Hyundai (HG190, HG220) C Series Engines Operation and Maintenance Manual - PDF

Hyundai (HG190, HG220) C Series Engines Operation and Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Hyundai (HG190, HG220) C Series Engines Operation and Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :149
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Hyundai (HG190, HG220) C Series Engines Operation and Maintenance Manual – PDF DOWNLOAD

Table of Contents
Section 1‐lntroduction 12
To The Owner and Operator 13
About the Manual 13
How to Use the Manual 13
Symbols 14
Illustrations 14
General Safety Instructions 15
Definition of Terms 16
Section 2‐Engine and Component Identification 17
Engine Identification 18
Engine Dataplate 18
Cummins Engine Nomenclature 18
Injection Pump Dataplate 19
General Specifications 19
ELECTRICAL SYSTEM 21
Engine Diagrams 22
Section 3‐Operating Instructions 24
General Operating Instructions 25
Starting Procedure Matrix 25
In‐Line Pumps‐General Information 26
Bosch In‐Line Pump Identification 26
Winterfronts 27
Shutters 27
Cold Weather Starting Aids 28
Cold Weather Starting With Starting Fluid 28
Starting Procedure With Mechanical Or Electrical Metering Equipment 28
Using Starting Fluid Without Metering Equipment 28
Cold Weather Starting with the Flame Start System 29
Cold Weather Starting with the Electric Grid Heater 29
Starting Procedure After Extended Shutdown or Oil Change 30
Operating the Engine 30
Engine Operating Range 31
Engine Shut‐down Procedure 31
Section 4‐Maintenance Guidelines 32
General Information 33
Tool Requirements 33
C Series Engine Maintenance Schedule 34
Section 5‐Daily Maintenance Procedures 36
General Information 37
Fuel‐Water Separator 37
Draining 37
Lubricating Oil Level 37
Checking 37
Coolant Level 38
Checking 38
Drive Belt 39
Inspection 39
Cooling Fan 39
Inspection 39
Section6‐Maintenance Procedures at 10,000 Kilometers [6,000 Miles], 250 Hours or 3 Months 40
General Information 41
Lubricating Oil and Filter Change Interval 41
Lubricating Oil and Filter 42
Changing 42
Air Intake System 45
Inspection 45
Charge Air Cooler 45
Air Cleaner 46
Restriction 46
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Section7‐Maintenance Procedures at 19,000 Kilometers [12,000 Miles], 500 Hours or 6 Months 47
General Information 48
Fuel Filter 48
Replacement 48
Fuel System 49
Bleeding 49
Low Pressure Lines and Fuel Filter(s) 49
Venting 49
High Pressure Lines 50
Venting 50
Antifreeze Concentration 50
Checking 50
Coolant Additive Concentration 51
Checking 51
Coolant Filer/DCA4 Corrosion Resistor Cartridge 51
Coolant Filter 51
Replacement 51
Section 8 ‐ Maintenance Procedures at 38,000 Kilometers [24,000 Miles], 1000 Hours or 1 Year 53
General Information 54
Valve Clearance 54
Adjusting 54
Drive Belt Tension 57
Checking 57
Drive Belt, Tensioner Bearing and Fan Hub 58
inspection 58
Section 9 ‐ Maintenance Procedures at 77,000 Kilometers [48,000 Miles], 2000 Hours or 2 Years 60
General Information 61
Cooling System Maintenance 61
Coolant Draining 61
Coolant System Flushing 62
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Coolant System Filling 63
Vibration Damper 64
Inspection 64
Air Compressor 64
Inspection 64
Air Compressor Discharge Inspection 64
Section 10‐System Diagrams 66
General Information 67
Fuel System 67
Lubricating Oil System 68
Lubricating for the Turbocharger 68
Lubricating for the power Components 69
Lubricating for the Overhead 69
Coolant System 70
Air System 71
Section 11‐Troubleshooting 72
Troubleshooting Procedures and Techniques 73
Troubleshooting Symptoms Charts 73
Engine Will Not Crank or Cranks Slowly 73
Engine Difficult to Start or Will Not Start (Exhaust Smoke Present) 74
Engine Charts, But Will Not Start‐No Smoke From Exhaust 75
Engine Start But Will Not Keep Running 76
Engine Will Not Shut Off 76
Rough Idle, Warm Engine 77
Engine Surges at Idle 77
Lubricating Oil Pressure Low 78
Lubricating Oil Pressure Too High 78
Lubricating Oil Loss 79
Coolant Temperature Above Normal 79
Coolant Loss 80
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Coolant Temperature Below Normal 81
Contaminated Coolant 81
Contaminated Lubricating Oil 82
Fuel or Oil Leaking from Exhaust Manifold 82
Exhaust Smoke Excessive Under Load 83
Exhaust White Smoke Excessive 84
Engine Will Not Reach Rated Speed When Loaded 85
Low Power 86
Engine Misfiring 87
Fuel Knock 88
Excessive Fuel Consumption 88
Excessive Vibration 89
Excessive Engine Noises 89
Alternator Not Charging or Insufficient Charging 90
Section 12‐Adjustment, Replacement and Repair 91
Repair Procedures 92
Repair Tools Required 92
Cooling System Repair Summary 92
Drive Belt 93
Replacement 93
Belt Tensioner 93
Replacement 93
Fan Pulley 94
Replacement 94
Water Pump 94
Replacement 94
Coolant Thermostat 97
Replacement 97
Fuel System Repair Summary 101
Fuel System Components 102
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Cleaning 102
Low Pressure Fuel Line 102
Replacement 102
Fuel Filter Head Adapter 103
Replacement 103
Fuel Transfer pump 103
Replacement 103
High Pressure Fuel Lines 104
Replacement 104
Venting 105
Fuel Drain Manifold 106
Replacement 106
Injectors 106
Replacement 106
Fuel Shutoff Solenoid 108
Replacement 108
RSV Governor fuel Shutoff Solenoid 108
RQVK Governor Fuel Shutoff Solenoid 109
Fuel Injection Pump 110
Replacement 110
Injection Pump‐Idle Speed Adjustment 116
RSV Governor 116
RQV and RQVK Governor 117
Air System Repair Summary 118
Intake Air Piping 118
Replacement 118
Intake Manifold Cover and Gasket 119
Replacement 119
Aftercooler and Gasket 120
Replacement 120
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Charge Air Cooler 122
Intake Manifold Pressure‐Check 122
Intake Manifold Temperature‐Checking 122
Leak Check 123
Turbocharger 123
Replacement 123
Exhaust Manifold and Gaskets 127
Replacement 127
Lubricating Oil System Repair Summary 129
Lubricating Oil Pressure Regulator, Valve and Spring 129
Replacement 129
Lubricating Oil Thermostat 130
Replacement 130
Lubricating Oil Cooler Element and Gasket 130
Replacement 130
Electrical System Repair Summary 132
Starting Motor 133
Replacement 133
Alternator 133
Replacement 133
Section 13 ‐Specifications and Torque Values 136
General Specifications 137
ELECTRICAL SYSTEM 138
Fuel Recommendations/Specifications 139
Engine Lubricating Oil Recommendations 140
Lubricating Oil Viscosity Recommendations 140
Arctic Operation 141
Coolant Recommendations 142
Antifreeze 142
Supplemental Coolant Additives 142
Coolant Test Kits 143
DCA4 Unit Maintenance Guide 143
Filter Selection 144
Lubricating Oil Filter 144
Fuel Filters 144
Engine Component Torque Values 145
Lubricants and Sealants‐Engine Assembly 147
Capscrew Markings and Torque Values 148
Capscrew Markings and Torque Values‐Metric 149

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