates that the
battery is low and the battery should be charged.
(5). When the temperature is low, turn on the pre-heater device(in installed), increase the
diesel fuel temperature to make sure fuel supply is properly. When starting at a very low
temperature, set the throttle to the fuel cut-off position and let the engine running at idle speed
for a while, so that all moving parts of the engine loosen a properly, it will reduce the adhesion
of cold lubricating oil, and then warm up and start the engine.
 In the winter, you should pay particular attention to:
When the temperature is below 0℃,the diesel will separate out wax ,which make oil becomes
thick and if summer diesel is used in winter , failure is highly likely. As a result, engine must be

31
used for special maintenance.。
(1). Fuel and oil for winter must be used and pay attention to the water content in the fuel to
avoid freezing
(2). Cooling system must fill antifreeze that be compatible with temperature
(3). In the cold season and region，vehicles should not stop in the open as much as possible.
(4). During cold starting, please start the pre-heater device, and start the engine when
pre-heater light is off.
(5). When the temperature is low, turn on the pre-heater device(in installed), increase the
diesel fuel temperature to make sure fuel supply is good.

7.Regular Technical Maintenance

Regular technical maintenance is the important things for using diesel engine reasonably. If you
want to keep your diesel engine in good technical status and long-term reliably, you must always
follow the standard seriously and make technical maintenance strictly.
At the time of maintenance, you should pay attention to the parts cleaning specially. Therefore,
Reinstalling the parts, you should ensure the parts be cleaned and be installed correctly, and then
check whether the engine running on normally or not.
 Technical maintenance included：
I Daily maintenance(work 8 ~ 10 hours）;
II First mandatory runing-in maintenance（work 50 hours cumulatively or 3 months）;
III Grade I Technical maintenance（work 100 hours cumulatively or 6 months）；
Ⅳ Grade II Technical maintenance（work 300 hours cumulatively or 12 months）；

32
 Daily maintenance：
1).Check it that whether the sump oil level between two scribed line of oil scale. If not ,you
should add oil. If you find oil level suddenly raise or lower,check out the reason immediately.
2).Check the coolant ,if not sufficient,you should add.
3).Check the height of battery electrolyte liquid surface, liquid surface should maintain higher
than plates 10 ~ 15 millimeter ,insufficient should add distilled water.
4.Check the fuel quantity within fuel tank, if it’s shortage ,you should add fuel.
5).Check whether each part of the diesel engine is loose and reliable connect or not, If it is
loose, tighten it.
6).Eliminate the abnormal phenomenon that diesel engine occur during operation fault and
fuel/oil/coolant leakage.
7).Clean the dirt and debris on the radiator surface。
 First running-in maintenance：
1) Check coolant’s level and all joints of the water pipes for coolant fluid shall have no leakage.
2) Check battery, check color marked holes are in green color, confirm the connection of
positive and negative pole is reliable and installed correctly. check whether there is the battery
electrolyte leakage around.
3) Check the tightness and abnormal abrasion of the belt by sight.
4) Check all parts of the diesel engine to be connected reliably and firmly.
5) Clean away the dirt on the radiating surface of the surface of radiator.
6) Use compressed air clean air filter element.
7) Completely release the engine oil.
8) Replace engine oil filter element.

33
 9) Fill in oil, check the oil level should be in between the fluctuation scale ruler and partial limit
position.
10) Check whether there is water in bottom of pre-filter, remove the water if there are
excessive water.
11) Check engein status at idling speed, slowly throttle up the engine and listen whether
there is abnormal sound of engine
12) Slowly throttle up the engine, after temperatures rising, you can use your ears to hear
whether the fan is normal operation
 Grade I Technical maintenance：
Except the lucubration oil and oil filter no need change, follow the same process as First
running-in maintenance
 Grade II Technical maintenance：
After " First running-in maintenance " , we still must do the followings:
1) Replace the fuel filter.
2) Replace the air filter element.

34
Chapter 4 Common Fault Analysis and Elimination Approaches for
Diesel Engine
1. Difficult Startup of Diesel Engine
Fault Characteristics & Causes Elimination Approaches
1). Fuel system a) Select proper fuel brand.
a) Fuel brand is selected improperly. b) Add fuel to the tank or switch it on.
b) Fuel tank is out of oil or it is switched off. c) Exhaust the air in fuel system, then tighten
c) Air in fuel pipeline or fuel pump the pipe joints.
d) Water is mixed in fuel d) Replace the fuel.
e) fuel pipeline or fuel filter is blocked. e).Remove the fuel pipe and filter for cleaning
f) No fuel supply from fuel pump or advance or replace the filter element.
angle is not improper. f) Check the lift pump or fuel pump, adjust the
advance angle properly.
g) Injector no fuel spray, less fuel spay, low g) Clean and polish the matching parts of the
spray pressure, bad atomization, injector injector, adjust the injection pressure; or
pressure adjusting spring broken, injection replace the injector assembly.
hole blocked
h) Fuel pump injection valve leakage, spring h) Replace the injection pump, spring or
broken, plunger coupling broken plunger.
2). Cylinder pressure is insufficient.
a) Valve clearance is too small. a) Adjust the valve clearance.
b) Air leaks from valve. b) In case of reduced elasticity of the valve

35
c) Air leaks from junction of cylinder head spring, replace the spring; in case of bad
and gasket. sealing performance of the taper surface,
d).Piston ring is worn, coked or the openings polish the valve.
are overlapped. c) Replace the head gasket.
e).Abrasions of cylinder liner and piston d) Remove the coking; replace the piston ring;
exceed the specified limits. adjust the opening position of the piston ring.
e) Replace the cylinder liner and the piston.
3).Fuel has large viscosity and is difficult to
3).Heat the cooling water and use proper
be atomized due to too low temperature,
diesel fuel.
even block fuel pipeline.
4).Check electric appliance system
a).Battery power is low or the a).Charge or provide with battery conforming
configuration is too small. to the requirement;
b) Connections of electric appliance b) Tighten the connections of the electric
system have poor contact. appliance system;
c) Electromagnetic switch of starter c) Repair the electromagnetic switch of the
malfunctioned. starter or replace the starter;
d) Gear of starter can not be engaged to d) Find out the reasons and solve;
ring gear of flywheel. e).Repair or replace the brush, clear up the
e).Electric brush of starter and commutator surface with fine emery paper,
commutator has poor contact. and blow off dust.
f) Preheating device malfunctioned or f).Replace the preheating device or extend
preheating time is short. the preheating time.

36
2. Unstable Minimum No-load Steady Speed (Idle Speed)
Fault Characteristics & Causes Elimination Approaches
1).The minimum no-load steady speed (idle 1).Go to FMT Group technical service station to
speed) is lower than 650rpm. check fuel system.
2). High-speed and idle-speed throttle in 2).Adjust the positions of the accelerator
wrong positions. handles.
3).The lever is bent or has loose connection. 3).Tighten or replace the handle.
4).Air is entrained in fuel pipeline. 4).Exhaust the air.
5).Nut connecting between injection pump
5).Tighten the connecting nut.
and diesel engine is loose.
6).Valve clearance is too large. 6).Adjust the valve clearance.
7).Cylinder pressure is insufficient. 7)
a) Valve clearance is too small. a) Adjust the valve clearance to specified value;
b) Air leaks from valve. b) In case of reduced elasticity of the valve
c) Air leaks from connection of cylinder head spring, replace the valve spring; in case of bad
and gasket. sealing performance of the taper surface, polish
d).Piston ring is worn, coked or the openings the valve;
are overlapped. c) Replace the head gasket;
e).Abrasions of cylinder liner and piston d) Replace the piston ring and adjust the
exceed the specified limits. opening position;
e) Replace the cylinder liner and the piston.
8).Gear mark is wrong. 9). Adjust gear timing marks.
9).Internal sieve of bolt is clogged. 9).Clean the sieve.

37
10).Fuel pump does not work properly. 10). Replace the pump.
3. Unstable Speed of Diesel Engine
Fault Characteristics & Causes Elimination Approaches
1). Fuel pipe a) Exhaust the air in the fuel system and tighten
a) Air exists in fuel supply system. the connections of the fuel pipe;
b) Excessive water in fuel. b) Replace the fuel;
c) Fuel pipe leaks. c) Tighten the connections of the fuel pipe or
replace the pipe.
2). Speed governor works improperly. 2). Adjust and calibrate the speed governor.
3). Cylinder head gasket performs bad 3).Check the bolts and the gasket of the cylinder
sealing. head. Tighten the bolts or replace the gasket.
4). Cylinders supply fuel differently.
a) Adjust the fuel supply from the cylinders to
a) Injection pump has different fuel supplies
injection pump;
from each cylinders;
b) Check the situation of injection, clean or
b) Injector performs badly or the matching
replace the matching parts;
parts are seized.
c) Replace the spring.
c) Piston spring for injection pump is broken.
4. Diesel Engine Power shortage
Fault Characteristics & Causes Elimination Approaches
1).Element of air filter is clogged. 1).Clean the element or replace it if necessary.
2).Clean up the stain as well as impurities and
2).Inter-cooler is too dirty.
dust inside the cooler.
3).Exhaust manifold or main pipe is clogged. 3). Remove the foreign matters in the pipe.

38
 4).Exhaust the air and tighten the connections of
4). Air exists in fuel pipeline.
the pipe.
5). Fuel tank fuel reserve is insufficient and 5). Fill up fuel to the tank; select the fuel in
the fuel used is in poor quality. accordance with the requirement.
6). Injection pump piston or delivery valve
seat malfunctioned; or the connecting nut of 6). Tighten or adjust.
high-pressure fuel pipe is loose.
7).Advance angle of fuel supply is improper. 7).Adjust the angle.
8).Injector has bad atomization. 8).Adjust the injection pressure.
9).Valve clearance is improper. 9).Adjust the clearance.
10).Compression pressure in cylinder is
10).Refer to Item 8 in (2) “unstable idle speed”.
insufficient.
11).Injection timing is improper. 11).Adjust the gear to align the mark.
12).Injection pump works improperly. 12).Adjust or replace the pump.
13).Exhaust the air and tighten the connections
13).Air exists in fuel pipeline.
of the pipe.
5. Exhaust Smoke Abnormal
Fault Characteristics & Causes Elimination Approaches
1). White smoke rises.
a) Water exists in cylinder. a) Check and eliminate the fault.
b) Water is into fuel. b) Replace the fuel.
2). Blue smoke rises.
a) Oil flees; piston ring is on backward, seized a) Adjust or replace piston ring.

39
or worn too much. b) Replace the valve.
b) Clearance between valve stem and valve c) Replace the oil seal.
guide is too large.
c) Oil seal for valve stem is damaged.
3).Black smoke rises. a) Reduce the load.
a) Diesel engine is under overload. b) Adjust the advance angle of fuel supply.
b) Fuel supply is delayed too much. c) Adjust injection pump and speed governor.
c) Fuel supply is excessive. d) Get rid of the dust in the air filter and exhaust
d) Air filter and exhaust pipe is clogged. pipe; or replace element of the filter.
e)Valve clearance is improper; valve is sealed e) Adjust the valve clearance; in case of bad
incompletely. sealing performance of the taper surface, polish
f) Timing for fuel injection is improper. the valve
f) Adjust the gear of the injection pump to align
the mark.
6. Diesel Engine Overheated
Fault Characteristics & Causes Elimination Approaches
1). Cooling water in the tank is insufficient or 1). Fill up or replace the cooling water in the
contaminated. tank.
2). Get rid of the scale, foreign matters in the
2). Cooling system is impeded.
pipes for free flowing.
3). Water pump belt is loose. 3). Adjust the tensity of the belt.
4). Water pump works improperly. 4). Repair or replace the water pump.
5). Temperature thermostat malfunctioned. 5). Repair or replace the temperature saver.

40
6). Lubricating oil is in poor quality. 6). Replace the lubricating oil.
7). Water thermometer malfunctioned. 7). Replace the water thermometer.
8). Diesel engine works under overload. 8). Reduce the load.
7. Abnormal Sound during Operation of Diesel Engine
Fault Characteristics & Causes Elimination Approaches
1). Fuel injection is too early; there is
rhythmic and clear metallic rapping in 1). Adjust the advance angle of fuel supply.
cylinder.
2). Fuel injection is delayed too much; there
2). Adjust the advance angle of fuel supply.
is dull and indistinct sound in cylinder.
3). Clearance between piston and cylinder is
too large so that there is clash in the cylinder
after startup of diesel engine. The sound will 3). Replace the piston or the cylinder liner.
be diminished with warming up of the
engine.
4). Clearance between piston pin and pin
4). Replace the parts to guarantee the
hole is too large. The sound is soft and
specified clearance.
sharp, which will be clearer at idle especially.
5). Clearance between main bearing and
connecting rod bearing is too large so that
5). Replace the parts to guarantee the
clash of machine members can be heard
specified clearance.
when the speed of diesel engine is
decreased suddenly. The sound is heavy

41
and strong when the speed is low.
6). Axial clearance of crankshaft is too large
so that clash of the crankshaft’s moving 6). Replace the crankshaft thrust plate to
forward and backward can be heard in case guarantee the specified clearance.
of idle speed.
7). Valve spring is broken; push rod is bent;
valve clearance is too large; splutter or soft 7). Replace the parts, adjust the valve
and rhythmic knock can be heard at cylinder clearance.
head cover.
8). Top of piston bumps cylinder head or
8). Adjust the valve clearance, valve timing or
valve so that metallic rapping can be heard
replace the head gasket.
near the cylinder head in case of low speed.
9). Gear clearance is too large due to
wearing so that clash can be heard at gear 9). Replace the gear as appropriate.
box when speed is decreased suddenly.
8. Excessive Lubricating Oil Consumption
Fault Characteristics & Causes Elimination Approaches
1). Lubricating oil is too much or splashed
1). Drain some oil.
excessively.
2). Oil leaks at drain bolt, oil filter, cylinder
head, oil pan gasket, cylinder head cover 2). Tighten the bolt, replace the gasket,
gasket, front and back oil seals, oil filter replace the end cap or plug.
gasket, end caps, and plugs.

42
3). Spill port of oil control piston ring is
3). Get rid of the coke at the spill port.
clogged by coke.
4). The oil is in poor quality. 4). Replace the oil.
5). Piston ring is worn or clamped. 5). Replace the piston ring.
6). Clearance between cylinder liner and
6). Replace the cylinder liner or the piston.
piston is too large.
7). Oil seal for valve stem is worn. 7). Replace the oil seal.
9. Excessive Fuel Consumption
Fault Characteristics & Causes Elimination Approaches
1). Air filter is clogged. 1). Clean or replace the filter element.
2). Get rid of impurities and dust on outside
2). Inter-cooler is too dirty.
surface of the inter-cooler.
3). High-speed stop screw is not sealed up. 3). Seal up the high-speed stop screw.
4). Fuel pipeline leaks. 4). Tighten fuel pipe joints, replace the pipe.
5). Exhaust pipe is clogged. 5). Get rid of the dirt in the exhaust pipe.
6). Adjust the min. no-load steady speed to
6). Min. no-load steady speed is too high.
specified value
7). Fuel is in poor quality. 7). Use specified fuel.
8). Advance angle of fuel supply is improper. 8). Adjust the advance angle.
9). Adjust the opening pressure of fuel injector,
9). Fuel out of Injector is in bad status.
check and clean the nozzle or replace it.
10). Valve clearance is improper. 10). Adjust the valve clearance.
11). Injection pump works improperly. 11). Adjust or replace the injection pump.

43
10. Malfunctioned Lubricating System
Fault Characteristics & Causes Elimination Approaches
1). Oil pressure is too low.
a) Oil pan is short of oil. a) Fill oil until it arrive at the marking line on
b) Oil passage is clogged. the dipstick.
c) Oil filter is clogged. b) Clean the oil passage and blow off by
d) Diesel engine is overheated so that the oil compressed air.
temperature is too high and the oil is thinned. c) Clean the oil filter or replace the filter
element.
d) Reduce the load, replace the oil and lower
the oil temperature.
2). Replace with the oil in conformity with the
2). The oil is in poor quality.
requirement.
3). Spill valve of oil filter is sticking or has
3). Repair or replace the oil filter.
excessive oil return.
4). Oil pump screen is clogged. 4). Clean the screen.
5). Oil pump gear is worn or the end clearance
5). Adjust or replace the gear.
is too large.
6). Oil pipe is broken or the joint gets loose. 6). Tighten the joint.
7). Oil pump malfunctioned. 7). Repair or replace the oil pump.
8). Connecting rod bearing and main bearing 8). Replace the connecting rod bearing and
are worn. the main bearing.
9). Oil pressure gauge is damaged. 9). Replace the pressure gauge.

44
11. Malfunctioned Cooling System
Fault Characteristics & Causes Elimination Approaches
1). Water temperature is too high.
a) Cooling water is insufficient. a) Fill up cooling water into the tank.
b) Spring of radiator cap is soft. b) Replace the spring.
c) Belt of water pump is loose or damaged. c) Tighten or replace the belt.
d) Temperature thermostat malfunctioned. d) Replace the temperature thermostat.
e) Water pump works improperly. e) Repair or replace the water pump.
f) Scale deposit in cooling water passage is f) Clean the cooling water passage to get rid
too much. of the scale.
g) Radiator is clogged. g) Clean the pipeline of radiator for clearing.
h) Water leaks from radiator. h) Repair or replace the radiator.
i) Water leaks from water pump. i) Replace the gasket or packing plate.
j) Connecting tube of radiator is loose or j) Tighten or replace the connecting tube.
broken.
2). Water temperature is too low.
a) Temperature thermostat malfunctioned. a) Replace the temperature thermostat.
b) Temperature thermostat is improper. b) Use as specified.
c) Ambient temperature is too low. c) Set shelter from wind for protection.

45
12. Malfunctioned Starter
Fault Characteristics & Causes Elimination Approaches
1). Starter does not work.
a) Connection wire has poor contact. a) Clean and tighten the contact.
b) Battery is undercharged. b) Charge up the battery.
c) Electric brush has poor contact. c) Clean the commutator surface.
d) Starter has open circuit. d) Repair or replace the starter.
2). Weak Start at no load a) Replace the bearing bushing.
a) Bearing bushing is worn. b) Clean the commutator surface.
b) Electric brush has poor contact. c) Clean the oil stain and polish with fine
c) Commutator is dirty or singed. sand cloth.
d) End terminal is desoldered. d) Weld the terminal firmly.
e) Poor contact. e) Clean and tighten the contact.
f) Switch has poor contact. f) Repair the switch.
g) Battery is undercharged or has small capacity. g) Charge up the battery or replace with
the battery having enough capacity.
3).Gear withdrawal difficult; electromagnetic
3).Replace the electromagnetic switch.
switch contact is burned out.
13. Malfunctioned Alternator

Fault Characteristics & Causes Elimination Approaches

Not charged completely; undercharged; unstable
charging current a) Replace in time if damaged.

46
a) Measure diode or IC regulator one by one with b) Replace in time if damaged.
multimeter after opening the back cover of c) Replace in time once any damage is
alternator. found; the width of the carbon brush must
b)Check the body, seat for cracks, core and not be less than 2mm.
alternator main shaft spline matching status, and
internal working surface whether there is serious
wear and scratch;

47
 Chapter 5 Preservation of Diesel Engine
For brand new diesel engine, if long-term storage is required, shall be disposed in
advance in accordance with the following requirements:
1. Drain the lubricating oil off.
2. Open water drain valve to drain the coolant fluid off inside the diesel engine.
3. Drain the diesel off inside the fuel tank and the pipeline.
4. Wipe out the oil and water stains, dust outside the diesel engine; apply anti-rust oil (add butter
into drier oil and mix thoroughly after melting) on the unpainted parts and components. Rubber
products as well as plastic products and parts shall not be applied with the oil.
5. The air filter (or air inlet) and the exit of exhaust pipe shall be packed well with oiled paper to
prevent dust and dirt from invasion.
6. The diesel engine shall be placed in the room with good ventilation, dry and clean conditions
and free of intense magnetic field (temperature: -30 ～ 60℃; humidity: 0 ～ 80%). It is strictly
prohibited to be piled at the place with corrosive chemicals. Pay attention to moisture proof for the
machine (especially for the electrical system).
For used diesel engine, if long-term storage is required, shall be disposed in advance in
accordance with the following requirements:
1. Drain the lubricating oil off when the engine is hot after shutdown; dismantle the oil pan for
cleaning.
2. Open water drain valve to drain the coolant fluid off inside the diesel engine.
3. Drain the diesel off inside the fuel tank and the pipeline.
4. Get rid of the dust on the element of air filter (paper type).
5. Dismantle the air intake pipe and fill 300g filtered HC-8 direr oil into each cylinder through air

48
passage (heat the oil to 110～120℃ till there is no bubble at all). Turn the crankshaft so that the
oil attaches to the surfaces of the valve, cylinder liner, piston and other parts uniformly. Fix the
intake pipe in place.
6. Wipe out the oil and water stains, dust outside the diesel engine; apply anti-rust oil (add butter
into drier oil and mix thoroughly after melting) on the unpainted parts and components. Rubber
products as well as plastic products and parts shall not be applied with the oil.
7. The air filter (or air inlet) and the orifice of exhaust pipe shall be packed well with oiled paper to
prevent dust and dirt from invasion.
8. The diesel engine shall be placed in the room with good ventilation, dry and clean conditions
and free of intense magnetic field. It is strictly prohibited to be piled at the place with corrosive
chemicals. Pay attention to moisture proof for the machine (especially for the electrical system).
 Notice:
The aforesaid method of preservation can be in effect for 30 months; do the same again if
expired.

49
 Chapter 6 Lifting, Installation and Depreservation of Diesel Engine
When carrying the diesel engine with packing case, use steel wire to cover the four bottom
corners of the engine box. When carrying diesel engine without package, move engine by lifting
lug assembly.
The installation for diesel engine must be laid properly when it is used for stationary work. It
shall be fixed in the workshop with the characteristics of rain-proof, moisture-proof, good
ventilation, little dust and spaciousness.
Diesel engine with oil seal had to be removed anti-rust oil before using. Continuously inject hot
water into the cooling system to preheat the engine. Open the oil drain plug to drain the
lubricating oil inside. Turn the crankshaft or drive it with starting dynamo (each starting time shall
not be more than 15s), which shall be intermittently done several times. Finally start diesel engine
according to the starting procedure; check and replace the rubber parts which require to be
replaced.