4Y Gas Engine Operation Manual

MPS Operation Manual of 4Y Gas Engine

Contents
Chapter 1 Technical Characteristics of Gasoline Engine ....................................................................... 3 1.1 Technical Specifications.................................................................................................................... 3 1.2 Performance Parameters.................................................................................................................... 4 1.4 External Characteristic Curve, Load Chain Curve, and Universal Characteristic Curve for 491Q (4Y) ......................................................................................................................................................... 5 Chapter 2 the Usage of gasoline Engine .................................................................................................. 7 2.1 The Engine Inspection before Start ................................................................................................... 7 2.2 The Start of Engine............................................................................................................................ 7 2.3 Check Engine during Running .......................................................................................................... 7 2.4 The Power-off of Engine ................................................................................................................... 8 Chapter 3 Operation and Maintenance of Gasoline Engine .................................................................. 8 3.1 Operation Caution ............................................................................................................................. 8 3.2 Break-in of Gasoline Engine ............................................................................................................. 8 3.3 Maintenance of Gasoline Lubrication System .................................................................................. 9 3.4 Maintenance of Engine Cooling System ......................................................................................... 10 3.5 Maintenance Cycle.......................................................................................................................... 10 Chapter 4 Engine Configuration, Maintenance and Adjustment ......................................................... 11 4.1 Cylinder Head ................................................................................................................................. 12 4.2 Cylinder Block ................................................................................................................................ 17 4.3 Connecting Rod Unit....................................................................................................................... 21 4.4 Air-distribution system .................................................................................................................... 24 4.5 Fuel Supplying System.................................................................................................................... 29 4.6 Lubricating System ......................................................................................................................... 31 4.7 Cooling System ............................................................................................................................... 33 4.8 Electrical System............................................................................................................................. 34 4.9 Crankcase Vent Unit........................................................................................................................ 40 4.10 Clutch and Operating System........................................................................................................ 41 Chapter 5 Trouble and Trouble Shooting ................................................................................................ 43 5.1 The Engine Is Difficult to Start ....................................................................................................... 44 5.2 Malfunction with Engine Accelerating............................................................................................ 45 5.3 Engine Power & Torque Not Enough.............................................................................................. 45 5.4 Engine Back Fire and Deflagrating ................................................................................................. 46 5.5 Engine Unstable at Idle Speed......................................................................................................... 47 5.6 Abnormal Noise from Engine.......................................................................................................... 48 5.7 Fuel Consumption Too High ........................................................................................................... 48 5.8 Oil Consumption Too High ............................................................................................................. 49 5.9 Engine over Heating........................................................................................................................ 49 5.10 Oil Pressure Too Low.................................................................................................................... 50 5.11 Firing Not Stops after Ignition Key Switches Off ......................................................................... 51 Chapter 6 Engines Preservation and Depreservation .......................................................................... 51 6.1 Long Storage of Engine................................................................................................................... 51 6.2 Start Engine after Long Storage ...................................................................................................... 52

MPS Operation Manual of 4Y Gas Engine

Preface
This instruction gives the technical data of 4Y gasoline engine, which are designed and manufactured by our company. It includes the main technical parameters of these engines, and their operation, maintenance, check, adjustment and malfunction analysis, it can be used for the people who operate and maintain the engines. 4Y gasoline engine have strong power, good fuel economy, low emission, small volume, light weight and compact structure with the new-type silencing design and air valve clearance automatic adjustment system, which greatly decrease the noise, they are ideal power source. As most of the components of 4Y and their model are general utility, the instruction is suitable for other types of engines. Please be noticed that there is possible difference between the content and the real structure because of the continuous innovation of the engines structure. They will be updated in the new revisions. Our new type 4Y and their innovated gasoline engines or good for domestic and overseas market benefit to their excellent power, reliability and fuel economy.

MPS Operation Manual of 4Y Gas Engine

Chapter 1 Technical Characteristics of Gasoline Engine

1.1 Technical Specifications

Model Type Cylinder Bore*stroke Shape of combustion chamber Type of cylinder liner Total displacement Average speed of piston Compression ratio Crank axle rotation direction Ignition angle Ignition order Inlet valve open Inlet valve close Exhaust valve open Exhaust valve close Lubrication model Total volume of engine oil (full in dry) Cooling model Without heater With front heater With front and rear heater Outside size(L*W*H) Net weight P/N performance 491Q(4Y) Line, 4-stroke water-cooling 4 91*86mm Cuneiform no liner 2.237L 13.19m/s 8.8 Left rotation 8-13 750r/min 1-3-4-2 15 53 53 13 Force-feed splash 4.2L Circulated pressed water cooling 7.9L 9.1L 10.1L 750*552*625 mm 150kg marked in left side of cylinder block

MPS Operation Manual of 4Y Gas Engine

1.2 Performance Parameters

Model Rated torque/ speed Max torque /speed Lowest fuel consumption Oil consumption Compression pressure/speed On rated power On max torque Power per liter Mass density 1.3 General Technical Requirement Fuel code Exhaust temperature(core pipe) Engine oil pressure At idle speed At 200050r/min At 300050r/min Max temperature of engine oil Outlet temperature of coolant Coolant code Opening pressure of radiator cover In take pipe vacuum speed Fast idle speed Idle speed Voted speed Air valve clearance Sparking plug electrodes clearance Fit new belt Fit used belt Forward chain looseness Crankshaft rotation moment 29.4kpa 170kpa 245.2-490.3kpa 110 85-105115 higher load good glycol coolant 73.6-103.0kpa 76kpa 2600100r/min 75050r/min 4200-4600r/min 0 0.8-1.0mm 5-7mm 7-8mm under 98N 30N.m Leadless gasoline 90 SH0041-93 740 491Q(4Y) 68kw/4200-4600r/min 177N.m-2800-3200r/min 285g/kw.h 2.0g/kw.h 1226kpa-250r/min 793.0kpa 983.0kpa 30.40kw/L 2.25kg/kw

MPS Operation Manual of 4Y Gas Engine Moment in fastening part Cylinder head-cylinder block Rock arm axle-cylinder head In take/exhaust pipe-cylinder head Sparking plug cylinder head Forward chain/camshaft Connecting rod-cover Crankshaft belt wheel bolt Flywheel crankshaft Other screw fasteners M6 M8 M10*1.25 M12*1.25 8N.m 18N.m 39N.m 71.5N.m 88N.m 25N.m 49N.m 18N.m 90N.m 49N.m 108N.m 83N.m

1.4

External

Characteristic

Curve,

Load

Chain

Curve,

and

Universal

Characteristic Curve for 491Q (4Y)

1.4.1 Spare part of gasoline engine Carburetor Gasoline pump Gasoline filter Engine oil pump Water pump Warmth saver Fan Sparking plug type Specification Electricity distributor Type Electric contact clearance Capacitor Alternator Starter Ignition coil
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double cabinet separated downward mechanic filmed paper filter cycloid rotor type centrifugal Open at 82 7 leaves or 5 leaves F6RTC M14*1.25 F7RTC

contacted 0.450.05mm 0.25uF 12V 65A 12V 1.4kw 12V

non contacted 0.300.05mm

12V 90A

MPS Operation Manual of 4Y Gas Engine 1.4.2 Dimension tolerance of the main components Line Part name 1 Cylinder hole and piston bottom axle(24m m to top)(by 3 line) 2 Con rod shell hole and axle neck by 3 line 3 Crankshaft main bearing hole and neck II I 58 +0.038 +0.022 +0.037 +0.022 +0.036 +0.022 +0.04 0 +0.04 0 +0.04 0 +0.04 0 +0.04 0 +0.016 22 +0.010 22 +0.003 58 0 -0.015 0 -0.015 0 -0.015 -0.025 -0.041 -0.025 -0.041 -0.025 -0.041 -0.025 -0.041 -0.025 -0.041 +0.006 0.004-0.013 0.025-0.081 0.10 0.021-0.051 0.022-0.052 0.022-0.053 0.10 48 +0.036 +0.02 48 +0 -0.015 0.02-0.051 0.10 91 III 491Q 4Y II I Standard size Tolerance Contain site 91 +0.01 -0 +0.02 +0.01 +0.03 +0.02 91 Contained site 91 -0.055 -0.065 -0.045 -0.055 -0.035 -0.045 0.055-0.075 Max wear Tolerance

91

91

58

58

II

58

58

Camshaft bearing hole and neck

46.5

46.5

II

46.25

46.25

III

46

46

IV V

45.75

45.75

45.5

45.5

Piston pin hole and pin

MPS Operation Manual of 4Y Gas Engine

Chapter 2 the Usage of gasoline Engine

To operate the engine properly will not only ensure the engine to run well but also for a long time.

2.1 The Engine Inspection before Start

Check the following items before starting the engine 2.1.1 Check the volume and leakage of cooling water and make sure that the water pipes are fastened well to it and fan belt is properly tens. 2.1.2 Check the volume of engine oil, its oil scale should between 2/4-3/4, adding more if it is inadequate. 2.1.3 Check the fuel tank to make sure that there is enough gasoline and that all pipes and connections are properly fastened. 2.1.4 Check whether the electric system is correct and safe, the storage battery is sufficient or not.

2.2 The Start of Engine

2.2.1 Engage the neutral shift and press the clutch in order to reduce the load when starting the engine 2.2.2 Switch the ignition key to start the engine 2.2.3 When engine starts, release the key and the key automatically to ignition position, when engine is cold started, engine will run at fast idle speed in the beginning and will run at normal idle speed when engine coolant temperature raise. 2.2.4 If the engine fails to start for several times, check it and determine the cause.

2.3 Check Engine during Running

2.3.1 Whether there are noises like knocks of other abnormal noises. 2.3.2 Whether there is burning smell which may attribute to overheat of starter or other elements 2.3.3 Whether there is any leakage from cooling and lubrication systems. 2.3.4 Whether the meters of oil pressure, water temperature, electric current, gasoline and the like can work.

MPS Operation Manual of 4Y Gas Engine

2.4 The Power-off of Engine

Before stop the engine which is running with big load, run it at lower speed for 2-3 minutes and then switch off the engine, in order to cool down the engine, otherwise some parts may become deformed due to sudden cooling down of the whole engine. In freeing season, add antifreeze to the cooling water and make sure it does not freeze if the car is parked in an open area, otherwise drain out all the coolant. Open the both cap: on the top of radiator and bleeder cock at the bottom. Do not leave until all the coolant is drained out. It is better to restart the engine to run for half a minute at low speed in order to remove water stored in water pump which may freeze the inlet.

Chapter 3 Operation and Maintenance of Gasoline Engine

3.1 Operation Caution

3.1.1 Maintain according to the method and regulations in this manual when operation. 3.1.2 Inspect the polarity of ground strap connection. This gasoline engine connect with cathode one. 3.1.3 New engine must be ran-in as required. It is not permitted to increase load abruptly. 3.1.4 Keep normal water temperature at 85-105. At medium speed, the normal engine oils pressure should be 245-490kpa. 3.1.5 The fuel must be 90# vehicle gasoline 3.1.6 It is not permitted to stop the engine after running 3-5minuted of low speed. 3.1.7 Before drain the cooling water, water temperature of coolant system must be decreased. Open the radiator cover first (otherwise the hot water will spout nod scald easily), then turn on the water valve at bottom of radiator and water switch at left front side of cylinder block.

3.2 Break-in of Gasoline Engine

The gasoline engines life related with working condition of newly running. The new engine on the vehicle should run 2500km on road work 50 hours on the test bench. Newly running of gasoline engine in vehicle should follow: 3.2.1 Check if engine oil, coolant, gasoline is enough, of not, must fill them, if leak exist, eliminate

MPS Operation Manual of 4Y Gas Engine leakage. 3.2.2 Running in vehicle should be on the cement of asphalt road, try not to be on other road especially on sand beach road. 3.2.3 New engine specifications of break-in refer to following table: Mileage(km) 0-200 201-800 801-1500 1501-2000 Load 25% of rated load 50% of rated load 75% of rated load Rated load Speed 3000r/min 3000r/min 3500r/min 4200r/min

3.2.4 When reaching following mileage (km), should change engine oil: 500 1,000 1,500 2,500 at 2,500kw should change engine oil collector 3.2.5 Fastening cylinder head bolt To prevent cylinder head gasoline leakage at air water, when running at 300km and 1000km, check the fastening moment of cylinder head bolt with the torsion spanner. Its fastening moment is 88N.m.

3.3 Maintenance of Gasoline Lubrication System

3.3.1. Engine oil Engine oil viscidity: SAE10w-30(winter), 15w-40(summer), or choose the brand of viscidity in the with environment temperature. Engine oil quality level (as per American petrol Academy): APZ, SE, SF. SG or higher level engine oil. After new engine running of 2500km or normal running of each time after 5000km. engine oil must be changed. Expanse life of engine is ensured only when maintained and change oil as per regulation. The recommended engine oil is: Imported shell brand, American Mobile, etc Note: different brand engine oil can not mix to use 3.3.2 Oil changes Except new running of engine, the engine oil should be changed according to regulated mileage. Normally change each 5000km on asphalt road. Drain the engine oil from oil tank when engine is still hot. Otherwise when engine become cool, some impurity will stay in the bottom of oil tank, hard to flow off wit the oil. If a lot of impurity exists in oil tank, clean the engine lubrication system with light spindle oil. It is absolutely prohibited to clean with gasoline or kerosene.
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MPS Operation Manual of 4Y Gas Engine When cleaning internal of engine, fill up 3.5-4.0L light spindle oil into oil tank, tear off all sparking plug, rotate crankshaft 2-3minutes, and then drain cleaning spindle oil entirely, Add new engine oil into tank as per regulation. 3.3.3 Change engine oil filter Change after newly running after 2500km, later change new one after running 10000km each.

3.4 Maintenance of Engine Cooling System

There must be enough coolant inside cooling system to ensure normal engine work well, so please check it before using vehicle each time. Add coolant of clear soft water, if not enough. It is prohibited to use hard water composing lots alkali of mineral material, bad liquid as well. 3.4.1 Change coolant: choose good glycol base coolant, and mix as per suppliers specifications. Change coolant each time after running 20000km, as per is the order as follow: (1)Open the radiator cover and radiator water switch, drain coolant (2) Dismantle water tank, drain coolant (3)Open the water switch of cylinder blocks left side, drain coolant (4)After drain all the coolant, close and fasten the water switch of radiator and engine (5)Add new coolant (6)Fasten radiator cover (7)Start engine and check if there is leakage (8)Check the coolant and add according 3.4.2 Replace and adjust the fan belt The fan belt is moving electricity generator, water pump and cooling fan. Low tensility or other faults will make engine over hot of generator less output. When belt is damaged, check, adjust and change as follows: (1) Stop engine loosen the adjustment belt, push the generator outward to make the belts, tensility reach the valve in regulation. (2)Measure fan belts tensility load 98N power on the middle of the belt between alternator and cooling fan, the belt deformation valve should be: New belt: 5-7mm, used belt:7-8mm (3)Fan belt should keep good status. If it can not work normally, replace the fan belt.

3.5 Maintenance Cycle

Please accord to the following procedure to assure engine work normally.
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MPS Operation Manual of 4Y Gas Engine 3.5.1 Everyday maintenance. (1) Check gasoline, cooling water, and height of coarse oil surface. Please add if necessary. (2) Clear ash and spilling electrolyte on the accumulator to assure small vent-hole expedite. Add distilled water betimes if electrolyte is lacking. (3) Checking whether there is oil leakage or water leakage after starting engine. (4) Checking whether joints of high-voltage and all the wires are loose. (5) After starting engine, check whether it can run normally. Assure instruments work normally. 3.5.2 Season maintenance. (1) Please add anti-freeze in winters. (2) Change concentration of electrolyte according to seasons.

Chapter 4 Engine Configuration, Maintenance and Adjustment

To ensure engines performance, repair and maintenance are necessary. To repair and adjust the engine correctly, please use the suitable equipments and special tools following the key points below.

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MPS Operation Manual of 4Y Gas Engine

4.1 Cylinder Head

4.1.1 To prevent from gasket air or water leakage, please inspect the torque of cylinder head bolts after 500km and 2,000km running for a new vehicle. The fastening torque is 88N.m (9kgf.m) (No. 1-10) and 19N.m (1.95kgf.m) (N0. 11-13).

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MPS Operation Manual of 4Y Gas Engine

4.1.2 Please follow the sequence in the picture to disassemble the rocker arm shaft assy, loosen the shafts bolts and nuts by 2-3 times, to avoid of breaking the shaft or damaging the bolts or nuts. Please follow the reverse sequence in the picture to install the rocker arm shaft assy., tighten the shafts bolts and nuts by 2-3 times with torque 24N.M (2.4kgf.m)

4.1.3 Loosen the cylinder head bolts 2-3 times gradually with reverse sequence as 4.1.1 while disassembling the cylinder head. Otherwise it may cause the cylinder head out of shape. 4.1.4 To keep from damaging the cylinder head, cylinder block and cylinder gasket while scraping off the stuffs on these parts and to avoid of cylinder gasket stuffs dropping into lifter holes, cooling water passage hole and bolts hole.

4.1.5 Cylinder gasket can be used once only. Please replace the gasket while reassembling the cylinder head.

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MPS Operation Manual of 4Y Gas Engine

4.1.6 Inspect the breaks on cylinder head and measure the flatness degree. The numeric value should be under 0.15mm. The flatness degree of manifold interface should be under 0.12mm. Please repair or change the cylinder head if the numeric value is up.

4.1.7 Inspect the fit clearance between valve pushing rod and valve guide. Please replace the valve and valve guide if the intake valve clearance exceeds 0.1mm and exhaust valve clearance exceeds 0.12mm. The standard clearance between valve pushing rod and valve guide should be 0.025-0.060mm for intake valve and 0.030-0.065mm for exhaust valve.

4.1.8 Inspect the valve conical surface if it is unevenness or if it has grooves or carbon deposition. Please modify the valves with 44.5conical angle. Please to be sure dont grind too much as you may damage the valve. Change the valve if the thickness is less 0.5mm (intake valve) and 0.8mm (exhaust valve) after grinding. Using grinding wheel to grind the valve rod to no more than 0.5mm if theres scratch on it. The standard length of total intake valve is 108.2mm, exhaust valve is 108.5mm.

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MPS Operation Manual of 4Y Gas Engine

4.1.9 Inspect the abrasion level and scratch on the valve seat. If necessary, please modify the valve seat. Firstly please inspect the abrasion level of valve guide and change it if the valve seat is over abrasion. Then grind the valve seat with grinding wheel as the numeric value shown in picture. The strip width between valve seat and valve conical surface is at the range of 1.2-1.6mm. The strip should be in the middle of conical surface. To grind it with 30or 45grinding cutter if it is up or with 60or 45grinding cutter if it is down. Finally, grind the valve and valve seat with grinding cream to make it fit tightly without leakage, and clean the valve seat, valve and inner hole of valve guide.

4.1.10 Inspect the free length of valve spring at 470.5mm. Check the uprightness degree of the valve spring using right-angle ruler and flat board. To be sure the degree should be less than 2mm, please change it if it exceeds 2 mm. measures the valve spring with spring tester. The elasticity while installing at 40.6mm should be 282.5N (28.8kgf). If it is less than standard please change.

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MPS Operation Manual of 4Y Gas Engine 4.1.11 Measure the gap between rocker arm and rocker arm shaft. The standard gap should be 0.013-0.041mm, maximum is 0.08mm. If the gap is more than the maximum, please change the rocker arm and rocker arm shaft.

Check the direction of back rocker arm shaft and assemble the rocker arm & spring with special tools according to the picture. If the contact surface of rocker arm and valve is abrasion, please grind it using whetstone or change it.

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MPS Operation Manual of 4Y Gas Engine

4.2 Cylinder Block

4.2.1 Inspect the breaks on cylinder block and measure the flatness degree. The numeric value should be under 0.05mm. If the flatness degree exceeds 0.05mm, please grind or change it.

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MPS Operation Manual of 4Y Gas Engine

4.2.2 Inspect the inner bore of cylinder block and measure the real dimension of the inner bore with cylinder-measure gauge from up to down. The maximum dimension should be Piston diameter Standard Enlarged 0.50mm for repairing Enlarged 0.75mm for repairing Enlarged 1.00mm for repairing Maximum cylinder inner diameter(mm) 91.24 91.74 91.99 92.24

If any inner diameter is more than the maximum, please re-bore it.

4.2.3 Please re-bore it if the cylinder wall is seriously scratched, burned or over worn. Select the most worn cylinder to confirm the size of enlarged piston while re-boring. The piston dimension is stamped on the top of the standard piston which is fixed on the engine. The specification is as following Line 1 2 Piston diameter(mm) 90.938-90.948 90.948-90.958
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MPS Operation Manual of 4Y Gas Engine 3 See the picture to measure the piston diameter. 90.958-90.968

The enlarged piston dimension is as 0.50, 0.75 and 1.00. See below Piston dimension Enlarged 0.50mm for repairing Enlarged 0.75mm for repairing Enlarged 1.00mm for repairing Piston diameter(mm) 91.438-91.468 91.688-91.718 91.938-91.968

Fit clearance between piston and cylinder is 0.052-0.072mm 4.2.4 The main bearings are not exchangeable and please dont install in reverse direction. To avoid installing in reversal, the order no and the mark TOWARDS FRONT are stamped on the main bearing.

4.2.5 It is fixed with crankshaft thrust washer gasket at the side of third main bearing seat and the side of third main bearing cover. Make sure the bush side with oil groove toward-out and dont fix it in reverse direction.

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MPS Operation Manual of 4Y Gas Engine 4.2.6 Theres oil grooves and oil hole on cylinder main bearing. Please dont fix it in reverse direction.

4.2.7 Take off the valve lifter by a metallic wire shown in picture and keep it in sequence to make it easy to reinstall.

4.2.8 Inspect the crankshaft clearance with standard 0.02-0.22mm. If the crankshaft exceeds 0.3mm please change the crankshaft thrust bush. The thickness of crankshaft thrust bush is as below. Standard Enlarged 0.125mm for repairing Enlarged 0.250mm for repairing 2.450-2.490mm 2.575-2.615mm 2.700-2.740mm

4.2.9 Inspect the fit clearance between crankshaft journal and main bearing with standard 0.020-0.051mm. If the clearance exceeds 0.10mm, please change the bearing or crankshaft. Please to be sure the standard main bearing is accordance with the dimension of main bearing hole which is stamped on right rear cylinder block undersurface (1st to 5th main bearing hole from

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MPS Operation Manual of 4Y Gas Engine front cylinder block). 3 dimensions of main bearing are corresponding with the marks 1, 2, and 3.

The standard diameter of crankshaft journal is 57.985-58.00mm. The maximum conicity and ovality is 0.02mm. Fastening torque of main bearing bolts is 78N.m (8kgf.m).

4.2.10 Inspect crankshaft bending degree Put front and rear crankshaft journal on the V-shape metal, measure the bending degree in the center of crankshaft journal using dial indicator. The maximum bending degree is 0.06mm. If it exceeds the maximum, please change the crankshaft.

4.3 Connecting Rod Unit

4.3.1 Theres mark on connecting rod and connecting rod cap, dont fix it exchangeable. The connecting rod and the semi-circle protrusion on connecting rod cap must be at the same side towards engine front.

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MPS Operation Manual of 4Y Gas Engine

4.3.2 Check the gap between big end of connecting rod and crankshaft at standard 0.160-0.312mm. Chang it if it is out of standard. Check the fitting clearance between crankshaft/connecting rod journal and connecting rod bearing at standard 0.020-0.051mm, maximum is 0.10mm. Change it if it exceeds the maximum. The standard dimension is corresponding with the size which is stamped on the side connecting rod or side connecting rod cap. 3 size for standard bearing as marked 6, 7 and 8. Standard diameter of crankshaft/connecting rod journal is47.985-48.00mm. The maximum conicity and ovality is 0.02mm.

4.3.3 Install the connecting rod corresponding with the marks on cap using torque wrench with 49N.m (dont move the crankshaft at this moment).

4.3.4 Inspect the bending degree using connecting rod adjuster with standard no more than 0.05mm at length 100mm. Please adjust or change it if it exceeds the maximum.

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MPS Operation Manual of 4Y Gas Engine

4.3.5 Inspect the abrasion of piston or piston ring groove. Please change it if necessary. Please change piston ring as you change the piston. Side gap of piston ring is 0.03-0.07mm. Change it if it is out of the standard. The split gap of piston ring is as below. 1st ring 0.027-0.039mm 2nd ring 0.040-0.055mm Oil ring 0.20-0.70mm Change it if it is out of the standard.

4.3.6 To avoid fixing in reversal direction, the small round hole in combustion chamber must be towards to the engine front. The open split must cross each other while installing the 3 rings in ring grooves. See picture.

4.3.7 The marks 1T on 1st ring and 2T on 2nd ring must be towards to cylinder head while installing.

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MPS Operation Manual of 4Y Gas Engine

4.4 Air-distribution system

4.4.1 Inspect the abrasion of rocker arm and rocker arm shaft. Change it if it is over abrasion. The gap between rocker arm and rocker arm shaft is 0.013-0.041mm, maximum is 0.08mm. Inspect the abrasion of contact surface between rocker arm and valve rod. Change or grind it if it is over abrasion.

4.4.2 Inspect the fitting clearance between hydraulic lifter and lifter hole in cylinder at standard 0.012-0.056mm, maximum is 0.1mm. Change it if it is out of standard or maximum. To inspect the lifter: put lifter in oil, press the lifter using pushing rod to let out the air in lifter, then
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MPS Operation Manual of 4Y Gas Engine the oil is filled inside lifter. Press the lifter seat again using pushing rod, if it is difficult to press down, it shows the lifter is good to use. If it is easy to press down, it shows the lifter is leakage, please change it. Otherwise the rocker arm hit the valve as PA while engine running. Let out the air inside lifter to fill with oil before the lifter is fixed on the engine. The lifter is a precise mechanical part matching with the lifter seat. Not allowed to exchange or disassemble. Clean it with clear oil.

4.4.3 Inspect the pushing rod if it is damaged or bent. Change it if necessary. The maximum bending degree of pushing rod is 0.3mm. Make the oil passage of inner pushing rod free instead of blocking. 4.4.4 Inspect the tension degree of timing gear at 98N (10kgf) with spring balance. Check the maximum gap of chain tension unit at 13.5mm. Change timing gear or timing chain if it is out of the maximum.

25

MPS Operation Manual of 4Y Gas Engine

4.4.5 Inspect the length of timing chain Measure it as shown in picture. The maximum length of chain is 291.4mm while adding force 49N (5kgf) on the spring balance. Change the chain if it exceeds the maximum length.

4.4.6 Inspect the diameter of sprocket Measure the diameter of sprocket (with chain) using slide gauge. Minimum length of sprocket (with chain) is as below. Crankshaft timing sprocket: 59mm Camshaft timing sprocket: 114mm. Please change the 2 sprockets and chains if the diameter is less than the minimum.

4.4.7 Inspect the abrasion of plug seal on chain tension unit. Measure the minimum thickness of plug seal at 12.5mm with slide gauge. If the thickness is less than the minimum, change the plug seal.

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MPS Operation Manual of 4Y Gas Engine

4.4.8 Inspect the abrasion of damper on chain with slide gauge at minimum 5mm on rubber damper. Change it if it is less than the minimum. 4.4.9 Install camshaft thrust plate Fix the camshaft thrust plate with 2 bolts and fasten with torque 18N.m (1.85kgf.m). Please note the installing direction shown in picture.

4.4.10 Inspect the bending degree of camshaft Put the front/rear camshaft journal on v-shape metal. Measure the bending degree of centre camshaft journal with dial indicator. Maximum bending degree is 0.06mm. Change it if it exceeds the maximum.

4.4.11 Inspect the protuberance degree of cam. First check the abrasion of cam surface. Please change it if necessary. If the abrasion is not serious, grind it using whetstone. Measure the protuberance length at the big head bevel of cam. The minimum protuberance length is as below. Intake cam: 38.26mm Exhaust cam. 38.27mm If the length is less than the minimum, please change the camshaft.

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MPS Operation Manual of 4Y Gas Engine

4.4.12 Inspect the fitting clearance between camshaft journal and cam shaft at the standard 0.025-0.081mm, and maximum at 0.1mm. if the fitting clearance exceeds the maximum, please change the crankshaft or camshaft.

4.4.13 Inspect the gap of camshaft. Fix the thrust plate and camshaft timing sprocket on camshaft and fasten the screw with stated torque. Measure the fitting clearance between thrust plate and front camshaft thrust surface with standard 0.07-0.22mm, the maximum is 0.3mm. If the clearance exceeds the maximum, please change the thrust plate or camshaft.

4.4.14 Fix the timing sprocket and timing chain. 1. The mark of small hole towards to engine front while installing camshaft thrust plate. 2. Turn the crankshaft, and make one piston position at the upper dead center (crankshaft moon

28

MPS Operation Manual of 4Y Gas Engine key towards up). Camshaft moon-key up-towards corresponding with the small hole mark on thrust plate. 3. Fix the timing chain onto the camshaft sprocket and crankshaft sprocket making the white strip mark on chain towards to the small hole mark on the 2 sprockets.

4.4.15 Mounting clearance of crankshaft position sensor. See 4.8.3. 4.4.16 Put some lubricant to the hole of seat while fix the chain tension unit.

4.5 Fuel Supplying System

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MPS Operation Manual of 4Y Gas Engine

1. Natural gas flow diagram

The gas inlet is connected with the natural gas pipeline, to connect the gas inlet of solenoid valve and natural gas pipeline with dedicated gas pipeline, the gas outlet port of solenoid valve is connected with Maxitrol RZ series zero pressure regulator, the maximum inlet gas pressure of which is 1psi (68mbar), and the outlet gas pressure is nearly zero, according to the requirements, the outlet pressure (-2.5mbar~3.75mbar) can be adjusted by turning adjusting bolt. Natural gas enters into the inlet port of the speed governor after regulated by a zero pressure regulator. The power regulation valve is installed in the inlet port of the speed governor to regulate the gas intake flow to change the air fuel ratio. The system has following advantages: By solenoid valve and zero pressure regulators regulation, the outlet pressure of gas is zero or negative, which makes engine easy to start, more stable and reliable. The speed governor is a mix of Venturi mixer and throttle body, easy to install and space-saving. The speed regulation is realized by the speed governors butterfly valve that controlling throttle valve, the built-in throttle return spring can ensure to close the throttle valve when failure occurs.

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MPS Operation Manual of 4Y Gas Engine

2. LPG flow diagram

It adopts IMPCOs solenoid valve and vaporizer, to connect the LPG tank and solenoid valve filter with gas copper tube, to install the vaporizer vertically, to fully vaporize the LPG by internal circulating water. The gaseous fuel enters into the inlet port of the speed governor after regulated by a zero pressure regulator. The power regulation valve is installed in the inlet port of the speed governor to regulate the gas intake flow to change the air fuel ratio. The system has following advantages: By solenoid valve and vaporizers regulation, the outlet pressure of gas is zero or negative, which makes engine easy to start, more stable and reliable. The vertical installation can effectively filter impurities in LPG, well avoid erosion of the impurities to diaphragm and prolong the service life. The speed controller is a mix of Venturi mixer and throttle body, easy to install and space-saving. The speed regulation is realized by the speed governors butterfly valve that controlling throttle valve, the built-in throttle return spring can ensure to close the throttle valve when failure occurs.

4.6 Lubricating System

4.6.1 Inspect the oil level Check the oil level in oil sump and the level must be at the center between the L mark and L mark. Check the leakage. If it is under the mark L, please add the oil to reach the F mark. The oil
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MPS Operation Manual of 4Y Gas Engine capacity is 4.2L. 4.6.2 Inspect the quality of oil. Check and change it if the oil is bad, polluted or diluted by water, otherwise it will cause the performance of the engine. Use SE 10W-3- or SE 15W-40 oil as the viscosity of oil shown in picture. Please dont mix the oil with other brand.

4.6.3 Inspect the pressure of oil. Inspect the pressure of oil while engine warming at the working temperature. At idle speed29kPa (0.3kgf/cm2) At 3000r/min 245-490kPa (2.5-5kgf/cm2)

4.6.4 Change the oil filter Take off the oil filter with special wrench. Put some oil on the oil filter seal; fix it on the oil filter seat and fasten the oil filter with special wrench. Please dont reuse the oil filter as it is one time use.

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MPS Operation Manual of 4Y Gas Engine

4.6.5 Inspect oil pump. As shown in picture, put a opener in oil pump and take the oil collector into oil sump. Turn the pump shaft in clock wise. The oil pour out from the hole. And block the hole with hand, thus its difficult to turn the shaft.

4.7 Cooling System

4.7.1 Inspect the cooling water in storage. If it is lack of cooling water, add it. If you use antifreeze liquid, please mix it according to the manual. 4.7.2 Fill full cooling water and start the engine. And stop the engine to fill full cooling water again till the water level dont change. 4.7.3 Inspect the quality of cooling water. 4.7.3.1 Change cooling water if it is dirty. 4.7.3.2 Inspect if the radiator cap and the filler choke are rusty. 4.7.4.1 Inspect the leakage of cooling system. 4.7.4.2 Inspect if the radiator and its hose are damage or out of shape. 4.7.4.3 Inspect if the hose clips are tight. 4.7.5.1 Inspect the belt fan and change it if necessary. 4.7.5.2 Inspect and adjust the tension degree of belt fan. Measure the center belt from alternator to water pump with torque 98N (10kgf). If the tension degree is out of the standard 7-8mm (5-7mm for new belt), please adjust it.

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MPS Operation Manual of 4Y Gas Engine

4.7.5.3 Please to be sure good contact with belt pulley.

4.7.6 Inspect the thermostat. Put thermostat into water and heat the water gradually, to check the opening temperature and raising length of the valve. Opening temperature of valve: 76 Raising length of valve: 8mm at 90 If the opening temperature rises, please change the thermostat. 4.7.7 Inspect the water pump Inspect the water pump and timing sprocket if it has split damage and if the water pump gear runs freely without noise. Obverse if the cooling water leak out from the cooling water out hole as shown in picture. 4.7.8 Inspect if the silicone oil fan is leakage.

4.8 Electrical System

4.8.1 Inspect he spark plug Take off the spark plug and clean it. Check if the spark plug electrode and thread are damaged. Change it if necessary. Spark plug type T4197J, F7TC M141.5

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MPS Operation Manual of 4Y Gas Engine Standard electrode gap: 0.8-1.1mm Installing with torque: 17.64N.m (18kgf.m) 4.8.2 Inspect the distributor Inspect ignition advance. Disconnect the vacuum tube and connect to vacuum ignition advance diaphragm. Add vacuum and check the status of ignition advance. If the ignition advance doesnt work well, please repair or change it. Inspect the regulator advance. Rotate ignition distributor with clockwise, and release it to check if the ignition distributor returns quickly with counterclockwise. Check if the ignition distributor is tight. 4.8.3 Inspect the distributor. Disconnect the distributor cap, ignition distributor and anti-dust cover. Measure the gap between signal rotor and coupling coil protuberance with standard 0.2-0.5mm. Adjust it if it is out of the standard. Inspect the coupling coil resistance with ohm gauge. Coupling coil resistance (cold): 420-550 (normal type) Integrative type: 200-250 Change it if it is out of the standard. Inspect the ignition coil resistance (integrative type) Measure the resistance of the 1, 2 terminals as shown in picture. The primary ignition coil resistance is 1.3-1.6 (cold). Measure the resistance of the 1, 3 terminals as shown in picture. The vice ignition coil resistance is 10.4-14 (cold). Change the coil if it is out of the standard.

4.8.4 Inspect the resistance of the 2 poles with ohm gauge. The primary ignition coil resistance is 1.3-1.6 (cold). Change it if it is out of the standard

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MPS Operation Manual of 4Y Gas Engine

Measure the resistance between positive pole and high voltage cable. The vice ignition coil resistance is 10.7-14.5 (cold). Change it if it is out of the standard.

4.8.4 Inspect the high voltage cable. Take the rubber sleeve and put off the high voltage cable from spark plug. Please be careful dont damage the conductor inside. Measure the resistance of high voltage at maximum 250,000. Check the terminals if the resistance exceeds the maximum and change it if necessary.

4.8.5 Fix the distributor Adjust the 1st piston to the upper dead center. Rotate the fuel pump gear and make the concave groove mark towards to the position as shown in picture. Rotate the distributor gear and make the concave groove mark towards to the concave groove mark on driving gear. Insert the distributor with the distributor gear towards to the mark on fuel pump gear.

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MPS Operation Manual of 4Y Gas Engine

4.8.6 Adjust the contactless distributor and ignition timing. Inspect the ignition advance angle with ignition advance tester at the engine speed 750r/min. The timing advance angle is 10-14at front upper dead center. Adjust the angle if it is out of the regulation. Loose the screw of distributor, rotate the distributor cover clockwise to advance the ignition timing. Rotate the distributor cover counterclockwise to delay the ignition timing. Fasten the screw with torque 1.85kgf.m. 4.8.6 Adjust the ignition advance timing of integrative distributor. Take off the vacuum from the front vacuum sub cavity and block it.

The adjust method is the same with above, but the ignition advance timing angle is 8at front upper dead center 4.8.7 Reinstall the vacuum tube to the vacuum front cavity box and recheck the ignition timing.

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MPS Operation Manual of 4Y Gas Engine

The ignition timing advance angle is 18-22at front upper dead center at the engine speed 75050r/min.

4.8.8 Starting system

Note: the following test must be finished within 3-5 seconds to avoid from the coils bursting out. 4.8.8.1 Take off the excitation coil from the connector. Connect the battery to the magnetic switch and check if the small gear moves towards out. If the small gear doesnt work, please change the magnetic switch assy.

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MPS Operation Manual of 4Y Gas Engine

Take off the negative pole from the connector and check if the small gear moves towards out. If the small gear returns inside, please change the magnetic switch assy.

Connect the battery and current gauge. Check if the starter moves stably with the small gear towards out and check if the current shown on Ampere gauge is under the standard. Standard current: 90A at 11.5V

4.8.9 Generating system

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MPS Operation Manual of 4Y Gas Engine

Take off the cables from generator. connect the negative pole of current gauge to generator. connect the positive pole to generator. Connect the negative pole of voltage gauge to ground. Connect the positive pole to generator. Speed the engine from idle to 2000r/min, check the volume of current and voltage on gauge. Standard current: 10A Standard voltage: 13.5-14.8V If it is not at the standard, please adjust or change the regulator.

4.9 Crankcase Vent Unit

The engine is fixed coercive crankcase vent unit. To clear the mixture, the mixture inside the crankshaft is blown to the intake manifold through the vent valve. It can avoid the fuel pollute the oil, and avoid the waste mixture and vapour erode the part surface. Please dont take off the crankcase at anytime. The crankcase consists of PCV valve, vent pipe connecting vent valve to the connector on carburetor heat insolating plate, and short pipes connecting the valve cover to inlet pipe of air filter. Avid the vent valve blocked. Not damaged connecting hose. No leakage.

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MPS Operation Manual of 4Y Gas Engine

4.10 Clutch and Operating System

4.10.1 Disconnect the gear, gear cover and release fork. Take off the thrust and pull out the gear and gear cover together.

Disconnect the disc. And plate. Please make mark.

4.10.2 Inspect if the parts of clutch plate are damaged or abrasion. Measure the depth of the rivets at minimum 0.3mm.

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MPS Operation Manual of 4Y Gas Engine

Check if the diaphragm spring is abrasion with micrometer. Maximum depth: 0.6mm Maximum width: 0.5mm Change the clutch plate assy. if necessary.

4.10.3 Install the clutch Fix the clutch plate on flywheel matching the fitting marks on flywheel and fasten the screws with torque 1.95kgf.m Check if the bottom of diaphragm is aligned with micrometer. Maximum gap: 10mm. Adjust it if the gap exceeds the maximum.

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MPS Operation Manual of 4Y Gas Engine

Chapter 5 Trouble and Trouble Shooting

After the engine has run for long time, some parts of the engine will wear or be damaged, which will cause its technical condition getting worse. When the technical specifications are not in the limited range, it indicates the engine is in trouble. The failure should be resolved in time as soon as it appears. If the engine works with malfunction, not only the power and economic capability will decrease, but also operation performance will change, even the accessories will wear quickly and the engine will be damaged. For some failures, such as air existing in oil system, clog of filter, loose of belt and so on that can be resolved after maintenance or adjustment. But for other failures, such as piston ring is further worn, cylinder gasket is damaged and so on, which cannot be resolved by maintenance or adjustment because of the limitation of the engine. The operator has to disassemble the engine or change accessories to resolve these failures.

Notes: (1) Usually failure is caused by inappropriate operation or missing maintenance. The operator should check if the engine is operated according to the regulations and maintenance guide when failure happening.

(2) Resolve failure in time. Firstly, find the reason of the failure. Then go to service station if the engine needs disassembly.

(3) For complicated failures, the technician should perform the process with professional instrument and equipment. If the clients are not qualified to adjust or maintain the engine, they should go to service station.

(4) It is not allowed for the engine to work with "sickness". Engine working with "sickness" will not only damage the parts and decrease the life span of engine, but also cause accident.

The following malfunction, cause and solution are for reference only.

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MPS Operation Manual of 4Y Gas Engine

5.1 The Engine Is Difficult to Start

Malfunction & Cause 1. Malfunction with Start System (1) battery voltage weakness (2) Battery loose connection (3) Fuse cutting off (4) Malfunction with starter (5) Malfunction with ignition switch 2. Malfunction with Ignition System (1) wrong ignition timing (2) Coil(s) damaged (3) Hi-voltage cable damaged or loose connection (4) Low-voltage cable damaged or loose Solution 1. (1) Charge battery (2) Tighten all connections (3) Change fuse (4) Change or repair starter (5) Change ignition switch 2. (1) Readjust (2) Replace coil(s) (3) Replace hi-voltage cable or fasten connection (4) Replace low-voltage cable or fasten connection (5) Adjust clearance (6) Dry or clear away the carbon deposit

connection (5) Improper clearance of spark plug electrodes (6) Wateriness of the spark plug(s) or carbon deposit on the electrodes (7) Insulator of the spark plug(s) damaged (8) Distributor cap or contact (s) damaged

(7) Replace the spark plug(s) (8) Replace the distributor

3. Malfunction with Fuel-supplying System (1) Over-rich gas mixture (2) Malfunction with fuel pump (3) No fuel supply to the carburetor (4) Improper working of the choke valve of the carburetor (5) Idle speed solenoid valve not open (6) Fuel over flow from the carburetor (7) Fuel supply hose plugged

3. (1) Make the gas mixture lean. Clean the air supply system. (2) Check or replace fuel pump (3) Check the fuel supply system (4) Adjust or repair the choke valve (5) Check the idle speed solenoid valve (6) Repair the float and needle valve (7) Clean the hose

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MPS Operation Manual of 4Y Gas Engine

5.2 Malfunction with Engine Accelerating

Malfunction & Cause 1. Malfunction with Carburetor (1) Fuel level too low (2) Gas mixture too lean (3) Malfunction with accelerating pump (4) Malfunction with power valve (5) Piston of the power valve improper working (6) Throttle opening not enough Solution 1. (1) Adjust the fuel level (2) Adjust or repair carburetor (3) Check or repair accelerating pump (4) Check or repair power valve (5) Replace the spring of the piston (6) Adjust the connecting rod

mechanism 2. Malfunction with Ignition System (1) Spark plug improper working (2) Hi-voltage cable damaged (3) Coil(s) damaged 3. Malfunction with Engine (1) Valve(s) leaking or damaged from burning (2) Improper cylinder pressuring (3) Cylinder gasket leakage (4) Intake manifold leakage 2. (1) Check or replace spark plug(s) (2) Replace hi-voltage cable (3) Replace Coil(s) 3. (1) Repair or change valve(s) (2) Repair or change related parts (3) Change cylinder gasket (4) Inspect manifold and its gasket, fasten the nuts

5.3 Engine Power & Torque Not Enough

Malfunction & Cause 1. Improper Compressing (1) Valve(s) leaking (2) Hydraulic lifter(s) improper working (3) Valve spring weakness or damaged (4) Cylinder head gasket leaking (5) Piston rings sticking together or damaged (6) Over wear of piston(s) or cylinder liner(s) 2. Malfunction with Ignition System (1) Improper timing
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Solution 1. (1) Grind the valve(s) (2) Check or replace hydraulic lifter(s) (3) Replace valve spring(s) (4) Replace cylinder head gasket (5) Replace piston rings (6) Repair or replace related parts 2. (1) Adjust timing

MPS Operation Manual of 4Y Gas Engine (2) Spark plug(s) improper working (2) Clean, adjust or replace spark plug(s) 3. Improper Fuel Supply (1) Dust in fuel tank (2) Fuel supply hose plugged (3) Fuel filter plugged (4) Fuel pump improper working (5) Fuel passage or carburetor metering bore plugged 4. Throttle Body Opening Not Enough 5. Improper Gasoline Quality Adjust the operating mechanism Follow the regulation on the gasoline quality 6. Intake Manifold Leaking 7. Leaking from Ventilation Valve of the Check intake manifold and gasket Fasten the connection 3. (1) Clean or replace fuel tank (2) Blow or clean the fuel hose (3) Replace fuel filter (4) Repair or replace fuel pump (6) Dismantle or replace carburetor

Crankshaft Chamber 8. Carburetor inlet air not enough (1) Air filter plugged (2) Throttle body opening not enough 8. (1) Clean the air filter housing and element (2) Repair or adjust the mechanism 9. Engine Over Heating Find 5.9 for details

5.4 Engine Back Fire and Deflagrating

Malfunction & Cause 1. Malfunction with Ignition System (1) Improper timing (2) Loose connection (3) Spark plug(s) improper working (4) Improper spark plugs Solution 1. (1) Adjust timing (2) Fasten connection (3) Clean, adjust or replace spark plug(s) (4) Use the right spark plugs 2. Improper Air/fuel Ratio (1) Gas mixture too lean 2. (1) Clean and adjust carburetor avoiding leakage (2) Fuel supply system plugged
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(2) Find 5.3.3 for details

MPS Operation Manual of 4Y Gas Engine 3. Malfunction with Valve System. (1) Valve(s) leaking or pasted together (2) Hydraulic lifter(s) in poor condition (3) Valve spring(s) weakness 4. Cylinder Head in Poor Condition (1) Carbon deposit in combustion chamber (2) Cylinder head over heating and poor cooling (3) Cylinder head damaged 3. (1) Grind or change valve(s) (2) Change or clean hydraulic lifter(s) (3) Change valve spring(s) 4. (1) Clear away carbon deposit (2) Remove air inside the cooling system (3) Replace cylinder head 5. High-voltage Wires in Wrong Order or Wires Damaged Reconnect or change the wires

5.5 Engine Unstable at Idle Speed

Malfunction & Cause 1. Malfunction with Carburetor (1) Malfunction with the metering bore (2) Fuel passage or low speed fuel metering bore plugged (3) Needle valve in wrong position or leaking (4) Choke valve not working (5) Solenoid valve not open 2. Air Leakage (1) Intake manifold leaking (2) Leaking from ventilation valve of crankshaft chamber (3) Loose bolts of carburetor 3. Malfunction with Ignition System 4. Malfunction with Valve System (1) Air leakage from valve(s) (2) Improper working with hydraulic lifter(s) (3) Over clearance between valve stem & valve guide 5. Air Leakage from Cylinder Head Gasket
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Solution 1. (1) Adjust idle speed screw (2) Clean (3) Clean, adjust or replace (4) Check and repair (5) Check solenoid valve

2. (1) Check intake manifold or replace gasket (2) Fasten connection (3) Fasten the bolts Find 5.1.2 for details 4 (1) Grind valve(s) (2) Replace hydraulic lifter(s) (3) Replace valve stem & valve guide

Replace cylinder head gasket

MPS Operation Manual of 4Y Gas Engine 6. Problem with Fuel Supply System Find 5.3.3 for details.

5.6 Abnormal Noise from Engine

Malfunction & Cause 1. Knocking Due to Early Timing 2. Problem with Hydraulic Lifter(s) 3. Piston Pins too Loosing 4. Over Wear from Piston(s), Piston Ring(s) and Cylinder(s) 5. Over Wear from Bearing(s) of Connecting Rod(s) 6. Over Wear from Main Bearing(s) 7. Over Wear from Crankshaft Thrust Washer Set 8. Over Clearance Between Camshaft and Camshaft Thrust Plate 9. Over Wear from Timing Chain and Timing Pulley 10. Improper Working of Chain Tensioner 11 Too Much Carbon Deposit in Combustion Chamber of Cylinder Head 12. Gasoline Do Not Meet Regulation 12. Use the qualified gasoline 10. Replace Tensioner 11 Clear away the carbon deposit 9. Replace 6. Check and replace bearing(s) 7. Repair or replace thrust washer set 8. Replace crankshaft Thrust Plate 5. Check and replace bearing(s) Solution 1. Adjust the timing angle 2. Check or replace hydraulic lifter(s) 3. Replace piston pin(s) or piston(s) 4. Check, replace or horning cylinder(s)

5.7 Fuel Consumption Too High

Malfunction & Cause 1. Fuel Leakage from the Fuel Supply Hose 2. Air Filter Plugged 3. Problem with Carburetor (1) Fuel level too high (2) Idle speed too high (3) Improper opening of Choke Valve (4) Leakage from power valve Solution 1. Fasten connections & clips 2. Check or replace air filter 3. (1) Check fuel level (2) Adjust idle speed (3) Check and repair choke valve (4) Check power valve

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MPS Operation Manual of 4Y Gas Engine (5) Loosing bolts or metering bore (6) Gasket damaged 4. Problem with Ignition System (1) Improper timing (2) Malfunction with spark plug(s) 5. Improper Compressing 6. Clutch skidding (5) Replace bolts or metering bore (6) Replace gasket 4. (1) Adjust timing (2) Check or replace spark plug(s) 5. Find 5.3.1 for details Check and adjust clutch

5.8 Oil Consumption Too High

Malfunction & Cause 1. Oil Leakage (1) Oil discharge screw loosing (2) Bolts of oil sump loosing (3) Gasket of oil sump damaged (4) Bolts of chain chamber loosing (5) Sealing gasket of valve chamber damaged (6) Oil seals of crankshaft damaged (7) Bolts of oil pump loosing or gasket damaged (8) Bolts of oil filter loosing or gasket damaged 2. Piston Oil Rings Over Wearing or damaged 3. Over Wear of Pistons with Cylinders 4. Oil Seals of Valve Stem Damaged 5. Over Wear of Valve Stems with Guides 6. Ventilation System of Crankshaft Chamber Plugged 7. Long Time Engine Running at High Speed with Low Load 7. Avoid long time engine running at high speed with low load Solution 1. (1) Fasten oil discharge screw (2) Fasten bolts (3) Replace gasket (4) Fasten bolts and replace gasket (5) Replace gasket (6) Replace oil seals (7) Fasten bolts or replace gasket (8) Fasten bolts or replace gasket 2. Replace piston oil rings 3. Repair or change 4. Replace oil seals 5. Replace valves & guides 6. Check & clean

5.9 Engine over Heating

Malfunction & Cause 1. Cooling Liquid Not Enough Solution 1. Add enough cooling liquid

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MPS Operation Manual of 4Y Gas Engine 2. Fan Belt Loosing or Damaged 3. Problem with Water Pump 4. Problem with Thermostat 5. Radiator, Cylinder Block, Cylinder Head and/or Related Passages Plugged or Leaking 6. Problem with Silicon Clutch 7. Late Timing 8. Oil Not Enough or Viscosity Too Low 9. Too Much Carbon Deposit in Combustion Chamber of Cylinder Head 10. Exhaust System Plugged 10. Clean or replace related parts 6. Check or replace 7. Adjust timing 8. Add oil or replace oil 9. Clean out the carbon deposit I 2. Adjust belt tension or replace belt 3. Check or replace 4. Replace thermostat 5. Clean, repair or replace parts

5.10 Oil Pressure Too Low

Malfunction & Cause 1. Oil Leakage 2. Oil Not Enough or Viscosity Too Lean 3. Oil Temperature Too High Solution 1. Find 5.8.1 for details 2. Find 5.9.8 for details 3. Cool down the engine and repair the cooling system 4. Problem with Pressure Reducing Valve of Oil Pump 5. Problem with Oil Pump 6. Oil Strainer Plugged, Oil Leaking from the Connection 7. Oil Filter Plugged 8. Problem with Oil Pressure Sensor 9. Problem with oil Pressure Gauge 10. Over Wear of Main Bushings and Crankshaft Bearings 11. Oil Leaking from Rocker Arm Shaft or Chain Tensioner 11. Check and fasten 7. Replace air filter 8. Replace oil pressure sensor 9. Replace oil pressure gauge 10. Replace bushings or bearings 5. Repair or replace oil pump 6. Clean and fasten connection 4. Repair the valve

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MPS Operation Manual of 4Y Gas Engine

5.11 Firing Not Stops after Ignition Key Switches Off

Malfunction & Cause 1. Engine Over Heating Solution 1. Run the engine without load until water temperature drops below 80. Then switch off the igniting key 2. Spark Plugs Over Heating 3. Too Much Carbon Deposit in Combustion Chamber of Cylinder Head 4. Late Timing 5. Problem with Carburetor (1) Maladjustment of the idle speed or fast idle speed (2) Problem with solenoid valve for idle speed 4. Adjust timing 5. (1) Check and adjust (2) Check or replace solenoid valve 2. Choose the right spark plugs 3. Clear away the carbon deposit

Chapter 6 Engines Preservation and Depreservation

6.1 Long Storage of Engine

6.1.1 Discharge all the cooling liquid from the radiator and water pump 6.1.2 Dismantle battery 6.1.3 Make sure the engine in good condition and clean the engine 6.1.4 Pull out the spark plugs. Then inject about 30 grams of dry oil. Crank the engine for 15-20 revolutions and install the spark plugs again. 6.1.5 Daub anti-rust grease to the parts which are easy to rust like flywheel, clutch plate & etc. 6.1.6 Loosen the fan belt. 6.1.7 Drain out all gasoline and clean fuel tank. 6.1.8. Pack the engine with water proof material. Put some drier inside the bag. 6.1.9 Put the engine in a room with good ventilation and keep away with corrosive goods. 6.1.10 Check the engine every 2 months for corrosion. Take measures to avoid corrosion.

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MPS Operation Manual of 4Y Gas Engine

6.2 Start Engine after Long Storage

6.2.1 Clear away the grease. 6.2.2 Refill coolant. 6.2.3 Refill oil. 6.2.4 Refill gasoline. 6.2.5 Check the battery liquid. 6.2.6 Connect the battery with engine. Apply Vaseline to the contacts. 6.2.7 Check and fasten all connections. 6.2.8 Follow the previous procedures to start the engine.

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