Foton Series Light Bus. Service Manual — part 4
OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·40·
First
44
Second
90° turning
Cylinder block x cylinder head
Third
90° turning
First
44
Cylinder block x crankshaft main bearing cap
Second
90° turning
First
25
Connecting rod x connecting rod bearing cap
Second
90° turning
Crankshaft x crankshaft pulley
245
Camshaft x distributor drive gear
74
Crankshaft x flywheel
88
Crankshaft x drive plate
74
Oil pan x oil plug
25
Alternator x bracket
59
Engine mounting isolator x engine mounting bracket
44
Intake manifold x TVSV
25
Coolant bypass flange x thermostat
25
EGR valve x intake manifold
20
EGR valve x EGR pipe
20
Exhaust manifold x EGR pipe
20
Fuel outlet pipe x intake manifold
20
Fuel outlet pipe x injector cover
4.4
NO 1 fuel supply pipe x fuel outlet pipe
29
No 1 fuel supply pipe x fuel filter
29
Cold start injector pipe x cold start injector
20
Cold start injector pipe x fuel outlet pipe
20
Pressure regulator x fuel outlet pipe
25
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Chapter 1 Main Data and Specification of VIEW Series Light-bus
·41·
1.5.5.2 Bolt standard tightening torque
Mark grade
Mark grade
No. mark on bolt head
4- 4T
5- 5T
6- 6T
7- 7T
8- 8T
9- 9T
10- 10T
11- 11T
Stud
W/o mark
4T
Hex bolt
W/o mark 4T
Hex flange bolt w. washer
Hex head bolt
W/o mark 4T
With slot
6T
Hex bolt
Two projecting lines 5T
Hex flange bolt w. washer
Hex head bolt
Two projecting lines 6T
Hex bolt
Two projecting lines 7T
Hex bolt
Four projecting lines 8T
Welding bolt
4T
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·42·
Specified tightening torque – standard bolts
Specified torque
Hex bolt
Hex flange bolt
Rating
Diameter (mm)
Pitch (mm)
N-m
N-m
6
1
5
6
8
1.25
12.5
14
10
1.25
26
29
12
1.25
47
53
14
1.5
74
84
4T
16
1.5
115
--
6
1
6.5
7.5
8
1.25
15.5
17.5
10
1.25
32
36
12
1.25
59
65
14
1.5
91
100
5T
16
1.5
140
--
6
1
8
9
8
1.25
19
21
10
1.25
39
44
12
1.25
71
80
14
1.5
110
125
6T
16
1.5
170
--
6
1
10.5
12
8
1.25
25
28
10
1.25
52
58
12
1.25
95
105
14
1.5
145
165
7T
16
1.5
230
--
8
1.25
29
33
10
1.25
61
68
8T
12
1.25
110
120
8
1.25
34
37
10
1.25
70
78
9T
12
1.25
125
140
8
1.25
38
42
10
1.25
78
88
10T
12
1.25
140
155
8
1.25
42
47
10
1.25
87
97
11T
12
1.25
155
175
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Chapter 1 Main Data and Specification of VIEW Series Light-bus
·43·
1.6 Model 4G64 Engine main technical specification
1.6.1 Model 4G64 S4 MPI engine performance curve
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·44·
1.6.2 Engine main technical parameters
SN
Description
Parameters
1
Model
Mitsubishi 4G64 S4 MPI
2
Type
In line, four cylinders, roof type combustion
chamber, SOHC 16 valves, four strokes, water
cooling, multi-point EFI gasoline engine
3
No.of cylinder
4
4
Cylinder bore (mm)
86.5
5
Piston stroke(mm)
100
6
Total displacement (L)
2.351
7
Compression ratio
9.5
8
Fuel injection and ignition sequence
1-3-4-2
9
Fuel rating
PON93 or above superior unleaded gasoline
(GB17930)
10
Oil rating
SE or above 10W-30 or 15W-40 (GB11121)
11
Oil volume (L)
4.3 (with 0.3L in oil filter)
12
Coolant volume (L)
8 (8.5 L with rear heater)
intake valve open
18° BTDC
Intake valve close
53° ABDC
Exhaust valve open
50° BBDC
13
Port timing
(Crankshaft turning angle)
Exhaust valve close
18° ATDC
14
Spark plug clearance (mm)
1±0.1
15
Cooling method
Forced close water cooling
16
Rated power / rated rpm (kw/rpm)
93/5250
17
Max torque/max torque rpm (N-m/rpm)
190.12/2750
18
Min. fuel consumption (g/kw/h)
258.4
19
Fuel consumption at limited operation (L/100km)
(for light bus)
8.54
20
Idle rpm
750±50
at idle
≥96
At 200 rpm
≥205
21
Oil pressure(KPa)
At 3000 rpm
≥386
CO%
1.0±0.5
22
Pollutant emission
HC(ppm)
2.≤500comply with GB18352.2
23
System fuel pressure (KPa)
300 ± 20
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Chapter 1 Main Data and Specification of VIEW Series Light-bus
·45·
SN
Description
Parameters
24
Dimension (L×W×H) (mm)
695×635×632
25
Total mass (with engine, water pump, without clutch
and housing) (kg)
161.8
26
Thermostat opening temperature (℃)
82 (100 at fully open)
27
Ignition advance angle
5°± 2°BTDC
28
Lubrication method
Pressure and splashing
29
Crankshaft turning direction
Counter-clockwise (viewing from engine front)
30
Cylinder sleeve type
W/o sleeve
31
Fuel supply method
Multi-point EFI
32
Valve train
SOHC, 16 valves (2 intake/exhaust valves for
each cylinder)
Check value 5.5~8.5
new belt
5.5~7.5
33
Drive belt deflection (under 98N.m) (mm)
Alternator
Power steering pump
AC compressor pump used belt
7.5~8.5
34
Tensioner projection(mm)
3.8~4.5
1.6.3 Fitting sizes of engine main parts
Description
Standard
Limit
Tensioner arm projection (mm)
12
--
Alternator belt
Tensioner arm press-in ( 98~196N-m) (mm)
≤1
--
Intake
37.39
36.89
Cam height (mm)
Exhaust
36.83
36.33
Camshaft
Shaft diameter (mm)
45
Lower plane flatness (mm)
0.03
0.2
Surface grinding limit ★total grinding amount (block
and head) (mm)
★0.2
Total height (mm)
119.9~120.1
Cylinder head
Length of cylinder head bolt (mm)
97.4
≤99.4
Intake
1.0
0.5
Top edge thickness (mm)
Exhaust
1.2
0.7
Valve stem diameter (mm)
6.0
Intake
0.02~0.05
0.10
Radial clearance—valve stem and
guide (mm)
Exhaust
0.03~0.07
0.15
Top cone angle (degree)
45~45.5
--
Intake
112.30
111.80
Valve
Height (mm)
Exhaust
114.11
113.61
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·46·
Description
Standard
Limit
Free height
51
50.5
Operating pre-tension / operating height (N/mm)
267/433
--
Valve spring
Verticality (degree)
≤2
≤4
Contacting width (mm)
0.9~1.3
--
Inner diameter (mm)
6
--
Outer diameter (mm)
11
--
Press-in height (mm)
14
--
Valve guide
Valve stem projection (mm)
49.3
49.8
Description
Standard
Limit
Drive gear
0.08~0.14
--
Oil pump
Side clearance (mm)
Driven gear
0.06~0.12
--
Piston
Piston clearance (mm)
0.02~0.04
Top ring
0.02~0.06
0.1
Side clearance (mm)
Second ring
0.02~0.06
0.1
Top ring
0.25~0.35
0.8
Second ring
0.4~0.55
0.8
Piston ring
End clearance (mm)
Oil ring
0.10~0.40
1.0
Outer diameter (mm)
22.0
--
Press-in force (N)
7399~17150
--
Piston pin
Press-in temperature
Room
temperature
--
Radial clearance – connecting rod journal (mm)
0.02~0.05
0.1
Radial clearance – main journal (mm)
0.02~0.04
0.1
Main journal (mm)
57
--
Connecting rod journal (mm)
45
--
Crankshaft
Axial clearance – crankshaft (mm)
0.05~0.18
0.25
Connecting rod
Big end side clearance (mm)
0.10~0.25
0.4
Flatness—upper surface (mm)
0.05
0.1
Grinding limit (mm) – upper surface ▲ total
grinding of cylinder block and head (mm)
--
▲ 0.2
Total height (mm)
290±0.1
--
Inner diameter – bore (mm)
86.5~86.53
--
Cylinder block
Bore cylindricality (mm)
0.01
--
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Chapter 1 Main Data and Specification of VIEW Series Light-bus
·47·
Description
Standard
Limit
0.05OS
11.05~11.07
0.25OS
11.25~11.27
Enlarged and second
processed size (mm) –
valve
guide
hole
(intake/exhaust)
0.50OS
11.50~11.52
0.30OS
34.435~34.455
Enlarged and second
processed size (mm) –
intake valve seat ring
0.60OS
34.735~37.755
0.30 OS
31.935~31.955
Cylinder head
Enlarged and second
processed size (mm) –
exhaust valve seat ring
0.60OS
32.235~32.255
Alternator
Rotor winding resistance (Ω)
3~5
--
1.6.4 Tightening torque of engine bolts
Tightening torque for main bolts
S.N.
Tightening location
Torque (N-m)
Rocker arm cap bolt
3.84
Bolt-rocker arm and camshaft assembly
31.4
Rocker arm and camshaft
Thrust cap bolt
18.6
Cylinder head bolt
1.96+90°~ +90°
Drain plug
44.1
Oil pan
6.86
Oil strainer bolt/nut
18.62
Oil pressure switch
9.8
Oil discharge plug
44.1
Bracket bolt – oil filter
18.62
Front cover bolt
23.52
Plug
23.52
Flange bolt
36.26
Bolt – oil pump cover
15.68
Oil pump front cover
Screw – oil pump cover
9.8
Connecting rod nut
19.6 +90°~ +90°
Flywheel bolt
132.3
Rear cover plate mounting bolt
10.78
Bell cover mounting bolt
8.82
Oil seal cover mounting bolt
10.78
Crankshaft, cylinder block and
flywheel
Main bearing cap bolt
24.5 +90°~ +90°
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·48·
S.N.
Tightening location
Torque (N-m)
Bracket bolt
4.9
Throttle position sensor
3.43
Idle air valve bolt
3.43
Throttle body
Mounting nut – idle speed adjusting screw
2.94
Cooling fan bolt
10.78
Fan clutch bolt
10.78
Alternator fixing bolt
23.52
Brace bolt
23.52
Pivot nut
22.54
Crankshaft pulley bolt
24.5
Spark plug
24.5
Distributor bolt
12.74
Ignition coil bolt
23.53
Alternator, ignition system
Locating bushing bolt – camshaft pulley
9.8
Bolt -- front lower cover
10.78
Bolt – tensioner
48.02
Bolt – tensioner arm
21.56
Bolt – auto tensioner
23.52
Bolt—center pulley
35.28
Brace bolt – tensioner
48.02
Bolt – timing belt rear cover
10.78
Timing belt indicator
8.82
Fixing bolt – oil pump pulley
53.9
Bolt – crankshaft pulley
117.6
Fixing bolt – tensioner “B”
18.62
Fixing bolt – balance shaft pulley
45.08
Bolt – camshaft pulley
88.2
Timing belt
Fixing bolt – balance shaft pulley
45.08
Throttle
18.62
EGR valve
21.56
Injector and distribution pipe
11.76
Fuel return pressure regulator
8.82
Fuel system
Intake manifold
8.82
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Chapter 1 Main Data and Specification of VIEW Series Light-bus
·49·
S.N.
Tightening location
Torque (N-m)
Engine lug bolt
18.62
Engine coolant temperature sensing plug
29.4
Coolant outlet pipe joint bolt
19.6
Intake manifold bolt
19.6
Coolant temperature sensor
10.78
Intake manifold
Intake manifold bracket
13.72
Bolt – exhaust manifold cover
13.72
Joint bolt – coolant inlet pipe
23.52
Exhaust manifold nut (M8)
29.4
Exhaust manifold nut (M10)
49
Joint bolt – coolant bypass pipe
23.52
Bolt – coolant pipe sets
12.74
Bolt – thermostat case
23.52
Exhaust manifold
Water pump bolt
13.72
Tightening toque for ordinary bolts
Tightening torque for bolts and nuts
Torque ( N-m)
Bolt (with spring washer)
Flange bolt
Bolt diameter
Pitch
Head mark 4
Head mark 7
Head mark 10
Head mark 4
Head mark 7
M6
1.0
--
8.82
12.74
--
10.78
M8
1.25
10.78
17.64
29.4
13.72
23.52
M10
1.25
19.6
33.32
58.8
29.4
49
M12
1.25
35.28
60.76
105.84
53.9
88.2
Bevel pitch tightening torque
Torque ( N-m)
Pitch size
Light alloy
Cast iron, steel
NPTF 1/16
4.9~7.84
7.84~11.76
PT 1/8
7.84~11.76
14.7~21.56
PT1/4
19.6~29.4
34.3~44.1
NPTF 1/4
19.6~29.4
34.3~44.1
PT 3/8
39.2~53.9
53.9~73.5
PT 1/2
68.6~98
117.6~156.8
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·50·
Plastic area tightening method (bolt)
▲ The method is used on following bolts:
1. Cylinder head bolts
2. Main bearing cap bolts
3. Connecting rod bolts
▲ Tightening methods
Tightening the bolt for another 90~100 ° (two 90° for a cylinder head) after it has been tightened with
specified torque. Tightening method varies in different area. Observe the indicated methods in this book.
1.6.5 Sealant application
(1) Sealant
Sealant is used on relevant part of an engine. Special care should be taken to sealant applying amount,
applying location and state of applying face so as to obtain a good sealing. Insufficient applying will lead to poor
sealing and leaking, while over applying will lead to sealant overflow to block coolant / oil ducts. Correct sealant
applying requires consistent and even application on connecting surface, ensuring the whole connecting surface
has a layer of flat sealant.
(2) Remove sealant on connecting surface
It is usually easy to remove the sealant-combined parts. In some case, the process can apply a wood stick or
same tool to knock slightly to break the sealant on connecting surface. A flat and smooth sealant scraper can also
be used for removing (insert it into connecting surface), but be sure not to injure the surface. Use oil pan special
tool (MD998727) to remove engine oil pan.
(3) Clean the connecting surface
Clear dirt on the surface with a sealant scraper or a wire brush to make sure the surface is flat and smooth,
free from oil stain and dirt. Note to remove the sealant on mounting holes and thread holes.
(4) Applying tips
Apply sealant evenly on specified diameter to circle the mounting hole. Mount parts while sealant is still wet
(with 15 minutes). Leave enough time for sealant to harden after parts-mounting (around 1 hour). Do not apply oil
on applying area or run the engine during the period.
(5) Sealant application location
Location
Sealant rating
Coolant outlet pipe joint
MD970389 or equivalent
Coolant bypass pipe joint
MD970389 or equivalent
Coolant temperature unit
3MATD No. 8660 or equivalent
Oil pan
MD970389 or equivalent
Oil seal cover
MD970389 or equivalent
Oil pressure switch
3MATD No. 8660 or equivalent
Coolant temperature sensor
3M NUT LOCKING NO.4171 or equivalent
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Chapter 2 Vehicle Technical Maintenance
·51·
Chapter 2 Vehicle Technical Maintenance
With the improvement of vehicle technology and quality, vehicle maintenance becomes more important.
Vehicle maintenance should be performed regularly based on preventive and forcible principles.
Vehicle maintenance procedures are arranged according to gradual changes of vehicle technical conditions,
and they should be preformed before these conditions become deteriorated. Therefore, vehicle maintenance is of
preventive nature. To perform forced maintenance according to maintenance interval and technical requirements
will keep vehicle clean and tidy, pinpoint and remove timely potential faults so as to prolong vehicle service life.
2.1 Routine maintenance
Vehicle parts tend to become loose, worn-out and damaged during vehicle’s operation, which harm vehicle’s
performance. Routine maintenance carried out by driver will reverse these effects and keep vehicle in a proper
working condition. Driver keeps watching vehicle’s technical conditions by means of routine maintenance is very
important to drive safely and avoid accident.
2.1.1 Routine maintenance procedures
a.
Before, within and after using vehicle, check safety mechanism and fittings for fastening;
b.
Keep oil, air, fuel filters and battery surface clean;
c.
Avoid fuel, water, air and electricity from leaking.
These steps will keep vehicle in a clean look and good working condition.
Figure 2-1 Vehicle routine maintenance procedures
Category
Procedures
External 1. Check and clean mirrors outside driver cab, windshield and window glasses;
2. Check vehicle appearance, paint and corrosion on body;
3. Check tyre adjustment and wheel lugs’ fastening.
4. Check and adjust windshield wiper;
5. Check and lubricate door hinges and engine hood;
6. Check and adjust battery fluid level or check battery gravity indication.
Interior
7. Check vehicle for any leaks;
8. Check and adjust vehicle lights and signals;
9. Check and adjust horn;
10. Check wiper and windshield washer;
11. Check windshield defroster;
12. Check and adjust rear view mirrors and sun-shield;
13. Check steering wheel free travel and its operation.
14. Check gas pedal performance;
15. Check clutch/brake pedals free travels and their travel smoothness at depressing and releasing;
16. Check brake performance;
17. Check parking brake performance.
Engine
compartme
nt
18. Check and add engine oil;
19. Check and add engine coolant;
20. Check and add windshield washer fluid;
21. Check and add fluid to brake master cylinder and clutch master cylinder.
22. Check and clean air filter element.
23. Check engine intake / exhaust systems for fastening.
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·52·
2.1.2 Procedures for routine vehicle maintenance
Before, within and after using vehicle, it is suggested to perform routine maintenance procedures indicated
with following flow chart (figure 2-1):
Figure 2-1 Routine maintenance flow chart
2.2 First level maintenance
For 1
st
level maintenance, the interval or mileage are 6 months or 7500km-15000km respectively, whoever
comes first will override. First maintenance is carried out by service technician, it focuses on cleaning, fastening
and lubricating procedures beside these have made in routine maintenance procedures, and also includes checks
on safety-related devices such as brake and operating mechanisms.
2.2.1 Procedures for 1
st
level maintenance (see chart 2-2)
Chart 2-2 Procedures for 1
st
level maintenance
Engine
1. Check lubricating, cooling, exhaust and fuel systems for leakage or damage;
2. Replace engine oil and oil filter element;
3. Check coolant level and its frozen-proof capability, add coolant or adjust coolant concentration
if necessary;
4. Clean air filter, replace filter element if necessary.
5. Check drive belt condition and tension, adjust belt tension or replace belt if necessary.
Chassis
6. Check clutch pedal travel;
7. Check transmission for leakage or damage;
8. Check UJ boot for damage;
9. Check tie rod ball joint for fastening and clearances, and check if boot is damaged;
10. Check brake system for leakage or damage;
11. Check brake fluid level, add fluid if necessary;
Check and clean
Fastening and
lubricating
Remove faults
Back to normal operation condition
Check before driving
Checking during driving
Check after driving
Replenish fuel, air,
coolant and electricity
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Chapter 2 Vehicle Technical Maintenance
·53·
12. Check brake pad lining’s thickness;
13. Check and adjust manual brake devices;
14. Check tyre for pressure, wear or damage;
15. Check wheel lugs torque;
16. Check tyre tread depth.
cabin and
cargo body
17. Check door hinges and limit arms;
18. Check for any crack and loosening,
Electrical
system
19. Check performances of headlights, alarm lights, turning lights and horn;
20. Check and adjust headlight beams;
21. Check windshield wiper and washer, add fluid if necessary;
22. Check battery fluid level, add distilled water if necessary;
Road test 23. Check and test vehicle technical performance.
2.2.2 Requirements to First Level Maintenance
1. All exposed nuts and bolts at following units are complete, fastened and crack-free: engine FR/RR
suspensions, intake/exhaust manifolds, assisted exhaust brake system, heating and A/C systems, engine radiator,
tyres, propeller shaft, vehicle body, accessory brackets;
2. Steering arm, steering tie rod and brake controls operate well with complete fittings; no free plays on tie
rod ball joints, steering cross bearings and propeller shaft cross bearings;
3. Fluid levels of steering gear, transmission, transaxle should be 0-15mm under inspection doors (check
when engine is cold), vent hole should not be blocked; and flange nuts on transmission, final drive are fastened.
4. Lubricating fluid nozzles are complete and on their right mounting positions; all lubricating spots are fed
without being ignored,
5. Air filter element is clean and effective,
6. Tyre pressure is up to standard, no stone or other hard objects embedded in tyre.
7. Free travel of clutch and brake pedals comply with technical standards.
8. Lights, meters, horn and signals are complete and work well.
9. Battery fluid level is 10-15mm higher than plates, and battery vent hole unclogged and connectors
fastened.
10. No free play on wheel hub bearings,
11. Test run vehicle to check maintenance result. During test, there should be no abnormal noise on engine
and chassis, each control mechanism should meet technical demands; steering and braking system are sensitive
and reliable, and no loosening on fittings. After test run, check engine and chassis for oil, fluid, air and electricity
leakages.
2.2.3 Flow chart of 1
st
level maintenance
Flow chart of 1
st
level maintenance is indicated as follow:
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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
·54·
Chart 2-2 Flow chart of 1
st
level maintenance
2.3 Second level maintenance
After being used for a longer period of time or mileage (30000km or 12 months), vehicle should be checked
and adjusted thoroughly to retrieval its safety, power and fuel economy. For these purpose, vehicle is required to
be serviced completely with Second Level maintenance. Second level maintenance mainly focuses on checks and
adjustments besides these have made during first level maintenance, it also dismantles tyres to check and rotate.
To avoid vehicle’s early damage, vehicle will be diagnosed and analyzed technically before starting this
maintenance, and additional services or repairs based on diagnosed results may be added to maintenance
procedures. Professional service technician performs 2
nd
level maintenance.
2.3.1 Vehicle’s Technical judgment before 2
nd
level maintenance
Before 2
nd
level maintenance, there should be checks both with instruments and manually. These checks will
diagnose possible faults and assass vehicle’s technical condition, so as to determine additional procedures to 2
nd
maintenance’s basic procedures.
Basic methods to assass vehicle’s technical condition:
1. To know how the vehicle is driving. Service technician will ask driver how the vehicle is running (includes
engine power, abnormal noise, steering and braking performance, and oil consumption).
2. Review vehicle’s technical records that include records on driving, maintenance, check/test, assembly
repair and minor repairs during maintenance cycles.
3. Analyze results from instrumental check/test and manual check to pinpoint faults.
2.3.2 Diagnosing procedures before 2
nd
level maintenance
1. Engine check and test: performances at acceleration and deceleration, and possible engine’s smoke
emission and leakage;
2. Power-train check and test: clutch performance, transmission internal coordination, sealing conditions of
transmission and final drive. And also check transmission and final drive’s working temperature, and check for
any abnormal noise in the system.
3. Brake system: performances of main brake system, parking brake system, exhaust assisted brake system.
And check systems for any leakage.
4. Steering system check/test: steering wheel free travel, system performance, and check for any leakage.
Workshop check
Service operation
Material and labor time calculation
F
ill
ou
t
tec
hn
ica
l
fil
es
Maintenance schedule
Process check
Finish check
Delivery
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Chapter 2 Vehicle Technical Maintenance
·55·
5. Drive line system check/test: abnormal tyre wear, suspension bushes wear, and check bolts on body for
any loosening, rust and distort, also check body surface for corrosion and paint peel-offs.
6. Electrical devices check/test: dashboard gauges’ indication, oil pressure, coolant temperature, alternator
charging indication, A/C, and heating device’s operation.
Checking methods: with check/test equipment, vehicle tester and by experience.
2.3.3 Technical performance assassment and additional service before 2
nd
level maintenance
Basis for additional service Description to 2
nd
level maintenance, details see chart 2-3.
Chart 2-3. Basis for additional service procedures to 2
nd
level maintenance
Category
Location
Check results
Faults
Additional services
Poor valve seal
Adjust valve clearance,
grind valve
Piston ring wear, top and
side gap increase, piston
ring breakage;
Replace piston ring
Cylinder worn, large
clearance
between
pistons
and
cylinder
walls;
Check
and
measure
cylinder,
select
piston,
bore cylinder if necessary
Piston ring stuck, ring
bank broken
Replace ring and piston,
check cylinder
Piston head burnt, bore
scratched
Replace
piston
(adjust
advance
angle
of
injection), check cooling
system.
Larger fitting clearance
between
crankshaft
/connecting rod bearing,
abnormal sound
Remove to check, adjust
clearance,
check
crankshaft journal wear,
measure its roundness and
cylindrical.
Cut
if
necessary.
Worn-out camshaft and
its timing gear
remove to check camshaft
and timing gear
Larger fitting clearance
and
abnormal
sound
--piston, piston pin and
connecting rod cooper
bush
Remove
to
check
clearances among them,
replace if necessary
Low
oil
pressure,
abnormal sound due to
larger crankshaft bearing
clearance
Remove to check, repair if
necessary
instrument
al check
engine
1. Engine’s power is 75%
lower than rated value;
2. Cylinder pressure is 80%
lower than rated value.
3. Uneven
power
outputs
among cylinders;
4. Excessive crankshaft case
gas leakage
>40L/min(1000r/min)
>70L/min(2000r/min)
5. Vacuum value is low and
unstable;
6. Higher cylinder leakage,
air pressure drops up to 0.25
Mpa;
7. Oil consumption increases
(>0.3L/100km);
8. Low oil pressure;
9. Piston top burnt, cylinder
scratched;
10. Crankshaft
bearing
whining;
11. Piston pin whining;
12. Cylinder knock;
13. Valve noise.
Larger valve clearance,
worn valve mechanism
Adjust valve clearance,
check valve mechanism,
repair
or
replace
if
necessary
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