Lovol KM/4L22 User manual

KM/4L22 Diesel Engines
MAINTENANCE MANUAL
THE PEOPLE’S REPUBLIC OF CHINA
LOVOL HEAVY INDUSTRY CO., LTD

MAINTENANCE MANUAL OF TE SERIES
1
Preface
This manual provides information on the diagnosis, maintenance and adjustment
of the two mechanisms and five systems of non-road three-cylinder and four-cylinder
engines made in Shandong Huayuan Laidong Engine Co., Ltd. (hereinafter referred to
as Laidong). This manual is intended to be used by maintenance technicians. If nec-
essary, refer to the corresponding volume of drawings of parts when reading this
manual.
To obtain information on product models, drawing numbers and special tools as
mentioned in this manual, call or write to Laidong. All data, illustrations and descrip-
tions collected in this manual are effective when this manual is being edited.
To improve the quality, performance and safety of engines, Laidong will make
changes the design of engine components from time to time. Some texts and illustra-
tions in this manual could vary with the engine being maintained. Contents of this
manual can be changed without notice.
Without the permission of Shandong LOVOL Heavy Industry International
Trading Co., Ltd, no part of this manual may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, including but not limited to
electronic, photocopying and recording. The statement shall cover all the texts,
illustrations and tables contained in this manual.

MAINTENANCE MANUAL OF TE SERIES
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Contents
Preface ......................................................................................................................................1
Part I Overview.................................................................................................................................1
Chapter 1 Safety Precautions....................................................................................................1
1. Scalding symbol.............................................................................................................1
2. No-touching symbol ......................................................................................................1
3. Engine hoisting equipment ...........................................................................................2
Chapter 2 Technical Parameters................................................................................................3
1. Main technical parameters............................................................................................3
2. Capacities ......................................................................................................................3
3. Overall dimensions........................................................................................................3
4. Technical Parameters.....................................................................................................4
5. Torque specifications.....................................................................................................6
6. Some exposed parts of engine ......................................................................................7
Chapter 3 Fuel and Engine Oil...................................................................................................9
1. Use and precautions for fuel .........................................................................................9
2. Engine lubricating oil...................................................................................................11
3. Engine coolant.............................................................................................................12
Chapter 4 Position of Product Nameplate ..............................................................................13
1. Information of diesel engine nameplate.....................................................................13
2. Fuel injection pump nameplate ..................................................................................14
3. Position of alternator nameplate ................................................................................15
4. Starter nameplate .......................................................................................................16
5. Air compressor nameplate ..........................................................................................17
Chapter 5 Product Features and Accessories..........................................................................18
1. Standard configuration................................................................................................18
2. Configuration (optional)..............................................................................................19
Part II Dismantlement, Installation and Adjustment.......................................................................20
Chapter 1 Dismantling/installing the valve mechanism..........................................................20
1. Maintenance equipments and tools ...........................................................................20
2. Torque and data ..........................................................................................................20
3. Dismantling the valve mechanism...............................................................................23
4. Installing the valve mechanism ...................................................................................31
Chapter 2 Dismantling/installing the crank-link mechanism ..................................................43
1. Maintenance equipments and tools ...........................................................................43
2. Torque and data ..........................................................................................................43
3. Dismantling the crank-link mechanism .......................................................................45
4. Installing the crank-link mechanism............................................................................51
Chapter 3 Cooling system........................................................................................................64
1. Maintenance equipments and tools ...........................................................................64
2. Torque requirements...................................................................................................64
3. Dismantling the cooling part.......................................................................................65
4. Assembling the cooling part........................................................................................71
Chapter 4 Lubricating System..................................................................................................75
1. Maintenance equipments and tools ...........................................................................75
2. Torque requirements...................................................................................................75
3. Dismantling/installing the oil pan parts ......................................................................76
3.1 Dismantling the oil pan parts ....................................................................................76
4. Dismantling/installing the oil pump parts...................................................................78
Chapter 5 Electric system........................................................................................................80
1. Maintenance equipments and tools ...........................................................................80
2. Torque requirements...................................................................................................80
3. Dismantling/installing the alternator assembly ..........................................................81

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4. Dismantling the alternator subassembly ....................................................................83
5. Dismantling/installing the starter ...............................................................................84
Chapter 6 Fuel supply system..................................................................................................85
1. Maintenance equipments and tools ...........................................................................85
2. Torque requirements...................................................................................................85
3. Dismantling the fuel supply system.............................................................................86
4. Assembling the fuel supply system .............................................................................90
Chapter 7 Dismantling/installing and adjusting the accessories.............................................92
1. Data and dimension ....................................................................................................92
2. Dismantling/installing the intake pipe ........................................................................93
3. Dismantling/installing the exhaust pipe......................................................................95
4. Dismantling/installing the gear chamber....................................................................97
5. Dismantling/installing the flywheel parts .................................................................105
Part III Inspection, Adjustment, Fault Diagnosis and Troubleshooting ........................................108
Chapter 1 Dynamic Inspection ..............................................................................................108
1. Overview ...................................................................................................................108
2. Inspecting engine oil level.........................................................................................109
3. Inspecting the coolant level and status.....................................................................110
4. Inspecting the fan and belt........................................................................................111
5. Inspecting the fuel system.........................................................................................112
6. Inspecting the air intake and exhaust system ...........................................................113
7. Inspecting the electric system...................................................................................114
Chapter 2 Operating principle...............................................................................................115
1. Valve mechanism.......................................................................................................115
2. Crank-link mechanism ...............................................................................................117
3. Lubricating System ....................................................................................................119
4. Fuel supply system ....................................................................................................120
5. Cooling system ..........................................................................................................121
6. Electric system...........................................................................................................122
Chapter 3 Inspection and adjustment...................................................................................129
1. Inspecting valve clearance (mm)...............................................................................129
2. Inspecting cylinder pressure......................................................................................130
3. Inspecting the engine oil pressure ............................................................................131
4. Inspecting fuel injection pump timing ......................................................................133
5. Calibration of the fuel injection pump ......................................................................134
6. Inspecting atomization by the fuel injector...............................................................135
Chapter 4 Fault analysis and troubleshooting.......................................................................136
1. White smoke .............................................................................................................136
2. Blue smoke ................................................................................................................136
3. Black smoke or grey smoke .......................................................................................137
4. Insufficient compression pressure of cylinders.........................................................137
5. Air intake obstructed.................................................................................................138
6. Black smoke...............................................................................................................138
7. Abnormal sound from the diesel engine...................................................................139
8. The engine cannot be operated normally or flames out frequently.........................140
9. Low power.................................................................................................................141
10. The engine oil is mixed with water..........................................................................142
11. Abrupt increase in speed.........................................................................................142
12. Erratic operation......................................................................................................143
13. Engine overheat ......................................................................................................143
14. Abnormal coolant temperature ..............................................................................144
15. No engine oil pressure or low pressure...................................................................145
16. The engine oil pressure is too high..........................................................................145
17. The engine oil temperature is too high...................................................................146

3
18. High engine oil consumption ..................................................................................146
19. Low starter speed....................................................................................................147
20. Cannot be started or be started difficultly ..............................................................147
21. The diesel engine is started difficultly.....................................................................148

MAINTENANCE MANUAL OF ENGINE
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Part I Overview
Chapter 1 Safety Precautions
This is a safety symbol. Safety symbols are
found on the tractor or in this manual. They
highlight hazards that may result personal in-
jury.
The tips for operating procedure and safety
precautions must be strictly followed.
1. Scalding symbol
To avoid scalding, stand away from the hot
surfaces of the engine while it is running.
2. No-touching symbol
Do not touch the engine body while the engine
is running.
Do not maintain the engine until it shuts down
and cools for at least half an hour to ambient
temperature.
Other symbols are described in the tractor
maintenance manual or operation instructions.

MAINTENANCE MANUAL OF ENGINE
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3. Engine hoisting equipment
Correct equipment and method shall be used
for hoisting the engine. Recommended hoist-
ing equipment is as illustrated. Attach the
chains to both of the lifting eyes of the engine.
Never use a single lifting eye.
Before hoisting the engine, check that the lift-
ing eyes are tightened to 44N.m without dam-
age and looseness.

MAINTENANCE MANUAL OF ENGINE
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Chapter 2 Technical Parameters
1. Main technical parameters
Note: Design and technical parameters of the engine may be changed without notice.
Diesel engine
Unit
Shandong Huayuan Laidong Engine Co., Ltd.
Model
KM385BT
KM390BT
4L22BT
Type
——
Vertical, water-cooled, 4-stroke diesel engine
Number of cylinders
——
3
4
Bore ×Stroke
mm
85×90
90×100
85×95
Rated power
kW
18.4
22
25.7
Rated speed
r/min
2350
2350/2400
2350
Maximum torque/speed
N·m/(r/
min)
≥86/≤1650
≥108/≤1750
≥124/1650
Fuel Consumption Rate
under Rated Working Con-
dition
（g/k
W h）
≤278
≤276
≤278
Oil Consumption Rate un-
der Rated Working Condi-
tion
≤2.04
≤2.72
≤2.04
Lubrication manner
——
Pressurization
Start-up manner
——
Electrical starter
2. Capacities
Model
Unit
LOVOL
TE200/TE204/TE240/
TE244/TE250/TE254
TE300/TE304
TE354
Fuel tank
L
32
Oil pan
5
6
3. Overall dimensions
Diesel engine
Unit
Shandong Huayuan Laidong Engine Co., Ltd.
Model
KM385BT
KM390BT
4L22BT
Overall
dimen-
sions
Length
mm
569
600-800
757
Width
525
480-850
494
Height
604
650-800
620
Mass
kg
180
220-280
200

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4. Technical Parameters
4.1 Main technical data
KM385BT diesel engine
No.
Rated power/speed (kw/rpm)
Maximum torque/speed （N.m/rpm）
1
19.4/2400
90/1480-1680
2
18.4/2350
86/1480-1680
3
17.7/2350
83/1480-1680
4
14.7/2350
69/1480-1680
4.2. Main technical parameters
1
Model
KM385BT
KM390BT
4L22BT
2
Type
Vertical, water-cooled, 4-stroke
3
Number of cylinders
3
3
4
4
Combustion chamber type
Direct injection
5
Cylinder bore (mm)
85
90
85
6
Piston stroke (mm)
90
100
95
7
Compression ratio
18
18
18
8
Rated net power/Rated speed
(kW/rpm)
18.4/2350
22/2400
25.7/2350
9
Maximum speed at no load (rpm)
≤2580
≤2640
≤2580
10
Minimum steady speed at no load
(rpm)
≤850
≤850
≤850
11
Minimum fuel consumption at max-
imum opening of valve (g/kW.h)
≤248
≤248
≤248
12
Ratio of engine oil consumption to
fuel consumption
≤0.8%
13
Ratio of maximum torque with en-
gine at full load to the torque with
engine at rated operating conditions
≥15%
14
Total piston displacement (L)
1.532
1.909
2.156
15
Maximum fume at full load (Rb)
≤4.5
16
Exhaust gas temperature (°c)
≤650
17
Engine oil pressure (KPa)
200-400
18
Engine oil temperature (°c)
85-95
19
Cooling water temperature (°c)
75-85
20
Firing order of cylinders
1-3-2
1-3-2
1-3-4-2
21
Crankshaft rotation direction (viewed
towards flywheel)
Counter-clockwise
22
Lubrication manner
Pressurization and splashing
23
Start-up manner
Electrical starter
24
Overall dimension (L×W×H)
567×494×610
662×497×703
757×494×664
25
Emission
GB20891 National II

MAINTENANCE MANUAL OF ENGINE
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4.3 Technical parameters of main accessories
Fuel injection pump model
No.1 pump, or BQ pump
Construction of fuel injection pump
Plunger
Diameter of plunger of fuel injection pump
￠8
Needle valve set of fuel injector
ZCK154S425
Accessory
Classification
Starter
Model
QD1315A or QD138C
Power
2.5KW
Voltage
12V
Accessory
Classification
Alternator
Model
JF11 or JFWB13A1
Power
350W
Voltage
14V
Water pump
Type
Centrifugal
Flow
≥68L/min
Oil pump
Type
Rotor type
Flow
≥22L/min
Diesel fuel filter model
C0506C
Oil filter model
J0810H

MAINTENANCE MANUAL OF ENGINE
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5. Torque specifications
No.
Description
Torque
Remarks
N.m
1
Bolts, cylinder head
135-150N.m
2
Long bolts, rocker arm shaft
base
21-25N.m
3
Bolts, connecting rod
50-60N.m
4
Bolts, main bearing cap
115-130N.m
5
Bolts, connecting water pump
to cylinder head and engine
body
25N·m
6
Screw, adjusting belt tension
90N

MAINTENANCE MANUAL OF ENGINE
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6. Some exposed parts of engine
6.1 Left side of engine
A- Fan B- Crankshaft pulley C- Fuel injection pump D- Oil pan E- Oil filter assembly
F- Engine oil pressure sensor G- Flywheel cover H- Intake pipe

MAINTENANCE MANUAL OF ENGINE
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6.2 Right side of engine
A- Cylinder head cover B- Breather C-Alternator D- Starter
A
B
C
D

MAINTENANCE MANUAL OF ENGINE
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Chapter 3 Fuel and Engine Oil
1. Use and precautions for fuel
1.1 Storage of fuel
Do not store fuel too long. If fuel has to be
kept in a tank or transport vehicle for a long
time, add fuel conditioner to prevent concen-
tration.
Contact Lovol's supplier for appropriate use
and maintenance recommendations.
Purchase high-quality clean fuel from the
well-reputed dealers.
Appropriate fuel storage is very important.
The fuel should be stored in a clean warehouse
and fuel tank, and it is required to drain water
and sediments from the bottom of the fuel tank
on a regular basis.
Store fuel in a readily accessible place, and
keep it far away from any building.
Note: In cold seasons, add conditioner into
fuel in storage, or store fuel in bulk, to reduce
fuel coagulation and wax separation.

MAINTENANCE MANUAL OF ENGINE
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1.2 Precautions for use of fuel
The biodiesel conforming to DIN51606
or diesel with equivalent performance are al-
lowed.
The diesel cannot be mixed with oil or
other type of lubricants.
Before the diesel is injected into the fuel
tank, be certain that the diesel is deposited
(generally above 48 hours), and then filtered
to remove foreign bodies, and prevent severe
wear of the precise parts (plunger and barrel
assembly, delivery valve assembly, and needle
valve assembly) the fuel system resulted from
the foreign bodies.
In case of lack of low condensation point
light diesel in a cold area and in a cold season,
it is possible to use the exhaust gas or circu-
lating water for preheating and heat insulation
of the fuel tank and fuel delivery pipe and im-
proving fluidity of the diesel, so as to use a
high condensation point light diesel.
1.3 Fuel injection
Add fuel referring to the fuel dipstick in fuel
tank.
For fuel addition marks, refer to Maintenance
Manual for TE Series Tractors.

MAINTENANCE MANUAL OF ENGINE
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2. Engine lubricating oil
Engine oil:
Select engine oil quality grade CD or
higher. Select engine oil viscosity according to
ambient temperature referring to the table be-
low.
Also you can use following other equiv-
alent international brands:
SHELL RIMULA R1 15W/40
MOBIL 15W-40
It is advisable to choose a multi-viscosity
engine oil.
Use of the recommended engine oil
above can extend service life. You may con-
tact LOVOL's supplier for details.
Attention:
1. Select a proper engine oil designation ac-
cording to ambient temperature. Replace en-
gine oil periodically.
2. Do not mix engine oil of different designa-
tions. Failure to do so could cause chemical
reaction thus deterioration of engine oil.
No.
Engine oil designation
Proper ambient temper-
ature
Remarks
1
15W/40
Above -5℃
2
10W/30
-5℃～-20℃
3
5W/30
Below -20℃

MAINTENANCE MANUAL OF ENGINE
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3. Engine coolant
Use as cooling water the clean soft water,
such as river water, rain water, snow water and
tap water. Soft water contains fewer minerals.
It generates little foul after heated. Less possi-
bility exists that soft water causes blockage in
the cooling system thus affects heat dissipa-
tion. If soft water is unavailable hence hard
water has to be used, for example, well water,
spring water or other hard water containing
many minerals, softening of the water shall be
performed. The simplest softening method is
to boil the water, wait for a period for deposi-
tion of minerals, and then remove the miner-
als.
If the diesel engine is used in a cold region,
depending on the ambient temperature, add
proper amount of anti-freeze into the cooling
water. The anti-freeze can be the mixture of
alcohol and glycerol or ethanediol.

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Chapter 4 Position of Product Nameplate
1. Information of diesel engine nameplate
The nameplate of diesel engine carries the
following data: manufacturer name, model,
rated power/rated speed, type approval num-
ber, serial number, manufacturing date, deliv-
ery number, and net weight.
Attention:
For Laidong to accurately provide spare parts,
the customer shall provide Laidong with all
the data indicated on the nameplate.
Position of engine nameplate
The nameplate is found below the intake pipe.
A-Diesel engine nameplate
A

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2. Fuel injection pump nameplate
Information of fuel injection pump nameplate
The nameplate of fuel injection pump carries the
following data: model, purchase order number, and
manufacturer name.
A- Position of fuel injection pump nameplate
Position of fuel injection pump nameplate
The nameplate is found right above the fuel injec-
tion pump.
A-Fuel injection pump nameplate
A
A