HAIMA HM484Q User manual

HM484QEngine
Service Manual

Cylinderblockandcrankconnectingrodmechanisms
Preface
Themaintenanceandrepairof engine isahighlyprofessionalwork. If not
receivedthemaintenance-related technicaltraining, it islikely tocause
propertydamage orpersonalinjuryduringmaintenanceoperations.Therefore,
itisverynecessarytoreceivetheappropriatetrainingorlearnbyyourselfthe
relatedtechnicalinformationpriortothe enginemaintenanceandrepairwork
Thismanualmainlydescribesthe maintenanceandrepairoperationsof
HM484Qseriesengine,andrelatedtechnicalparametersofprocess
standards. Inthecourseofuse,it isproposedtoapply incombinationwiththe
maintenancemanual,circuitdiagramsandotherrelevantinformationof
correspondingvehicle, and strictly comply withthe operationpractice
presentedinthesematerials.
Thecontentsof manualarecategorized according tothe component
assembliesand systemsof engine(Suchas:generator,starter, lubrication
system, etc.); theorderofeachpartofcontent inthismanualis arranged
accordingtotheorderbrokendownofenginefromoutside toinside (the
enginecan becompletelydecomposedaspertheorderof operationsset out
inthismanualthat). Itisproposedtoreadthroughthismanualbeforethe
operationsofrepairand maintenance.
Allcontentsof thismanualarethe latest information at thetimeof publication,
andtheapplieddataareinline withthe technicalstandardsofHM484Qseries.
FAWHAIMAPowerCo., Ltd.reservestherighttochange theengine technique
featuresand contentsrelevantinthismanual.Thetechnicalpersonnelusing
thismanualshallpayattentiontothe updatedinformationat anytime.
FAWHAIMAPowerCo., Ltd

TableofContents
I
HowtoUseThisManual......................................................................................................1
Technique parameters..........................................................................................................2
Techniqueparametersofcompleteapparatus.............................................................2
Technicalspecificationofservice.................................................................................3
Technicalspecificationofservice.................................................................................6
Tightening torque..........................................................................................................8
Specialtools.......................................................................................................................11
Inspection and maintenanceon CBU...............................................................................13
Checkof compression pressure................................................................................13
Checkof oilpressure.................................................................................................14
Checkof engineoilpressure.....................................................................................15
Replacementof engineoilpressure..........................................................................15
Replacementof oilfiler..............................................................................................16
Others........................................................................................................................16
Useof Engine ServicePlatform........................................................................................17
UpperServicePlatformofEngine.............................................................................17
LowerServicePlatformofEngine.............................................................................18
Generatorandstarter........................................................................................................19
LubricationsystemofEngine....................................................................................19
Checkof enginebelt..................................................................................................19
Deflectioncheckof enginebelt..........................................................................19
Tensioncheckofenginebelt..............................................................................20
Adjustmentofenginebelt..........................................................................................20
Checkof engine.........................................................................................................21
Lubricationsystemofstarter.....................................................................................22
Checkof starter..........................................................................................................22
Ignitionand controlsystems.............................................................................................23
LubricationsystemofignitionandPVCvalve...........................................................23
Instructionsofplug removal/installation.............................................................23
CheckofPVCvalve............................................................................................24
Disassembly/assemblyofcontrolsystemparts.........................................................25
Removal/installationinstructionsofwatertemperaturesensor.........................26
Checkof crankshaftpositionsensor..........................................................................26
Intakeand exhaustsystems.............................................................................................27
Removal/installationof intakeand exhaust systems.................................................27
Assemblyinstructionsof intakemanifoldsealantring.......................................27
Installationinstructionsofthrottlebodysealantring..........................................28
Installationinstructionsofexhaustmanifoldgasket...........................................28
Timingsprocket.................................................................................................................29
Lubricationsystemoftimingsprocket.......................................................................29
Lubricationsystemoftensioner..........................................................................30
Instructionstotheremovaloftensioner.............................................................30
Disassemblyinstructionsofcrankshaft pulley...................................................30
Disassemblyinstructionsofcylinderheadcover...............................................30

TableofContents
II
Disassemblyinstructionsoftimingsprocket......................................................30
Assemblyinstructionsof tensioner.....................................................................31
Assemblyinstructionsof tensionerarm.............................................................31
Assemblyinstructionsof timing sprocket...........................................................32
Assemblyinstructionsof cylinderheadcover....................................................32
Assemblyinstructionsof crankshaft pulley........................................................33
Assemblyinstructionsof waterpumppulley......................................................33
Lubricationsystem............................................................................................................34
Removal/installationof oilpan...................................................................................34
Disassemblyinstructionsofoilpan....................................................................34
Assemblyinstructionsof oilpan.........................................................................35
Removal/installationof oilpanbody..........................................................................35
Disassemblyinstructionsofoilpan body...........................................................35
Assemblyinstructionsof oilpanbody................................................................35
Removal/installationof timingsprocket casing..........................................................36
Disassemblyinstructionsofoilpumpseal.........................................................37
Assemblyinstructionsof oilpumpand timingsprocket casingassemblies......37
Assemblyinstructionsofoilfilter...............................................................................38
Breakdown/installationofoilpumpandtimingsprocket casing...............................38
Rotorclearanceinspection.................................................................................38
Checkofpressurespring ...................................................................................40
Coldsystem......................................................................................................................40
Removal/installationof thermostat............................................................................40
Assemblyinstructionsof thermostat..................................................................40
Checkof thermostat...................................................................................................40
Removal/installationof coolingwaterpipe................................................................41
Assemblyinstructionsof cooling waterpipe ......................................................41
Removal/installationof waterpump...........................................................................42
Cylinderheadandvalves..................................................................................................42
Removal/installationof cylinderhead........................................................................42
VVTDisassemblyinstructionsofintakeandexhaust........................................44
Disassemblyinstructionsofcamshaft................................................................44
Disassemblyinstructionsofcylinderhead.........................................................45
Assemblyinstructionsof cylinderhead..............................................................45
Assemblyinstructionsof camshaft.....................................................................46
Assemblyinstructionsof VVT.............................................................................46
Removal/installationofvalvegear.............................................................................48
Disassemblyof valvesplitcollets.......................................................................48
Disassemblyof valveoilseal.............................................................................49
Assemblyof valveoilseal..................................................................................49
Valvespring........................................................................................................50
Installationof valvesplit collets..........................................................................50
Inspectionof valveclearance....................................................................................50
Adjustmentofvalveclearance...................................................................................51

TableofContents
III
Check/repairofcylinderhead....................................................................................53
Checkofvalveand valveguide.................................................................................54
Replacementof valveguide......................................................................................55
Disassemblyof valveguide................................................................................55
Assemblyof valveguide.....................................................................................55
Check/repairof valveseat.........................................................................................56
Checkofvalvespring................................................................................................57
Checkof spring..........................................................................................................58
Checkof tappet..........................................................................................................59
Flywheeland clutch...........................................................................................................61
Removal/installationof flywheelandclutch...............................................................61
Disassemblyinstructionsofclutchcompressing discanddiscplate.................61
Disassemblyinstructionsofflywheel..................................................................62
Disassemblyinstructionsofpilotbearing...........................................................62
Disassemblyinstructionsofrearoilseal............................................................62
Assemblyinstructionsof rearoilseal.................................................................63
Assemblyinstructionsof crankshaft rearcover.................................................63
Assemblyinstructionsof flywheel......................................................................63
Assemblyinstructionsof pilotbearing................................................................64
Assemblyinstructionsof clutchdisc plate..........................................................65
Assemblyinstructionsof clutchcompressingdisc.............................................65
Checkof clutchcompressingdisc.............................................................................65
Checkof clutchplate.................................................................................................67
Checkof pilot bearing................................................................................................67
Checkof flywheel.......................................................................................................68
Cylinderblock andcrankconnecting rodmechanisms....................................................69
Breakdown/installationofcylinderblockandcrankconnecting rodmechanisms...69
Disassemblyofconnectingrod cap...................................................................70
Disassemblyofpiston and connecting rod........................................................70
Disassemblyofpiston pin...................................................................................70
Disassemblyofmainbearing cap......................................................................70
Disassemblyofcrankshaft .................................................................................71
Installationofmainbearingcap..........................................................................71
Installationofpistonpin......................................................................................72
Installationofpistonring.....................................................................................74
Installationofpistonconnecting rodassembly..................................................74
Installationofconnectingrodcap.......................................................................75
Check/repairofcylinderblock...................................................................................75
Checkof piston, pistonringandpistonpin................................................................77
Checkof connecting rod............................................................................................79
Checkof piston and connecting rod..........................................................................80
Check/repairofcrankshaft.........................................................................................81

TableofContents
IV

Howto UseThisManual
1
How to Use ThisManual
Subjectscope
lThismanualincludesproceduresformaintenanceoperations,specificallydivided intothe
followingfivebasicoperations.
Removal/installation
ⅡBreakdown/installation
ⅢReset
ⅣCheck
ⅤAdjustment
lSimpleoperationsmaybe completedbyobservingtheengineoutlook,e.g.
Removal/installationofperipheralparts,partscleaningand visualobservationetc.,
Repairsteps
1.Priortothemostofthe maintenancework,theillustrationsshallbeobserved,asitcan
identifytheparts, explaininghowtheywerefixedtogether,howtochecktheappearanceof
parts.Figuredescriptionsareavailablefortheremovalandinstallationtobedemonstrated
bythesystem.
2.Thevulnerableparts,tighteningtorque andlubricants,aswell asthe sealantssymbolsare
illustratedinthefigures, ofthetagsandinstructionswerealsomadeforthespecialtoolsor
equipmentrequiredbytheremovalorinstallation.
3.Theoperationsequencesandthe mainoperationproceduresofpartshavethe
correspondingnumberinthechart descriptions. Thisinformationisoftenthe keyorcore
elementarycontentofdiagnosticprocedures, pleaserefertothisinformationatthetimeof
themaintenanceof spare-parts.
Cuesignal
Inthemanual,youwillreadthewarnings, cautions, attentions,statementsandtheupper/lower
limits.
Warning
lAlertthatit will causepersonalinjuryifneglected.
Caution
lNotethatitmaycauseenginedamageifneglected.
Attention
lAttention toadditionalinformationprovidedtocompletesomeprograms.
Statement
lPromptthetolerantrangewhencheckingoradjusting.
Upper/lowerlimits
lPrompttheupperandlowerlimitnot toexceed whenchecking oradjusting.

Techniqueparameters
2
Techniqueparameters
Techniqueparametersofcompleteapparatus
Items Parameters Remark
Model HM484Q HM484Q-B
Numberofcylindersand
arrangement Inline4-cylinder
Combustion chamberPentroof
Ignitionorder 1 342 Aspercylinder
number
Direction ofrotation Counterclockwise
Lookingforward
frombehind(the
flywheelsideis
the backend)
Valvetimingmechanism Doubleoverheadcamshaft, timingsprocket
drive,doubleVVT
Numberofvalves 16
Displacement(cc) 1995 1840
Cylinderbore ×stroke
(mm) 84×90 84×83
Compression ratio10
Valve
timing
(°)
Intake On
-4～36(BTDC)
Off
64～24(ABDC)
Exhaust
On
56～32(BBDC)
Off
0～24(ATDC)
Maximum power
(kW/rpm) 102/6000 94/6000
Maximumtorque
(N·m/rpm) 180/4500 166/4500
Idlingspeed(rpm) A/CIdle: 800±50
Target idlespeed: 750±50
Sparkadvanceangle(°) 6±3 Inthe idlestate
Startingmethod Electricstart
Coolingmethod Watercooling forced circulation
Lubrication method Pressureand splashingcomplex
Overalldimension(mm) 584.1×638.1×641.9
Net mass(kg) 130 128.25

Techniqueparameters
3
Technicalspecificationofservice
Items Parameters
Cylindercover
Height(mm{in}) Standard 124.45 ～124.55{4.8996 ～
4.9035}
Maximumgrinding
allowance 0.2{0.0078}
Deformationat jointfaceof
cylindergasket (mm{in}) Max. 0.03{0.0011}
Deformationat jointfaceof
manifold(mm{in})
Max. 0.05{0.0019}
Maximumgrinding
allowance 0.20{0.0078}
Valvegap(coldstatusofengine)
(mm{in}) Intake 0.18～0.26{0.007～0.0102}
Exhaust 0.26～0.34{0.0102～0.0133}
Valveandvalveguidepipe
Edgethickness
(mm{in})
Intake Standard 0.85{0.0334}
Min. 0.35{0.014}
Exhaust Standard 1.50{0.0590}
Min. 0.9{0.035}
Valvelength
(mm{in})
Intake Standard 101.15 ～101.65{3.9822 ～
4.0019}
Min. 100.95{3.9744}
Exhaust Standard 101.07 ～101.57{3.9791 ～
3.9988}
Min. 100.87{3.9712}
Valvestem
diameter
(mm{in})
Intake Standard 4.965～4.980{0.1954～0.1960}
Min. 4.915{0.1935}
Exhaust Standard 4.955～4.970{0.195～0.1956}
Min. 4.905{0.1931}
I.D.of valveduct (mm{in}) Standard 5-5.012{0.1968-0.1973}
Enlargedsize 5.012-5.022{0.1973-0.1977}
Protrusion heightofvalveguide
pipe(mm{in})Intake 19.8-20.4{0.7795-0.8031}
Exhaust 14.6-15.2{0.5748-0.5984}
Valveseat
Contactwidthofvalveseat (mm{in}) 0.9～1.3{0.0354～0.0511}
Valveseatangle(º)Intake 43.5～44
Exhaust 43.5～44
Sinkof valveseat(protrusion
heightof valve)(mm{in}) Intake 44.37{1.7468}
Exhaust 44.37{1.7468}

Techniqueparameters
4
Technicalspecificationofservice
Items Parameters
Valvespring
HeightHpressureof
valvespring (N{kgf,
lbf})
Intake H:38.8mm{1.528in} 203 ～225{20.71 ～22.95,
45.62～50.56}
Exhaust H:38.8mm{1.528in} 203 ～225{20.71 ～22.95,
45.62～50.56}
Perpendicularity
(mm{in}) Intake Max. 1.86{0.073}
Exhaust Max. 1.86{0.073}
Valveoilseal
DepthL(mm{in}) Intake 22.1{0.87}
Exhaust 16.9{0.665}
Camshaft
Axialrun-outofcamshaft
(mm{in}) Max. 0.03{0.0012}
Protrusion heightof
cam(mm{in})
Intake Standard 43.81{1.7248}
Min. 43.61{1.7169}
Exhaust
Standard 43.78{1.7236}
Min. 43.58{1.7157}
Journaldiameter(mm{in}) Standard 25.936～25.965{1.0211～
1.0222}
Min. 25.906{1.0199}
Journalgap (mm{in}) Standard 0.035～0.085{0.0014～0.0033}
Endgap (mm{in}) Standard 0.08～0.20{0.0031～0.0078}
Max. 0.21{0.0082}
Tappet
Tappetholediameter(mm{in}) Standard 31.000～31.025{1.2205～
1.2215}
Tappetdiameter(mm{in}) Standard 30.964～30.980{1.2191～
1.2197}
Gapbetweentappetand tappet
hole(mm{in})Standard 0.020～0.061{0.00079～
0.00240}
Max. 0.180{0.0071}
Cylinderblock
Height(fromtopsurfacetomain
coverboundaryline)(mm{in})
Standard 273.5{10.7677}
Maximumgrinding
allowance 0.20{0.008}
Deformationat topsurface
(mm{in}) Standard 0.05{0.002}