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226B

系列柴油机维修保养手册

Maintenance Manual for

226B

series Diesel Engine

13mm 套筒扳手
13mm Sleeve wrench
装好喷油泵齿轮，拧紧螺栓。
Put on the gear of fuel injection

pump and tighten the bolt on it.

13mm 套筒扳手
13mm Sleeve wrench
装好喷油泵检查孔盖板，拧紧螺

栓。

Put on the inspection hole cover

of fuel injection pump and tighten the
bolt on it.

Summary of Contents for DEUTZ 226B Series

Page 1: ...1 226B The signification of the code of 226B series diesel engine Application code T B D 2 26 B 6 G net cylinder liner Diesel engine serie number Water cooled Inlet air method D D natural aspiration...

Page 2: ...D Generating set CD Marine generating set G Construction machinery T Tractor T B D 2 26 B 6 C A B C Power feature Code A B C EURO II emission 6 3 3 4 4 Number of cylinders 6 3 refers to 3 cylinder whi...

Page 3: ...gauge temperature gauge warning indicating lights and other instruments shall be checked every day for their normal function Daily inspection and maintenance should be done according to this instruct...

Page 4: ...eeded The usable coolant must be under the conditions of temperature 30 or 50 pH value 7 8 neutral general hardness value 5 15 d 9 27 f hardness If the coolant cannot meet the above mentioned requirem...

Page 5: ...necessary to use the excessive fuel device Start up in low temperature Flame preheat starting device with electronic control 23 50s 850 950 25 When the water temperature of the engine is below 23 open...

Page 6: ...il pressure gauge and coolant temperature meter Stop the engine if the pressure and temperature cannot meet the standard requirement 60 100 Note Diesel engine can not continue to run when the coolant...

Page 7: ...V belt is cracked or scratched Check whether the accessories are fixed well Check whether the water or oil is leaking Check whether the charging indicator light is in order 2 2 Periodic Maintenance Re...

Page 8: ...ours h Running Kilometer 1 The first inspection 30 50 1500 2000 Periodical inspection 250 Every 250 1 10 000 1 Level 1 Maintenance 500 Every 500 2 20 000 2 Level 2 Maintenance 1000 Every 1 000 4 40 00...

Page 9: ...ve clearance Tighten pipe clamps Tighten V belts Routine checking Oil Oil filter Tighten V belts 1 Level 1 maintenance Oil Oil filter Fuel filter Valve clearance Air filter Air intake system Tighten p...

Page 10: ...ance Air filter Air intake system Tighten pipe clamps Tighten V belts Inspect and adj ust the injection fuel pump on test bench 4 Level 4 maintenance Oil Oil filter Fuel filter Coolant Air filter Valv...

Page 11: ...Manual for 226B series Diesel Engine R 2 3 Maintenance Record Engine number Engine number Engine number Engine number Date Running Kilometers hours or interval hours Actual Kilometers Maintenance cont...

Page 12: ...e Contents Of Diesel Engine 3 1 Daily Maintenance Preventive maintenance should be done everyday in order to understand the engine s condition Before starting the engine should check the oil level and...

Page 13: ...limit it is not allowed to start the engine 5 After the engine stopped inspect the oil level at least 5 minutes later in order to ensure the oil can flow back to the oil sump 3 25 3 5 4 6 6 The oil v...

Page 14: ...coolant level Inspect the coolant level through the vitreous view hole if the coolant is not sufficient open the inlet cover and fill into the coolant Note When opening the inlet cover must press dow...

Page 15: ...an Check whether the plastic fan is distorted For steel fan check whether the rivet loosened and the vane is curved to ensure reliable running Check V belt Inspect the V belts with your eyes to find i...

Page 16: ...The following contents will be added except daily maintenance items Replacement of the oil and oil filter The oil will be polluted after using the pollution contents is of accordance with the consumpt...

Page 17: ...er to clean the impurities containing in oil Note The oil should be drained off when it is hot 7 25 3 9 5 4 13 6 Dismantle draining plug screw prepare to collect the oil of 7 25 L 9 25 L and 13 L resp...

Page 18: ...26B series Diesel Engine R Tool The special wrench forfilter Clean the end surrounding of the filter and remove it Install the new oil filter Note Adjust the seal ring and smear some lubricating oil O...

Page 19: ...ring and then install the whorl plug 7 25 3 9 5 4 13 6 Fill the cleaned oil into diesel engine and let it reach the upper scale mark of dipstick The capacity of oil sump is 7 25 L 9 25 L or 13 L resp...

Page 20: ...gine R Run th e engine at idling speed and check the filter to find whether it leaks or not 5min Stop the engine and make the oil run into the sump from the upper parts 5 minutes later then check the...

Page 21: ...ve wrench Dismantle the cylinder head cover OT Turn diesel engine slowly make the upper scale mark on flywheel housing align the 0T scale mark on flywheel and at this time let the piston of the first...

Page 22: ...s 0 20 mm 0 30mm The clearance of exhaust valve is 0 30 mm 60 Note When check the clearance of valve the engine should be at the Cool condition its temperature is less than 60 When the clearance guage...

Page 23: ...ances of 4 cylinder engine and the 1st 2nd 3rd 6th 7th and 10th of 6 cylinder engine from crankshaft pulley end Adjust the clearance by using the feeler and tighten the lock nuts of the rock arm Reche...

Page 24: ...st the 4th 5th 7th and 8th valve clearances of the 4 cylinder engine and the 4th 5th 8th 9th 11th and 12th of the 6 cylinder engine counted from the crankshaft pulley end Loosen the lock pinch nut of...

Page 25: ...ve wrench Install the gasket and cylinder head cover 10 15N m The tightening torque of bolt is 10 15N m Check the tension of V belts 4 5kgf 20mm Measure the flexibility in the max span of poly V belt...

Page 26: ...mm the poly V belt is shown loose Unscrew the tensioning bolt and the lock nut re tension the V belt and then tighten the tensioning bolt and the lock nut Check the rubber hose in the cooling pipeline...

Page 27: ...B series Diesel Engine R 3 3 500h 2 Add the following maintenance contents every 500h 20 000 Kilometers Replace the fuel filter Special spanner for filter Clean the fuel filter around the head and tak...

Page 28: ...e low pressure fuel passage and the fuel filter Unscrew the fuel draining screw fixed in the fuel inlet of injection pump Press on the plunger of fuel transfer pump until no air exists in diesel fuel...

Page 29: ...speed and full load If this resistance reaches the maximum permissible limited value the filter element shall be cleaned or replaced according to the requirements of manufacturer Caution Never operat...

Page 30: ...r element from the air filter clap it at end lightly and make dust on it fall down Alternatively blow it inversely with compressed air from inner to out Nole Don t blow off the air filtering paper Don...

Page 31: ...m Intake and exhaust system Fuel supplying system 226B To understand the main system flow chart of the engine will give help to you for operating and maintaining the engine 4 1 Lubricating system 1 St...

Page 32: ...Main oil passage 3 Oil to the main crankshaft joumal 4 Connecting rod journal 5 The main journal of crankshaf 6 Oil to connecting rod beating 7 The branch oil passage passing to main Dearing 8 Sub pa...

Page 33: ...ystem 1 Oil flowing from the oil branch passage 2 Tappet oil hole 3 Push rod oil hole 4 Oil hole of rocker arm bolt 5 Oil hole of rocker arm 12 Lubricating fuel injection pump with oil from secondary...

Page 34: ...eries Diesel Engine R 4 2 Cooling system 1 Water pump inlet 2 Water pump 3 Water jacket of cylinder block 4 Oil cooler Lubricating turbocharger 1 Oil from the main oil passage 2 Oil inlet of turbochar...

Page 35: ...wing from water jacket of cylinder block 3 Cylinder head gasket 4 Cooling water passing through the water passage of cylinder head 5 Cooling water outlet 1 Coolant flowing from cylinder block 2 Thermo...

Page 36: ...er into supercharger no supercharger unless supercharged engine 2 Pressurized air through inter cooler no inter cooler for supercharged and nonintercooled engine 4 Intake manifold 5 Intake valve 1 Exh...

Page 37: ...stem 1 Fuel from the fuel tank 2 Fuel delivery pump 3 Fuel filter 4 Fuel delivery pipe 5 Air limiting pipe of fume limiter Only existing in supercharger 6 Fuel injection pump 7 High pressure fuel pipe...

Page 38: ...linder engine and 14 pcs for 6 cylinder engine sleeve wrench 22mm 6 For a 6 cylinder engine tightening is done in two times in sequence as shown in the above figure 70N m Firstly in 70 N m 90 4 3 4 2...

Page 39: ...leeve wrench Following such tightening sequence Step 1 Cylinder head must be aligned after amounted i e the sides of both air inlet and exhaust outlet should be on the same plane Step 2 The cylinder h...

Page 40: ...e 2 1 3 4 2 3 4 1 4 cylinder engine 2 3 4 1 6 3 4 5 2 1 6 6 cylinder engine 3 4 5 2 1 6 3 And as per Step 2 the course of screw down shall be carried out in three times 0 2 0 6mm 160 5mm Caution In ev...

Page 41: ...olt M12x1 5 19mm Total nos 2 pcs M12x1 5 for each connecting rod Tool 19 mm sleeve wrench 30N m Step 1 Tighten tightly then tighten these bolts symmetrically with a torque of 30N m 60 5 Step 2 Turn th...

Page 42: ...el Bolt 6 M16 24mm 6 pieces M16 24mm sleeve wrench Step1 Firstly screw on symmetrically 285 295N m Step 2 Screw down symmetrically in 285 295N m torque The bolt under the expected torque must be chang...

Page 43: ...ew on the bolts M10 80 85N m M12 140 145N m Step 2 Screw down the bolts in such tightening torque for M10 80 85N m and M12 140 145N m Replace the bolt under the required torque 2 The flywheel housing...

Page 44: ...pieces M10 15mm sleeve wrench 60N m Step 1 Tighten the bolts with torque 60N m symmetrically 90 100 125N m Step 2 Turn the bolts 90 let the torque value come to 100 125N m Replace the bolt under the...

Page 45: ...piece 13mm sleeve wrench M8 30 40N m M8 20 25N m The bolt M8 is once tightened to 30 40N m and the lock nut to 20 25N m 242 Before screwing in the thread should be coated with the LOCTITE 242 sealant...

Page 46: ...bolts M10 16mm sleeve wrench 35 40N m The bolt is once tightened to 35 40N m 10 Fastening bolt for injection pump gear 4 M8 M10 13mm 16mm 4 pcs bolts M8 M10 13mm 16mm sleeve wrench 30 35N m 60 65N m...

Page 47: ...The nut is once tightened to 100 110N m 242 Before screwing in the thread should be coated with the LOCTITE 242 sealant 12 Fastening bolt for camshaft gear 4 M10 1 25 16mm 4 pcs M10 1 25 16mm sleeve w...

Page 48: ...ssor 4 M8 13mm 4 pcs M8 13mm sleeve wrench 55 60N m The bolt is symmetrically tightened to 55 60N m Before screwing in the thread should be coated with the LOCTITE sealant 14 Fastening bolt for belt p...

Page 49: ...226B 52 Maintenance Manual for 226B series Diesel Engine R 15 Fastening nut for intake and exhaust manifolds M10 16mm M10 16mm sleeve wrench 45 50N m Symmetrically tightened to 45 50N m...

Page 50: ...er No 10 Diesel Fuel GB252 87 20 20 30 35 In winter when the temperature is 20 you should use No 20 Diesel Fuel If the te mperature is below 30 you should use No 35 Diesel Fuel 6 2 Lubricant 6 2 1 GBl...

Page 51: ...the oil and refresh it after the working period of 2000km or 50 hours It is recommended to make use of the oil product by name as Changcheng Diesel Engine Oil CD grade 15W 40 produced by China Petroch...

Page 52: ...her temperature eg Apply to the bolts of exhaust outlet of turbocharger 3 242 Loctite 242 glue Blue Apply to thread to seal eg Apply to bolts and thread 4 262 Loctite 262 glue Red Apply to thread to l...

Page 53: ...r 226B series Diesel Engine R Caution in this Chapter To ensure that the diesel engine you have bought functions normally you must have a correct option relating to the brand and type of fuel and oil...

Page 54: ...ator The generator is three phase alternator after silicon rectification the current change into direct current 214V 80A 28V 27A 35A 55A 70A Output voltage 14V Current 80A output voltage28V According...

Page 55: ...electrode of battery generator shell is grounded the screw specification M6 Starter 12V 4kW 24V 6KW 4KW 10 DC starter voltage 12 V Power 4 kW Dcstarter voltage 24V Power 6KW 4KW right rotation face t...

Page 56: ...ce poly V belt 8mm 16mm Inner hexagon spanner 8mm open ended spanner 16mm Unscrew the fastening bolt and nut of tensioning bolt and take down the belt of generator Replace water pump 8mm 16mm Inner he...

Page 57: ...6B series Diesel Engine R 6 6 screw driver Loosen the clamp ring on rubber hose for small cycle 13mm Open ended spanner 13mm Loosen the fastening bolt of fan and dismantle the fan intermediate flange...

Page 58: ...nce Manual for 226B series Diesel Engine R 6 6 screw driver Loosen the hose clamp ring in the water inlet of water pump 13mm Sleeve wrench 13mm Take apart the fastening bolt on water pump and take awa...

Page 59: ...Engine R Clean the sealed surface of water pump Change the seal gasket of water pump 13mm Sleeve wrench 13 mm 4 Put on a new water pump and screw down the 4 bolts to fix it 6 6 screw driver Tighten th...

Page 60: ...for 226B series Diesel Engine R 13mm Open ended spanner 13mm 4 Reassemble the belt pulley inter flange and fan in the proper order and tighten the 4 bolts 6 6 screw driver Tighten the clamp ring on r...

Page 61: ...enance Manual for 226B series Diesel Engine R 8mm 16mm Inner hexagon spanner 8 mm open ended spanner 16mm Put on the V belt and tension it properly and then re tighten the fastening bolt and nut of te...

Page 62: ...nance Manual for 226B series Diesel Engine R 8 2 Lubricating System Replace oil cooler Special wrench for oil filter Dismantle the oil filter 6 6 screw driver Loosen the water inlet out hose clamp rin...

Page 63: ...226B 66 Maintenance Manual for 226B series Diesel Engine R 16mm 16mm Open ended spanner Unscrew the fastening bolt of oil cooler 27mm 27mm Sleeve wrench Unscrew the nipple and take down the oil cooler...

Page 64: ...67 226B Maintenance Manual for 226B series Diesel Engine R 17mm Open ended spanner 17mm Dismantle the water draining valve 17mm Open ended spanner 17mm Mount the drain valve on the new oil cooler...

Page 65: ...7mm 27mm Sleeve wrench Clean the oil cooler and the connecting surface of filter seat change the seal gasket and substitute the oil cooler with a new one and then tighten the nipple 16mm 16 mm Open en...

Page 66: ...69 226B Maintenance Manual for 226B series Diesel Engine R 6 6 screw driver Tighten the water inlet out hose clamp ring on the oil cooler Special spanner for oil filter Put on the oil filter...

Page 67: ...hexagon spanner Unscrew the bolt connecting the oil sump with the flywheel housing loosen the fastening bolt of oil sump and take down the oil sump 13mm 19mm 13mm and 19mm Sleeve wrenches Loosen the m...

Page 68: ...mm 8mm Inner hexagon sleeve wrench 16mm open ended spanner Unscrew the fastening bolt and nut of tensioning bolt of generator and then pull down the poly V belt 4mm 4mm Inner hexagon sleeve wrench Uns...

Page 69: ...es Loosen the hose clamp ring in the water inlet and the fastening bolt on water inlet connecting pipe and then dismantle the water inlet connecting pipe 8mm Inner hexagon 8mm sleeve wrench Unscrew th...

Page 70: ...Diesel Engine R 14mm Inner hexagon 14mm sleeve wrench Dismantle the hub after loosening the hub bolt 4mm 13mm Inner hexagon 4mm sleeve wrench 13mm sleeve wrenches Unscrew the fastening bolt on front w...

Page 71: ...wrench Unscrew the fastening bolt and nut dismantle the oil pump 13mm Feeler 13mm Sleeve wrench 0 2mm Clean the connecting surface of oil pump with cylinder block mount a new oil pump adjust the side...

Page 72: ...up the connecting surface of the front wall cover with the cylinder body coat the sealant on it and then re mount the front wall cover and tighten the bolt on it 14mm Inner hexagon 14mm sleeve wrench...

Page 73: ...leeve wrench Put on the shock absorber and the belt pulley of crankshaft in turn and then screw down the bolt on the belt pulley of crankshaft 6 13mm 6 screw driver 13mm sleeve wrench Put on the water...

Page 74: ...R 4mm Inner hexagon 4mm sleeve wrench Mount the generator and tighten the bolt on it 8mm 16mm Inner hexagon 8mm sleeve wrench 16mm open ended spanner Put on the poly V belt and adjust it properly and...

Page 75: ...lace the O seal ring fit on the lubricating oil inlet pipe and instalt the oil inlet pipg and fasten with bolt on the angle plate 18mm 6mm 18mm Sleeve wrench 6mm Inner hexagon spanner Fit on the oil s...

Page 76: ...18mm 6mm 18 mm Sleeve wrench 6 mm Inner hexagon spanner Loosen the connecting bolt between oil sump and flywheel housing unscrew the fastening bolt on oil sump and take down the oil sump 17mm 17 mm O...

Page 77: ...eeve wrench Unscrew the fastening bolt and take down the two stage balancing mechanism 16mm 16mm Sleeve wrench 0 3 0 4mm 34 40N m R e m o u n t t h e t w o s t a g e balancing mechanism adjust the sid...

Page 78: ...gine R 17mm 17mm Open ended spanner Screw down the joint of lubricating oil pipe 18mm 6mm 18mm Sleeve wrench 6mm Inner hexagon spanner Fit on the oil sump tighten the bolt connecting oil sump with fly...

Page 79: ...9mm 19mm Open ended spanner Dismantle the fuel injection pump and the oil in out pipes of fuel filter 8 3 Fuel supply system Replace fuel injection pump 18mm 18mm Open ended spanner Dismantle the join...

Page 80: ...26B Maintenance Manual for 226B series Diesel Engine R 16mm 16mm Open ended spanner Dismantle the lubricating oil pipe of the fuel injection pump 18mm 18 mm Open ended spanner Dismantle the oil inlet...

Page 81: ...net 13mm 13mm Sleeve wrench OT Unscrew the bolt and dismantle the cover of inspection hole on fuel injection pump Make a slow barring of engine and let the scale mark on the flywheel housing align the...

Page 82: ...or 226B series Diesel Engine R 13mm 13mm Sleeve wrench Unscrew the bolt and take down the fuel injection pump gear 16mm 16mm Sleeve wrench Unscrew the bolt and take down the fuel injection pump O Caut...

Page 83: ...226B series Diesel Engine R 27mm 27mm Sleeve wrench Unscrew the nut and dismantle the fuel injection pump hub 27mm 27mm Sleeve wrench Put the hub on a new fuel injection pump and screw down the lock n...

Page 84: ...B series Diesel Engine R 16mm 16mm Sleeve wrench Mount the new pump and tighten the bolt to fix it 27mm 27mm Sleeve wrench Turn the camshaft of fuel injection pump until the fuel level in the first cy...

Page 85: ...or 226B series Diesel Engine R 13mm 13mm Sleeve wrench Put on the gear of fuel injection pump and tighten the bolt on it 13mm 13mm Sleeve wrench Put on the inspection hole cover of fuel injection pump...

Page 86: ...Diesel Engine R 16mm 16mm Open ended spanner Fix the lubricating oil inlet pipe and tighten the hollow bolt 19mm 19mm Open ended spanner Mount the inlet and outlet pipes of fuel injection pump and fu...

Page 87: ...R 18mm 18mm Open ended spanner Mount the high pressure fuel pipe and tighten the joint Replace fuel injector 18mm 18mm Open ended spanner Clean the fuel injector all round and dismantle the joint conn...

Page 88: ...for 226B series Diesel Engine R 10mm 10mm Open ended spanner Dismantle the fuel return pipe of fuel injector 13mm 13mm Open ended spanner Unscrew the fastening nut on support and take down the support...

Page 89: ...r seat hole Replace the seal gasket O Mount a new fuel injector and then put on new shaft checking ring flat gasket and O seal ring Mount a new fuel injector in the fuel injector s seat hole 13mm 13mm...

Page 90: ...Manual for 226B series Diesel Engine R 10mm 10mm Open ended spanner Mount the fuel return pipe of injector 18mm 18mm Open ended spanner Screw down the joint connecting the fuel injector with the high...

Page 91: ...exagon spanner Dismantle the inner hexagon bolt on the inlet pipe of supercharger and lift the flange of inlet pipe 8 4 Intake and Exhaust System R e p l a c e t h e w a s t e g a s supercharger 6mm 6...

Page 92: ...he flange connecting exhausting pipe with supercharger and then take down the supercharger Replace the supercharger C a u t i o n I f t h e w a s t e g a s supercharger is not replaced immediately so...

Page 93: ...unt new inlet pipe gasket and tighten the bolt on the inlet pipe Caution When the oil inlet pipe is mounted it is necessary to align the oil holes of the gasket and the supercharger flange to add the...

Page 94: ...e There are various symptoms of diesel troubles The failure causes vary from one diesel engine to another because of the differential structures and using environments of different diesels A trouble m...

Page 95: ...ssion pressure of cylinders 1 1 Excessively worn piston rings or cylinder liners Check and change the piston rings If necessary change the cylinder liners and pistons 2 Valve leakage Check the valve c...

Page 96: ...tem jammed Clean or change the fuel filter 3 Uneven fuel delivery for each cylinder Check the fuel injection pump and adjust the pump on the test rig to uniform the fuel delivery for each cylinder 4 S...

Page 97: ...adjust the fuel supply advance angle 5 5 Poor fuel quality or water in fuel Check the fuel Change it if necessary 2 Low compression pressure of cylinders 1 1 Excessively worn piston rings or cylinder...

Page 98: ...Clean or change the fuel filter element 4 Excessively worn crankshaft main bearing and connecting rod bearings Check or change them 5 Incorrect engine oil grade or water in engine oil Check the oil g...

Page 99: ...to requirement 2 2 Oil cooler jammed Clean or change the oil cooler 4 Overheated coolant 1 Insufficient coolant Change engine oil pump 2 Low delivery capacity of the water pump Check the impeller cle...

Page 100: ...el in sump Drain the redundant engine oil 2 2 Piston ring wear or low flexibility oil blow by Check and change the piston rings 3 3 Valve sealing failure Check the valve sealing and change the seal sl...

Page 101: ...liners locked together Check and change the pistons piston rings and cylinder liners 2 Crankshaft is able to rotate easily after diesel stopped 1 Air in fuel system Exhaust the air and check the seali...

Page 102: ...liners fit clearance Change the pistons and cylinders 5 Excess clearance between the piston pin and small rod connecting bearing pealing with a metallic beating sound especially at high or low speed C...

Page 103: ...otton yarn are never close to the rotator shaft of supercharger while the engine is running in order to avoid damage to the engine and an injury to the person The rotator assembly may not be dismantle...

Page 104: ...ng time idle speed may not be permitted After running with a heavy load do not stop running immediately except for emergency but do so after keeping low speed revolution for 5 10 minutes 8 0 If the am...

Page 105: ...fields of coach bus truck engineering machinery tractor agricultural implement construction machinery generating set and marine main auxiliary engine 226B Structural characteristics operation and main...

Page 106: ...teration without notification in advance You as our clients are always welcome to make opinions and suggestions for our improving products Please send your letters to Marketing Department together wit...

Page 107: ...nce guide 3 13 Maintenance contents 4 33 The main system flow chart of engine 5 41 Tightening torque and tightening mehthod of main bolts 6 53 Fuel lubricant coolant and auxiliary materials 7 57 Elect...

Page 108: ...Filling full charge such as lubricating oil cooling water etc Deflating Draining off lubricating oil or cooling water Unloosing such as unloose clamping equipment loose proof fixed Coat fluid sealant...

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WEICHAI DEUTZ 226B Series, Usage Instruction

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