WEICHAI R6160 Series Operating Instructions Manual Download

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R660系列柴油机维修保养手册

-6-

Maintenace Manual For R660 Series Diesel Engine

2．冷却系统

Cooling system

2.1 R6160A 系列柴油机冷却系统流程图

Flowchart for cooling system of R6160A series diesel engine

气缸盖Cylinder head
节温器Thermostat
热交换器Heat exchanger
生水腔Raw water cavity
净水腔Treated water cavity
水源Water source

净水泵Treated water
生水泵Raw water pump
机体水腔Water cavity of cylinder block
机油冷却器Oil cooler
飞轮Flywheel

Summary of Contents for R6160 Series

Page 1: ...n period of a new engine is 100 hours After initial running in of a new engine replace the engine oil and clean oil filter Failure to do so may result in excessive wear or damage of diesel engine part...

Page 2: ...an radiate the heat produced while engine running in order to prevent over temperature in the room When installing your engine sufficient space must be kept above the engine for removal and assembly o...

Page 3: ...e without seawater fresh water heat exchanger the heat exchanger should be provided by user It is forbidden to cool the engine with seawater directly Diesel Engine Alignment Requirements Diesel Engine...

Page 4: ...pour engine oil heated to 100 120 onto moving parts on cylinder head to melt the antirust oil Check before operation all pipelines screwed connections and hose couplings for tightness and they must be...

Page 5: ...ting air bottle then open the switch valve of pneumatic motor and the engine will be started immediately Close the switch valve of the motor immediately after the engine is started and then close all...

Page 6: ...revolutions to avoid piston seizure Constantly pay attention to oil pressure and circulating water temperature so as not to cause any accident due to control system failure Constantly pay attention t...

Page 7: ...e for leakage Engine oil pressure exhaust gas temperature and color and engine speed should be stable Temperature of cooling water External cleanness of air filter If there is oil gas or water leakage...

Page 8: ...ce Maintenance to New Engine Replace engine oil and clean oil filter Clean fuel filter remove the dirty oil on the upper face of cylinder head Check the connecting parts and tighten parts 200 For engi...

Page 9: ...f fuel injections of all injection pump cylinders if necessory Dismantle the cylinder heads remove the carbon deposit in the combustion chamber Check the wear conditions of inlet outlet valves and val...

Page 10: ...earing replace if necessory Check the sealing of outlet valve if injection pump repair or replace if necessory Check the working performance of needle valve and seat of injector replace if necessory C...

Page 11: ...Daily Maintenance You should perform daily preventive maintenance to learn about operation conditions of your diesel engine Check prior to starting your diesel engine engine oil level coolant level fo...

Page 12: ...fter engine shutdown wait at least 5 minutes to let the engine oil in your engine return to oil sump Check engine oil level Pull out dipstick from engine block to check engine oil level Do not start y...

Page 13: ...ow on heat exchanger and add cooling water from water filler on top of heat exchanger if necessary Caution Do not open water filler cap of heat exchanger at once after the engine is shutdown so as to...

Page 14: ...aily maintenance you should Replace engine oil Run in of new engine will result in more abrasive dust in the oil Replace oil and clean oil filter is necessory to ensure proper lubrication condition in...

Page 15: ...gine 6 Take out filter element Disassemble filter element Clean with brush in oil liquid Remove plug and blow it with compressed air from inside to outside and Reassemble it Fill with clean oil from f...

Page 16: ...stem is primed wait for a while about 5 minutes until the oil level becomes stable add oil again to the upper limit mark of dipstick Prime the oil supply system before each start until the needle of o...

Page 17: ...rding to the procedure below 3 Screw off tighten nut 3 9 Take off filter casing 9 4 6 Screw off compression nut 4 take off cover 6 7 Take out filter element 7 Disassemble filter element replace filter...

Page 18: ...own in time to avoid accident trouble Retighten the cylinder head bolts 200 5 After the engine is operated for 200h loosen all cylinder head bolts and then retighten them according to the requirement...

Page 19: ...the arrow pointer on the rear cover of the engine aligning with the 1 6 mark on the flywheel housing The piston of 1st cylinder is at TDC and the inlet outlet valves are closed at this time if the in...

Page 20: ...ll be measured with engine at cold state i e temperature less than 60 The measured clearance is an exact value if a slight resistance is felt when feeler gauge is sliding between air valve bridge and...

Page 21: ...e revolution with barring rod to align needle with 1 6 dent mark on flywheel 6 5 4 3 2 1 Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Adjust valve clearance as per Tab...

Page 22: ...rew the release screw on cylinder head rotate the flywheel slowly with the working direction and watch out for the fuel level at outlet of fuel pump When the fuel level is just fluctuating it means th...

Page 23: ...t to an angle bigger than the specified value to eliminate the side clearance of gear Then bar the engine with the rotating direction of crankshaft to the specified angle After the advance angle is co...

Page 24: ...eck the tension of the V belt when it is used for a period of time Adjust or replace if necessory Unscrew the bolt for tightening the tension pulley change the position of tension pulley to adjust the...

Page 25: ...water the water inside the engine is cooled through water radiator So the radiator should be cleaned timely to ensure the cooling effect 4 1000 Maintenance of engine after 1000 hour s operation 1000 I...

Page 26: ...Check injection pressure of injector and clean needle valve and seat assembly of injector Remove injector as described in Para 8 3 Connect this injector to the tester and operate the handle of tester...

Page 27: ...sound nor perceptible vibration on handle Middle test speed Sprayed fuel atomized notable jetting sound and perceptible vibration on handle Concentrated fuel stream without atomized fuel spray and jet...

Page 28: ...s loosen the screw take out needle valve and valve body mated couple can not be exchanged wash them in clean petrol or kerosene Check injection pressure Disconnect the pressure tester and push the han...

Page 29: ...thickness with an increment of 0 05mm Clean heat exchanger element Caution Drain cooling water from your engine before removing and checking heat exchanger To clean heat exchanger element remove seaw...

Page 30: ...nrod bolt Tighten the loosened bolt according to Chapter 5 5 3000 M a i n t e n a n c e o f e n g i n e a f t e r 3000 hour s operation 3000 In addition to the Maintenance 2 this maintenance also incl...

Page 31: ...move clamps from rubber hose connecting inlet pipe of treated water pump to thermostat and disconnect hose to thermostat 4 Remove 4 bolts for connecting water outlet manifold and thermostat and remove...

Page 32: ......

Page 33: ...Primary Systems Of Diesel Engine Lubricating system Cooling system Air inlet and exhaust system Fuel system Starting system 170Z System flowcharts for 170Z Series Diesel Engines can assist you to ope...

Page 34: ...amshaft Oil cooler Main oil passage Main bearings and connecting rod bearings Electric oil pre supply pump Bed plate Rocker arm Piston Oil pump Oil filter Pressure limiting valve Flywheel Return bed p...

Page 35: ...gine Rocker arm Tappet Camshaft Oil pump Oil cooler Oil filter Main oil passage Adjusting valve Main bearing Connecting rod bearings Connecting rod bearings Turbocharger bearing Hand pump or electric...

Page 36: ...2 Cooling system 2 1 R6160A Flowchart for cooling system of R6160A series diesel engine Cylinder head Thermostat Heat exchanger Raw water cavity Treated water cavity Water source Treated water Raw wat...

Page 37: ...chart for cooling system of R6160ZC series diesel engine Cylinder head Thermostat Heat exchanger Raw water cavity Treated water cavity Water source Treated water Raw water pump Water cavity of cylinde...

Page 38: ...R6160 38 Maintenace Manual For R6160 Series Diesel Engine 2 3 Closed circulation for stationary engine...

Page 39: ...ystem R6160Z R6160A 5 R6160A 6 The air cooler is attached with R6160Z series diesel engine Model R6160A 5 and R6160A 6 diesel engine Expansion pipe Exhaust manifold Intake manifold Air cleaner Air coo...

Page 40: ...R6160 40 Maintenace Manual For R6160 Series Diesel Engine 4 Fuel system Injector Injection pump Transfer pump Fuel filter solenoid valve Fuel inlet pipe provided by user...

Page 41: ...Series Diesel Engine 5 Starting system 5 1 5 1 Pneumatic starting system Cylinder head Starting charging valve Starting air bottle Air compressor Pressure relief valve Barometer Switch valve Fuel atom...

Page 42: ...nace Manual For R6160 Series Diesel Engine 5 2 Electric starting system Clearance to gear ring Starting motor Contactor Electric oil pre supply pump Inspection cover to battery positive pole to batter...

Page 43: ...160 Series Diesel Engine Tightening Torque And Method of Bolts And Nuts on DieseEngine 1 Main Bearing Nuts M18 14 Size M24 14 used on 6 cylinder engine and 18 used on 8 cylinder engine Tightening orde...

Page 44: ...que 600 650N m for engine which power is less than 220kW 650 700N m for engine which power is 220kW and more 3 Connecting rod nuts 300kW M16 4 140N m For engine which power is 300kW and more the size...

Page 45: ...N m First time 30N m second time 430N m 470N m 262 Before the bolts are screwed in apply LOCTITE 262 sealant on their thread 5 Connecting bolts between cylinder block and bed plate M14 70 90 N m 130N...

Page 46: ...sed tightening torque is 400 450N m tightened at 1 time before it is screwed in apply LOCTITE 262 anaerobic sealant on its thread 7 Connecting bolts for damper M12 10 60 90N m Size M12 10 in all tight...

Page 47: ...el 2 Lubricating Oil R6160 15W 40 L ECD GB11122 1997 It is recommended to use GB 11122 1997 diesel engine oil 15W 40 L ECD for 170Z series diesel engines 40 L ECD GB11122 1997 40 L ECD diesel engine o...

Page 48: ...water containing soda industrial water and waste water Tap water of most cities must be dechlorinated before use Cooling system can be added with long term coolant to prevent rust and freezing As for...

Page 49: ...d seal Example thread positions of various bolts 3 262 LOCTITE 262 Red Apply to thread position for locking and seal high force Example Main bearing bolt 4 510 LOCTITE 510 Red Apply to the metal surfa...

Page 50: ......

Page 51: ...is 11kW operating voltage is 24V double wire system for marine engine and single wire system for stationary engine 70mm2 Cross section of main conducting wire connecting starter and battery is at leas...

Page 52: ...ly and give an alarm when any abnormal condition appears during diesel engine operation Functions 1 Monitoring an measuring ability Marine diesel engine is usually furnished with mechanical type instr...

Page 53: ...ithin specified range by switching on and switching off the stop solenoid valve until the speed is stabilized Setting alarm values are shown in the Table below No Items S e t t i n g a l a r m values...

Page 54: ...Monitoring system requires a power voltage from 18 to 31 2V To ensure longer service life of monitoring system switch off power source after diesel engine stops All operating points were pre adjusted...

Page 55: ...gine the pump supply oil to every oil site with certain pressure through a set of controls first switch on the loop of electric oil pre supply pump by pressing the electric key the electric pump start...

Page 56: ......

Page 57: ...l type Raw water pump is provided with an oil cup on its external body for the purpose of grease lubrication Manually fill the cup with grease periodically The treated water pump is lubricated by spla...

Page 58: ...bleed air if necessary The other 2 plugs are fit with 2 zinc blocks which shall be checked every 1000 hours for corrosion condition by screwing off plugs and replace if necessary Intercooler does not...

Page 59: ...59 R6160 Maintenace Manual For R6160 Series Diesel Engine Remove oil outlet pipe for oil pump Remove oil return pipe...

Page 60: ...gs for oil pump body and cover replace them if worn seriously CAUTION During replacing and assembling the bushings the oil grooves on the bushings should be aligned with the straight oil grooves on th...

Page 61: ...d of a set of copper back flow pipe the oil flows inside the copper pipe that is cooled by cooling water outside the pipe In normal case the cooler can ensure the oil temperature below 85 However the...

Page 62: ...R6160 62 Maintenace Manual For R6160 Series Diesel Engine Loosen the oil inlet pipe of coole Loosen the oil outlet pipe of cooler...

Page 63: ...l cooler and engine block and remove the oil cooler Loosen the bolts for connecting end cap and cooler body and draw out the element Clean the cooler body Clean the cooler element 3 Fuel supply system...

Page 64: ...R6160 64 Maintenace Manual For R6160 Series Diesel Engine Remove the low pressure fuel pipe connecting to injecto Loosen the connecting bolts between intermediate flanged pipe and diaphragm...

Page 65: ...place the injection pump on its bracket and then tighten connecting bolts 0 1mm Caution During installing the injector the coaxiality of injection pump camshaft and driving shaft should not exceed 0 1...

Page 66: ...R6160 66 Maintenace Manual For R6160 Series Diesel Engine Connect the intermediate flanged pipe and diaphragm properly Connect the fuel pipe to fuel pump...

Page 67: ...eries Diesel Engine Caution Check the fuel supply advance angle and adjust it if necessary after installing the high pressure fuel pump Replace fuel injector Loosen the high pressure fuel pipe on inje...

Page 68: ...R6160 68 Maintenace Manual For R6160 Series Diesel Engine Remove the cylinder head cove Loosen bolts and remove nozzle fixed mount...

Page 69: ...out the injector with special tool and mark symbol as per cylinder number to later installation 4 Adjust injector pressure and check fuel atomization and leakage conditions refer to maintenance of inj...

Page 70: ...ect position to avoid generating initial pressure Assemble the gasket for cylinder head cover and mount the high pressure fuel pipe and fuel return pipe Install injector into cylinder head 4 Air intak...

Page 71: ...0 Maintenace Manual For R6160 Series Diesel Engine L o o se n o i l i n l e t p i p e n i p p l e f o r turbocharger Loosen two bolts connecting turbocharger and its oil return pipe remove the oil ret...

Page 72: ...w a n d r e m o v e turbocharger Replace new turbocharger Caution All openings of turbocharger should be covered properly to prevent entering foreign objects if turbocharger is not replaced immediate...

Page 73: ...rature required by self combustion 3 Injection of well atomized diesel fuel into cylinder and sufficient air supply required by fuel combustion Your diesel engine should start successfully within 5 se...

Page 74: ...replace starting motor Start with air motor 1 Low air pressure in valve bottle 1 Re charge air bottle 2 Motor fails to engage or engages too late 2 Repair or replace motor 3 Pressure regulating valve...

Page 75: ...y pump fails to supply or supplies fuel intermittently 1 Check fuel inlet pipe of fuel supply pump for air leakage or check and repair fuel supply pump 5 Injection pump fails Incorrect fuel supply adv...

Page 76: ...arance 1 Grind sealing surface or replace air valve Check and adjust valve clearance 2 Cylinder head and or gasket leakage Inadequate tightening torque of cylinder head nuts Cylinder head gasket damag...

Page 77: ...ce incorrect 2 Check and adjust to specifications 3 Valve spring broken 3 Replace valve spring 4 Air filter clogged 4 Clean air filter 5 Air inlet pipe restriction 5 Clean air inlet pipe 6 Excessive c...

Page 78: ...pply system failure is operation of cylinders unbalances and or flameout in individual cylinder s Cause Remedy 1 Air in fuel supply system 1 Bleed air by unscrewing air bleed plugs of the system 2 Fue...

Page 79: ...quality 2 Use diesel qualified 3 Air filter and or air inlet pipe becomes restricted 3 Clean air filter and or air inlet pipe 4 Air inlet of turbocharger compressor and or intercooler is restricted d...

Page 80: ...4 3 Blue Smoke Emission Blue smoke emission is usually oil vapor caused by blow by of engine oil into cylinder which is evaporated and unburned It results in remarkably increase of engine oil consump...

Page 81: ...cessary 3 Sharp impact sound can be heard from upper part of cylinder when diesel engine speed changes in particular when speed is reduced 3 Excessive clearance between piston pin and brass bush of sm...

Page 82: ...rly 1 Check and adjust fuel injection timing 2 Deep and indistinct knocks from cylinder 2 Fuel injection too late 2 Check and adjust fuel injection timing 3 Slight metal knocks are audible near by cyl...

Page 83: ...top the engine immediately and replace connecting rod bolts 2 Clear knocks audible from lower part of cylinder block 2 Main bearing burnt 2 Replace main bearing 3 Clear knocks from cylinder block at l...

Page 84: ...e to STOP position and turn off fuel switch When throttle loses control to fuel pump plunger loosen fuel injection pipe coupling nut 2 Shutoff air passage You can use explosion proof equipment if avai...

Page 85: ...ear rack seized at maximum fuel supply position Disengagement between gear rack and pull rod Engaging position error between gear rack and gear 2 1 2 3 Check and repair Check and tighten up after re a...

Page 86: ...joint Remove check and clean Replace spring Replace and adjust spring 3 1 2 3 4 Air Distribution System Failure Air valve spring fracture Air valve binding in conduit Excessive air valve clearance or...

Page 87: ...aining water 3 Fuel passage restriction 4 Fuel pipe fracture or loose connection 5 Fuel pump plunger binding 6 Fuel pump spring fracture 7 Speed governing spring fracture 1 1 2 3 4 5 6 7 Add fuel 2 Ch...

Page 88: ...viscosity 2 Identify causes and remove failure and replace oil 3 Worn oil pump gear or improper installation 3 Check oil pump performance repair and replace 4 Oil or air leakage due to loose connectio...

Page 89: ...and fuel supply advance angle Check and adjust fuel injector 2 1 2 3 4 5 Poor machining accuracy of parts or unqualified equipment Bent or deformed crankshaft Crankshaft unbalance Flywheel unbalance D...

Page 90: ...failure Repair the circuit Replace sensor Press pressure test button indicator comes on but no low pressure is issued while engine is running Pressure sensor open circuit Pressure sensor failure Repa...

Page 91: ...n off air 2 Water pipe clogged or frozen in cold weather 2 Clean and fill hot water or pre fill antifreeze liquid 3 Gas leakage due to sealing device or sealing gasket for water pump damaged 3 Repair...

Page 92: ...R6160 2007 7...

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