Huafengdongli R4100D1 Operation And Maintenance Manual Download Page 74

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Summary of Contents for R4100D1

Page 1: ...HUAFENGDONGLI RSeries Diesel Engine OPERATION AND MAINTENAN ANUAL Shandong Weichai Huafeng Power Co Ltd...

Page 2: ...be exchanged between both two types of diesel engine R series diesel engine features easy adaptation to meet the various needs of matched equipments according to the requirement of users It can be fur...

Page 3: ...pplied for reference And the picture in the manual cant be the accord ance of check upon delivery The manual is compiled by Wang Jinghai Zhao Ruian Yang Lin Sun Chuanhai Wang Luhai Dou Yuxiang Jiang B...

Page 4: ...eping the water in the oil cooler should be forbid den 5 Never run the diesel engine without and air cleaner so as to prevent the unfiltered air from entering the cylinders 6 The engine must be filled...

Page 5: ...erprise standard 13 The No of production license of this series diesel engine is XK06 205 00160 XK06 205 00161 XK06 205 00279 14 The position of safety warning marks 1 Theres a guard against burning m...

Page 6: ...d adjusted characteristic curve for Model R6105G R610SGt R610SZG and R610SZGl diesel engine used for engineering machine Fig 7 9 8 Load characteristic curve for Model R6100ZDl and R6100ZD2 diesel engi...

Page 7: ...le CHAPTER N Technical maintenance of diesel engine 61 1 Working day maintenance 2 First grade technique mainenance 3 Second grade technique maintenance 4 Third grade technique maintenance 5 Technique...

Page 8: ...ddenly 14 Charged dynamo out of order 15 Starting motor be in trouble 16 Governor in trouble 17 Turbocharger in trouble 18 Air compressor in trouble 19 Clutch in trouble CHAPTER VI Installation instru...

Page 9: ...Fig la Longitudinal sectional drawing for R4100 R4105 die el engine 1...

Page 10: ...1 I L AlIIIJ r 7 7 7 L J Fig lb Crcss sectional drawing for R4100 R4105 diesel engine 2...

Page 11: ...Fig 2a longitudinal s ctional drawing for R6100 R6105 diesel engine 3...

Page 12: ...4 Fig 2b Cross sectional draw ng for R6100 R610S diesel engine...

Page 13: ...h 240 230 220 210 1 j I i 1 l v V il V v V v J V V V v J V I 1 I r F r Pe kW 70 60 50 40 30 20 1200 1400 1600 1800 2000 2200 2400 1 r TTlin Fig 3 Speed and speed adujsted cha racteristic curve for Mod...

Page 14: ...350 ge g kW h 240 230 220 210 1 I r I I I I I I I V I V I J r _ Pe kW 110 90 70 50 30 1200 1400 1600 1800 2000 2200 2400 n r min 6 Fig 4 Speed and speed adjusted characteristi curve for Model R6105 R6...

Page 15: ...e g kW h 280 270 260 250 240 230 220 210 J 4 V 1 I i A V I A V f 0 v l 1 t Me N m 280 240 200 160 120 80 40 10 20 30 40 Pe kW Fig 5 Speed and speed adjusted characteristic curve fo Model R4105T and R4...

Page 16: ...230 220 210 y K 1 n V V l A V 1 t V 1 r J I J V v r Pc kW 60 50 40 30 20 1000 1300 1600 1900 2200 2500 2800 n r min 8 Fig 6 peed and speed adjusted characteristic curve for Model R4105G diesel engine...

Page 17: ...__ 1 J Ii I I r i I J I I I JII I I i JI 1 I I J l1 V 1 Pe kW 110 90 70 50 1200 1400 1600 1800 2000 2200 2400 2600 n T min Fig 7 Speed and speed adjusted haracteristic curve for Model R6105G R6105Gl...

Page 18: ...ge g kW h 360 340 320 300 280 260 240 220 1500r min V r 800r min v 1 1 1 t L 20 40 60 80 Pe kW Fig 8 Load characteristic curve for Model R6100ZDl and R6100ZD2 diesel engine for generating sets 10...

Page 19: ...I J J I I r I I 4 I V l C V 4 l 17 V J V V V r f V V glkw h 340 320 300 280 260 240 220 1000 1200 1400 1600 1800 2000 n r min Fig 9 Propellant characteristic curve for Mo el R4105C R4105CI R610SC and...

Page 20: ...0 340 320 300 280 260 240 220 1 1 1 R4105Zpi f R4105P R6105P t 1 0 r 1 _ I 10 20 30 40 50 60 70 Pe kW Fig 10 Load characteristic curve for Model R4105P R4 105ZP and R610SP diesel engine for stationary...

Page 21: ...d Working Ih OutpuVSpeed KW r min Condition 2H Output Speed KW r min 3611500 42 1800 47 1500 8 Highest Idling Speed r min 1575 1890 1575 9 Lowest Idling Stable SPeed r min e 600 10 Max Torque Speed N...

Page 22: ...Irurbocharged Na urally 6 Aspirated Aspirated 55 2200 70 2200 7 47 1500 55 1800 45 2000 48 2000 48 2000 1575 E 1890 2376 2160 5 2376 8 600 9 275 1400 350 1600 252 1400 268 1500 246 1540 10 957 933 69...

Page 23: ...min 4SI2000 50 2000 6012200 8 Highest Idling Speed r min E 2160 s 2376 9 Lowest Idling Stable SPeed r min 600 10 Max Torque Speed N mlr min 265 1400 26311500 300 1540 11 Average Effective Pressure Kp...

Page 24: ...60 2400 59 2400 59 2400 55 2400 7 50 2200 35 1500 2595 2688 2376 1700 8 E 600 9 270 1560 275 1560 270 1560 275 1680 250 1680 10 681 693 681 681 635 630 647 11 243 247 E 243 239 231 12 E 1 63 13 600 14...

Page 25: ...min 43 2000 35 1500 42 1500 8 Highest Idling Speed r min E 2200 E 1700 E 1575 9 Lowest Idling Staljle SPeed r min 600 10 Max Torque Speed N mlr min 11 Average Effective Pressure Kpa 596 647 176 12 Rat...

Page 26: ...Naturally 6 Aspirated Aspirated 7 46 1800 40 1500 56 1500 56 1500 48 2000 48 2000 48 2100 Ei1890 lS7S 1575 1575 E 2I60 2200 E 2200 8 600 9 258 1500 258 1500 10 708 739 1034 1034 665 665 633 II 231 231...

Page 27: ...on 12H OutpuVSpeed KW r min 8 Highest Idling Speed r min 2376 2160 E 2376 9 Lowest Idling Stable SPeed r min Ei600 10 Max Torque Speed N m r min 286 1400 301 1400 300 1400 11 Average Effective Pressur...

Page 28: ...Aspirated 82 2200 105 2200 85 2400 81 2400 85 2400 81 2300 82 2200 7 2376 2376 2592 2688 2484 2576 2376 2420 8 e 600 9 410 1400 525 1600 390 1680 375 1650 380 1680 377 1610 410 1560 10 689 882 655 62...

Page 29: ...2300 52 1500 8 Highest Idling Speed r min 2860 2484 1700 9 Lowest Idling Stable SPeed r min 600 10 Max Torque Speed N mlr min 380 1820 389 1725 11 Average Effective Pressure Kpa 604 643 641 12 Rated W...

Page 30: ...d Naturally Turbocharged 6 Aspirated Aspirated 7 65 2000 53 1500 88 2000 72 2000 58 1500 68 1800 84 1500 22 E 1700 2266 Ei2160 E 1575 1890 1575 8 Ei600 9 10 601 653 814 665 715 698 1035 11 E 239 231 2...

Page 31: ...2H OutputiSpeed KW r min 7511500 100 1500 8 Highest Idling Speed r min lS7S Ei1575 2592 2688 9 Lowest Idling Stable SPeed r min 600 10 Max Torque Speed N mlr min 510 1600 11 Average Effective Pressure...

Page 32: ...y 6 Aspirated Aspirated 103 2800 96 2800 125 2600 147 2600 110 3000 8512200 90 2200 7 3080 3080 2860 2860 Ei2376 E 2376 3300 8 Ei600 9 400 1800 390 1800 520 1700 621 1700 424 1400 451 1400 403 1950 10...

Page 33: ...njector tightening nut 80 lON m 4 Main adjusting data Valve lash cold state Air intake valve 0 3 40mm Exhaust valve O 40 0 S0mm Valve timing crankshaft rotating angle Air intake valve open 12 before t...

Page 34: ...and connecting rod bushing Shaft 36 0 025 0 050 0 15 6 Hole 36 7 Piston pin and piston pin seat hole Shaft 36 g i Hole 360 0 008 0 002 0 0011 0 05 8 The first compression ring and ring grave 0 065 0 1...

Page 35: ...arance of tooth 19 0 60 flank 0 10 0 15 Shaft f 9 5 20 Air intake valve and valve guide 0 20 Holet 4 9 50 0 019 Shaft 4 9 5 21 Exhaust valve and valve guide 0 30 Holet 4 9 50 0 019 Shaft 4a5 22 Rocker...

Page 36: ...f cylinder when disassembly and assembly When sealing condition be tween valve and valve seat is not good lapping is necessary and should be clean be fore assembly After long time operating the width...

Page 37: ...be changed each other For this reason each main bearing cover has its sequential number and a triangle symbol the arrow of triangle is to the front Each upper mainbeatihg half has oil holes on it The...

Page 38: ...er parts of con necting rod including connecting rod ele ment connecting rod bear ing are all in terchangeable Each piston of diesel engine has two com pression rings and one scraper ring The first co...

Page 39: ...l temperature is prohibited othervise the pinhole may be ruined Piston pin should stagger 1mm to non pressure plane relative to piston center to de crease piston knock Connecting rod body and connecti...

Page 40: ...sy of engine rubber shrunk in torque insulator element can be used if necessary Flywheel is positioned by cylindrical pin and fastened on the rear end of crankshaft by seven high strength bolts Flywhe...

Page 41: ...pump timing gear and oil pump gear Camshaft timing gear may drve air compressor gear of work pump gear and bydraulic pump gear if necessary Hydraulic pump gear may drive the front and the rear hydrau...

Page 42: ...iesel engine more fuel will be burned thoroughly and the out put of the diesel engine will be increased accordingly The turbocharger is combined with constant pressurt single inlet turbine bousing or...

Page 43: ...ing compressed with plunger mate to high pressure through fuel cock and high pres sure fuel pipe it enters into injector When the pressure is high enough to open the needle valve nate of the injector...

Page 44: ...cup the water in the cup should be drained off regularly 8 3 Fuel injection pump There is type A of high pressure pumps The body of the type A pump is an all in one piece style as shown in Fig 7 The q...

Page 45: ...o prevent the delivered fuel quantity and the fuel quantity in cylinders from being changed if necessary the adjustment should be o perated on a high pressure pump test bench 8 4 Governor There is a R...

Page 46: ...antity of air intaked we can install the inlet manifold pressure compensator on the governor of the turbocharged type diesel engine thus avoid exhausting smoke 8 5 Advancer The 0285 0286 type advancer...

Page 47: ...valve mate but their assemblies can be exchanged When the injector is installed on the cylinder head there is a copper washer on the front this can assure the tightness 9 Lubricating System Fig 9 Inj...

Page 48: ...ure gauge 13 turbocharger 14 push rod valve tappet 15 rocker arm and arm shaft 16 valve and valve guide 17 main oil passage 18 camshaft and bushing 19 piston injection cooling oil passage For the supe...

Page 49: ...valve should be installed in the oil groove of the engine block as seen in Fig 12 to limit the low temperature and the high viscosity of the oil protect the oil pressure gauge thus assure the oil pum...

Page 50: ...er inlet tube 2 Water outlet tube l Oil coolor uppor Qvcr Fig 14 Oil filter 1 Oil filter seat 2 Oil filter wick 3 housino Fig 13 Oil fil1 er 1 Oil filter seat 2 Oil filter wick 3 housing 4 Bypass valv...

Page 51: ...ng water from the cooler flows back into the cylinder head through the hose and the cooled oil fol ws into the main oil passage through the oil filter When using the engine we should often observe whe...

Page 52: ...fan and the whole circulation is achieved If the temperature of he wat r is too low the thermostat will shut down the water could t enter into the up per water case of the radiator and it flows back i...

Page 53: ...block To avoid the water leak into the rotating bearing a water relief hole is drilled under the seat hole of the pump bearing and a water throw ring is installed on the bearing to make the water leak...

Page 54: ...water heat exchanger Marine diesel engine adopts sea water and fresh water heat exchanger The struc ture is shown as Fig 17 11 Sea water inl t Fig 17 Sea water and fresh water heat exchanger 1 Double...

Page 55: ...ment must meet the voltage pequirrement of the e lectric system In order to improve the diesel engine 5 coaly starting capacity the coolly starting equipment installed at the air inlet pipe can be use...

Page 56: ...lator is to keep the voltage at the range of 13 5 14 5V or 27 29V respectively when the speed of the 14V or 28V generator changed These two types of generators adopt FTIII FT211 AND FT226 voltage regu...

Page 57: ...be turned pn At the start position only starting motor will be turned on To loose the switch it will automatically moves back to the 0 position and the whole circuit will be cut off 12 Air compressor...

Page 58: ...is blocked up by screw plug A compound multi functional load discharge valve is contacted between the air compressor and the air storage tube The compressed air enter into the load discharge valve fir...

Page 59: ...isc type spring is adopt ed as elasticity compensation shown in Fig 20 Fig 20 clutch assembly 1 dutch housing 2 fixed pressure disc 3 friction slice 4 screw cover 5 moveing pressure disc 6 pressure le...

Page 60: ...with the fixed pressure disc by the inner teeth and the outer teeth Through the rear moving pressure disc moves axially with the pressure lever the engagement and disengagement of the clutch is achie...

Page 61: ...ert the lock pin into the corresponding gap 2 ush the clutch to the engagement state use a special rule to test whether the distance be een the rear moving pressure disc and the top end or the sleeve...

Page 62: ...stipulation the working place should be spacious well Nenti lated clean and rain proof If the diesel engine is going to be laid up for a long time it should be preserved and stored as the below metho...

Page 63: ...water inside the oil precipita ted to the botto m then pich up the top clean fuel oil the fuel oil must be strictly fil tered when filled to the fuel tank 2 2 Lubricationg oil The diesel engine should...

Page 64: ...me dium The antifreeze mixture can be mixed with water and alcohol according to the below ratio Volume ratio of antifreeze mixture water alcohol 90 10 80 20 70 30 60 40 50 SO Ice point of antifreeze m...

Page 65: ...n for starting 3 1 The diesel engine should be thoroughly checked before starting Closed attention should be paid to see whether foundation bolts and the connection with the driv en equipment is rigid...

Page 66: ...tch counterclockwise to the charging position 4 6 Check the oil pressure after the engine starts t the oil pressure in ilde speed nev er be lower than O lmpa After the engine starts for 5min stop it a...

Page 67: ...l thak valve 6 2 It is forbidden to stop the engine suddenly at high water temperature 6 3 It is not permitted to stop the engine by shutting off the valve of the fuel tank so as to preventiong the ai...

Page 68: ...ve power take out equipment have already wearied in preliminarily so cus tomers can reduce the wearing in time properly 8 Safe and technical operating instruction 8 1 It forbidden to let the person wh...

Page 69: ...rking hours lOOOh or for the cargo vehicle traveling distance over S km 5 Technique maintenance on winter use I Working day maintenance 1 1 Check the oil surface in the oil sump oil bath type air filt...

Page 70: ...3 Clean the oil filter replace the element 3 4 Replace the oil in the air compressor 3 5 Clean the fuel tank oil delivery pump screen and pipe clean the fuel filter element with clear fuel 3 6 If the...

Page 71: ...ean the carbon deposit 4 11 Check the clutch t clean the inside dust deposit oil dirt and replace the lubrica ting grease 4 12 Check the turbocharger clean the parts wipe off the cabon deposit and tes...

Page 72: ...system 2 Too much water in fuel 3 Leakage in fuel passage 2 Vent the air from the system withe the fuel delivery pump check whether t her is leakage of fuel and air in the fuel pipes 3 Check and repa...

Page 73: ...on deposited inside the engine 12 Exhaust manifold not expe dite 4 Abnormal noise during engine operation Trouble cause and its featre 1 Injecting time is too early to 4 Check and adjust the governor...

Page 74: ...at low speed 6 The axile gap of the crankshaft is too large t pounding notse when idling 7 Valve spring broken push rod bent valve clearance too large and so on dis orderly sound or lignt and rhythmi...

Page 75: ...ting fuel too much to burns thoroughly Thouble cause ahdits feature 5 1 Blue smoke 1 Lubricating oil flees piston ring installed inversely choked or worn out to badly 2 Clearance between valve and pip...

Page 76: ...cause and its feature 1 Engine is over loaded 2 oil is insufficient or overmuch 3 Piston ring leaks heavily 4 Oil cooler choked inside dirt 68 2 Adjust the fuel delivery amount of the fuel injection...

Page 77: ...high Trouble cause and its feature Remedy 1 Water temperature gauge or 1 Inspect and replace inductor be in trouble 2 Cooling water is not enough 9 Trouble in the injection pump Trouble cause and its...

Page 78: ...supply of the injection 2 Add suitable thick washer 4 1 Repair or peplace 2 Clean or replace 3 Tighten replace parts 3 1 Clean or replace 2 Clean is too 3 Adjust the pressure adjusted washer Remedy 1...

Page 79: ...ible 3 Speed floating 1 Speed adjusted spring distorted 2 Fly hammer assembly loosen 3 Too large friction resistance inside the governor 4 Too Large axile lash of the injection pump camshaft 4 Overrun...

Page 80: ...d brus contacted badly 3 Dytnarro silicon parts out of order 2 Insufficient charging or charging un steadily 1 Brush contacts badly insufficient spring pressure oil dirt on slip ring 2 Transmitting V...

Page 81: ...and tighten the contacting point 2 Recharging 3 Clean the contacting surface of the commutator 4 Repair 2 1 Replace bearing bush 2 Clean the contacting surface of the commutator 3 Clean and tighten th...

Page 82: ...t 2 Black or blue smoke 1 Passage of air filter or air pump dirty 2 Altitude or temperature too high 3 Fuel return pipe of the turbocharger choked 3 Abnormal noise insde the turbocharger 1 Pounding so...

Page 83: ...ch in trouble Trouble cause and its feature I Clutch slips 1 Friction dsc V OTl out or bum out 2 Oil dirt on friction disc 2 Clutch disconnects not completely 1 Pressing lever worn out 2 Adjusting pla...

Page 84: ...he diesel engine is connected with alternator air compressor etc a clearance of 3 Smm should be kept between the diesel engine flywheel and the connecting disc of the applied machines in case the pull...

Page 85: ...Corred connedion Wrong connection Fig 22 x 77...

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