Deutz 226B Operation Manual Deutz 226B Operation Manual

Page 1
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It!ffl
ifi*~226B~JU
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Operation
Deutz
226B
Series
.-.
-
-
-
--
WEICHAI
and
Generating
DEUTZ
Manual
Diesel
._,---""®
of
Engine
~tJj~~mfR~~Mm:fI~&*1§1
WeiIang Weichai Deulz Diesel Engine Company Ltd
~
1Ii.~9"
--
Page 2
Special attention
In ordertoprotect your legal interest, it is forbidden to dismantle the fuel pump lead seal op­tionally
If
the injection pump were adjusted or lead seal were removed, the quality guarantee of the
company would become invalid immediately.
We would not provide free service for the dismantled injection pump.
part,
Turbocharger rotor shaft is of precise quality guarantees of the company will
forbid disassembling and colliding, Otherwise the
be
of invalid.
There are strict torques Users don of invalid.
Before starting the
Connecting rod bolt can
Meaning of identification:
• Exhaust gas contains noxious composition, therefore it must
t loose
and
and
dismantle
engine,
t
tum
angles for the main bearing bolts and connecting rod bolts,
them,
check coolant and oil whether they are filled up or not.
be
reused.
otherwise the quality guarantees of the company will
be
discharged outdoors.
he
Page 3
Cautions
1.
The engine has been tested strictly in accordance with the test stipulations in delivery. The throttle has been tle. Otherwise users would better pay attention to this.
2.
The engine operator must read this Opf..ration and Maintenance Manual carefullytoknow the en­gines structure, and abide by the operation and routine rules in this manual.
3.
During use new engine, a load operation is allowed.
sealed,
we
would not provide free service for returning product, replacement and repair,
it is forbidden to dismantle the seal optionally and to enlarge the throt-
50
hours runin must be carried through, during which period no over-
4. Mter start cold engine, the speed should be increased slowly. It is forbidden to run the engine
in high speed suddenly gine immediately and run the engine in idling for 5 - 10 minutes.
5. Mter stop the engine,
the coolant, the coolant in water tank and diesel engine should be drained
6.
It is forbidden that the engine works without
7.
Applied fuel and lubricating oil must strainer, and the special clean container is used. The fuel should be settled more than
hours.
8. Assembly
9.
The oil seal period of the engine is one year. Inspect the engine and adopt necessary measures
and
maintenance of the engine must be done by specialized personnel.
and
in idling for a long time.
if
the ambient temperature is lower than
air
be
accord with specified trademark and be filtered by
Mter
filter and unfiltered
removed the
oee
and
air
load,
dont stop the en-
no antifreeze is used in
off.
enters into the cylinder.
72
if
beyond a year.
10. Rated power and power correction are in accordance Its
11.
forbiddentosmoke when filling fuel and / or oil.
with
1503046 - 1.
Page 4
Contents
J>reface
Diesel engine photo
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Diesel engine characteristic curve 0 0 0 • 0 0 0 0 0 0 0 0
1
Main perfonnance and specifications
2 Specifications of main accessa
Fuel system matching table
3.
Diesel engine construction
3.
1 Cross and longitudinal section view
30
2 Cylinder block subassembly .0
3.
3 Crank shaft and connecting rod mechanism
3.
4 Gear train
3.
5 Cylinder head and valve system 0
3.
6 Fuel supply system
3.
7 Lubricating system
3.
8 Cooling system 0 • 0 0 0 •
3.
9 Intake & exhaust system
3.
10
Electrical system .0 0 0 • 0 0 0
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2
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7 8
10
11
11
13
16
19
19
22
26
29
31
3.
11
Main bolts tightening torque
4.
Operating requirement and procedures
4.
1 Rules on the working fluid and the auxiliary material
4.
2 swinging requirement
4.
3 J>reparation before the start
4.
4 Start .0 • 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 • 0 • 0 0 0 0 • 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 0 • 0 0 • 0 0 • 0 0 0 0
4.5
Speed regulating
4.
6 stopping the engine
4.
7 Operating environment 0 0 0
5.
Maintenance
5.
1 Time table for Maintenance
5.
2 Maintenance procedure 0
6.
Trouble shooting 0 0 0 0 0 0 0 0 0 0 0 0 0
Appendix
1:
000 000
Relationship between crankshaft angle
Appendix 2 : Wear Limits of
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34
36
36
39
39
41
42
42
43
44 44
45
50
51
52
Page 5
Preface
2,26B
series diesel engine is manufactured by Weifang Weichai Deuzt Diesel Engine Company Ltd ( composed Weifang Diesel Engine Works and Germany Deutz Company). According to intake mode, 226B series diesel engine is divided into natural aspirating, turbo - charging, charging and inter - cooling type. With3,4 and 6 cylinders, it is a high - speed, 4 - stroke, water - cooled, in
- line and direct - injection engine. It has advantages of reliable and economical in working, advanced technical
data,
low emission, good range is the following meanings:
1500r/min
T
-1800r/min
B D 2 26 B 6 - D - X
low
- temperature start, simple operation and convenient maintenance. The speed and
power range is 30
-135kW.
The symbols in each typeofengine represent
turbo-
of
I
I
..
I
I
'-------
1...-
1...-
1...-
L.-
Nameplate is fitted on the engine in delivery, model, design number, power, speed, serial number, manufactur­er,
address, manufacturing date and weight are marked on the nameplate. Each design number corresponds to
certain engine, each model may has several design numbers. The serial number is marked on the cylinder block
3.Ild
located under the oil filter seat.
data,
This manual introduces the main technical inspection points of 226B series diesel engine. it applies
to
In order refertostructures and the engine operating methods so astoplay its active role. With the development of the production technology, the construction, accessories and performance parameters of 226B engine will one,
make 226B series diesel engine provide better service
be
improved gradually. The product in the manual maybeslightly different
pay attention to the supplementary manual. It is subjectedtochange without notice.
construction features, operation and maintenance methods and
to
al the generator engine model for the customers.
Serial
No.
Generator Cylinder Wet
No Water
Nat In
T u r b 0 - G h a r g e d : T
for
you,
liner
of
cylinder cooled:2
u r a 1
t e r -
coole
its
better for users to know the basic
model
number
asp
d : B
ira
tin
from
line
g
6
to
the supplied
1
Page 6
2
4
Thermostat
Heat
5 8 Oil
13
shield for
dipstick
Warer
Remark:The they
are
compositiions of
tank
counter
2 Water
turbocharger
9 Fuel
parts
13
6-cylinder diesel engine
pump
of
CE-certifitated
3
6
supply
number
12
Air Exhaust
pump
5,
11
clearer 4
Intake
pipe frock 7 Inection
10
Fuel filter
6,
12
are
not
equipped on general gen
models.
10
manifold(only for intercooled engine)
11
pump
Oil filler
and
12
-engine,
governor
guard
However,
shield
Page 7
2
3
4
Warer
5
tank
Exhaust
7 Oil dipstick 8
Remark:The they
are
counter
compositiions of
11
2
Air
pipe frock(
parts
10
4-cylinder
clearer
Only
Fuel filter
of
CE-certificated
for
number
3
turbocharged
9 8 7 6 5
diesel engine
Turbocharger
engine) 6 Inection
9 Fuel supply
4,
5,
11
are
models.
pump
not
4
Heat
equipped
shield
10
on
for
Oil filler
general
turbocharger
pump
11
and
guard
governor
shield
gen-engine,However,
Page 8
Gf(kg/h)
8
D226B-3Dload characreristic curve
rated rated
power speed
30kW(no
1500r
/min
fan)
be(g/kW.h)
270
6
4
2
10
Gf(kg/h)
14
15
TD226B-3D load speed characreristic curve
20
P(kW)
rated rated
25
power speed
30
45kW(no
1500r/min
250
230
210
35
fan)
be(g/kW.h)
300
10
280
260
240
6
220
2
o
10
20
30
P(kW)
4
40
50
200
60
Page 9
Gf(kg/h)
18
TD226B-4D characreristic
load
curVE}
rated
power
rated speed
60kW(no fan)
1500r/min
be(g/kW.h)
370 350
14
10
6
2
o
Gf(kg/h)
24
10
TD226B-6D characreristic
20
load
curve
30
P(kW)
40
rated
rated
power speed
50
90kW(no fan)
1500r/min
60
330 310
290 270 250 230 210
70
be(g/kW.h)
300
20
16
12
280
260
240
8
4
o
20
40
60
80
100
P(kW
5
220
200
120
Page 10
Gf(kg/h)
30
TBD226B-6D load
characreristic curve
rated rated
power speed
°120k
1500r
W(no
Imin
fan)
be(g/kW.h)
240
20
10
o
o
Gf(kg/h)
40
20
TBD226B-6D5 load
characreristic curve
40
60
P(kW)
rated rated
80
power speed
100
132kW(no
1500r
Imin
120
fan)
220
200
180
140
be(g/kW.h
240
30
20
10
o
o
220
200
,
20
40
60
80
P(kW)
6
100
120
140
160
Page 11
1
"Main
Item
No. Borel Displacement
Type
Rated Rated 110%ofrated power
Speedat110%ofrated power (
rfmin)
Mean effective pressureatrated conditions
Mean piston Compression ratio
Cold compression pressure Min
-J
Steady governing speed Aspiration Firing order
Oil Oil Oil
Max
Max Exhaust Starting
Permitted gradient longitudinall Crankshaft rotation (from freeend)
Noise
Weight
Steady governing speed
performance and specifications
of
cylindr
stroke
(mm)
(L)
power(kW) speedrlmin
(kPa)
speed
idle speed
capacity( sump) pressure pressure at idle
permitted permitted water outlet
dB(A)
temp method
(kg)
(r/min)
(kPa)
(kPa)
oil
temp
after turbine(
(m1s)
(L)
( 'C)
(kW)
temp
'C
(kPa)
(
'C
)
CI'088
D226B
-3D
3
-4D
4
TD226B
-3D
3
TD226B
-4D
4
TD226B
-6D
6 6
TBD226B
-6D
TBD226B
6
-6D5
D226B
105/120
25(0)
4.156
40
44
770
800
:1:50
1-3-4-2
9 7.25
3.117
4.- stroke, water -
45
1500
49.5 1500
1155
15.5
3000
(Min
25(0)
800
:1:50
1
-3-2
3.117
30
1500 1500
33
1500 1500
770
6 6 6 6
16.4 3000
(Min
800
:1:50
Natural
aspiraed
1
-3-2
7.25
4.156
cooled,inline,DI,wet
60
1500
66
1500
1155 1155
2700
22(0)
(Min
800
:1:50
~5
Turbocharged
1-3-4
-2
9
300
-550
6.234
liner
90
1500
99
1500
6
800
:1:50
1
-5 -3-6-2-4
13 13
6.234
120
1500
132
1500
1534 1687
6
800
:1:50
Turbocharged and inter- coded
6.234
132
15Qll
145
1500
800
6
:1:50.
13
;;,100
~120
)
~600
25130
Clockwise
=E;110
520
~600
30/40
=E;110
560
For the
models
~550
25130
=E;110
530
that are egaipped
Allofthe
Refertoelectronic
models
with
above
~90
;,;;550
Electric
30/40
=E;110 =E;110
570
elecfronic governor,the
governing
can be installed
instruction
with
governipg
electronic
~550
20/45
760
speed
governor.
isnomore
than
:ii550
2(}/45
=E;110
780
1.
S
~550
20145
=E;110
780
Page 12
2"Specifications
No.
00
Name
Injection
1
pump
2
Governor
Fuel
3
pump
4 Injector
5
6
7
8
9
Fuel
filter
Water pump
Oil
pump
Crankshaft
damper
TurhochaIt.er
feed
of
main accessories
Item
~
Rated
speed
Rated
fuel
delivery(mm3/cyc)
Part
Open
Nozzle
Part
Part
Impeller diamcter(
Rated
speed
Part
Rated
speed(r/
Part
Outer diameter(
D226B
-3D
Multi
Type
Model
(r/min)
Type
Model
Type
Model
Type
No.
pressure
Model
Type
No.
Type
No.
mm)
(r/min) 3000
Type
No.
min)
Type
No.
mm)
Type
Model
12270162
12166769
- cylinder
61
- -
-
-
- Radial
-
D226B
-4D
integrcoted
81
12270162
12166779
- -
-
-
type
750
12270392 .
12273212
TD226B
BQortype
-3D
A
88
12153057
Centrifugal
4>86
12166769
-
-
K14orSJ50
See"
Fuel
Mechanical
See"
Fuel
See"
Fuel
Multi
See"
Fuel
See"
Fuel
(scroll
TD226B
system
system
Plunger
system
- hole, 12270162
system system
Spiral
caseison
Gear
12166779
Rubber type
12160595
K240rJ60S
matching
I
87 and
matching
matching
valve
matching matching
paper
type
1700
4>182-
-4D
centrifugal
type
needle
element
the
- 2
table"
table"
table"
table" table"
middle
TD226B
-6D
Multi
- cylinder integrated typeADor
83
plate)
12159770
Silicon-oil
n6
DorS2B7623
TBD226B
750
106
12153057
13020488
2210
121559765
12272805
4>3
HHO.
-6D
type
1
0
A
4>HO
85D9orK27
TBD226B
HI
1273240
-6D5
Page 13
Specifications
No.
10
Name
Oil
filter
of
main accessories(2)
~
Type
Part
No.
D226B
-3D
0226B
-4D
12272453
T02268
-3D
Spiral
TD226B
paper
-4D
element
T0226B
-6D
TB0226B
01174421
-6D
TBD226B-6D5
11
12
13
\0
14
15
16
17
Oil
cooler
Thermostat
/
Starter
Generator
Intercooler
Water cooler
Fan
Full open temperature('C)
Type
Type
Opentemperature('C)
Type
Power
Voltage
Type
Part
No.
Power
Voltage!current
Type
Type
Model(or
Radiation
area
Type
Part
Outer dia(
part
No.
No.
(m
mm)
2
Three
- phase
12903819
-
Air
cooled
finand
)
)
and
tube type
13025078
20
Exhaust
13021367 13020367
~6
-
Air
cooled
finand
and
tube
type
13025078 13025078 13025078
20
Exhaust
~
-
Air
cooled
finand
and
tube
type
20
Exhaust Exhaust
13021367
~
Round
plate type
Wax
75
90
DC,
selfexcitation
4kW
24
V(12Visoptional)
AC,
commutated
0.75kW
28V127A(14V
Air
cooled
finand
13021367
~
-
tube
20
type
and
is
optional)
and
type
voltage
regulated
13020748
Air-oiv
Air
finand
13024933
Exhaust
13021535
intercooled
cooled
tube
30
cf>54O
and
type
Air-oiv
Air
finand
13024933
13021190
intercooled
cooled
tube type
40
Exhaust
clJ600
and
Air-oil'
Air
finand
13024933
13021190
intercooled
cooled
tube
40
Exhaust
clJ600
and
type
Page 14
Fuel System Matching Table
Diesel
engine
Model
TBD226B
-6D
TD226B
-6D
TD226B
-4D
D226B
-3D
TD226B
-3D
TBD226B
-6D5
Injection
pump
Injection
Governor
Electronic
(I2V,24Vare
Supply
Fuel
delivery
Injector
assembly
pump
model
governor
optional)
pump
model
advance
number
model
model
anggle
no.
13020436
CPES6AD100 D320RS2139
CRSV450
CDES6ADlOO
D320RS2140
...
13021799
CRSV450
...
750ADOC139R750ADOC139R
SAD/H2206
16
±0.5
12153057
SAD/H2206
18
±0.5
12153057
13021656
CPES4AD95
D320RS2152
CRSV450
750ADOC139R
ESG
2000
ESGI500Cl
SAD/H2206
18
±0.5 20.5 ±0.5 20.5 ±0.5
12270162
13021938
BH3QT80R9
BH3A95R504
...
1'300
-750Z
msv330
-
750A504
- D
SVHZ2204 SAlH2208 SAlH2208
12270162
13022109
BH3QT85R9
BH3A95R501
TI00-750Z
'mSV33O
-750A501
SVHZ2204
12153057
13023574
BP1213
+TRSUV
4500
-750P
ESG2000
ESGI
oooC
5505
14
±O.
12153057
1
5
Injector
InjectIon
Injection
High-pressure
pipe
body
nozzle
pressure
Cuter
model
model
(MPa)
dia
dia{mm)
inrer
KBEL90S3/13
DLLA151S972
KBEL90S3/13
DLLA151S972
10
KBEL90S3/13
DLLA152S1l80
22
6.1.
KBEL90S3/13
DLLA152S1180
+0
••
75
KBEL90S3/13
DLLA151S972
KBEL90S3/13
DLLA151S972
Page 15
3. Diesel engine construction
3. 1Cross and longitudinal section view of diesel engine
3.1.1
Longitudinal section view of D226B
-4
diesel engine
13
10
9
8----t
7---~tt¥:~~~~
6----~
14
15
16
17
18
II-++-+---t+-+--
,~--24
22
23
2
1 Oil sump 2
5 4 3
Two
- stage balancing mechanism 3 Pre - filter 4 Oil pipe 5 Oil dipstick
6 Gear case cover 7 Oil pump 8 Crankshaft belt pulley 9 Speed sensor
10Fan 15 19
11
Inspirator 12 Water pump
Cylinder head cover
16
Piston 20 Cylinder liner
13
Cylinder head
Water outlet pipe
21
Connecting rod 22 Rear oil seal cover 23 Flywheel
17
Intake valve
14
Rocker arm and rocker arm support
18
Exhaust valve
24 Flywheel housing
11
1
(on
the flywheel housing)
Page 16
3.1.2
Cross section view of D226B
16
----___+_
15----F-
14
------l~-___=+~.t"rn~..,.,~~
13--------k"
12-----....
-4
diesel engine
17
18
19
20
I
-"I!=-------
~------22
~~~\-~--tt-------
21
23
11-----
10-----"....:~---W
9
---::~=_fI4---,.._r~1f';1
8-----'-oo~-r
7---r---1'n,;;\i
~~~
6-----
5-----~
4
-------;--'1-\
3-------~~'-
I
ft---+liH-++------
/<:JT--25
/
2--------
1--------~
1 Oil sump 2 Pre - filter 3
Two
- stage balancing mechanism 4 Cylinder block
\......::::=-.+----.;;;::::.:..JJt::i
5 Crankshaft 6 Engine stop lever 7 Camshaft 8 Fuel supply pump
Oil
pipe(toinjection pump)
9 13
High - pressure pipe 14 Push rod
17 Rocker
21
Injection pump 22 Cylinder head
ann
18
Cylinder head cover 19 Water outlet pipe 20 Intake/exhaust valve
10
Oil
filler (various position)
"15
23
Exhaust pipe 16 Intake pipe
Piston 24 Connecting rod 25 Oil dipstick
26 Oil filter 27 Safety valve 28 Oil drain plug
~-----28
11
Tappet
24
27
(or
piston pump)
12
Injection
pump
and
governor
Note: For 3 - cylinder and 6 - cylinder engine, there is
12
no
two
- stage balancing mechanism.
Page 17
30
2 CyJ.inder block subassembly
Cylinder hlock suhassemhly mainly consists of cylinder hlock, liner, gear case, rear oil seal cover, flywheel housing and oil sump.
(£1
2
3
4
E
D
5
ctJl
A
1 Gear case(front cover) 2 Cylinder hlock
4 Flywheel housing 5 Rear oil seal cover
7
Oil
sump 8 Seal strip 9 Seal plate
When
A structure is adopted, coat seal glue on Djoint face; When B structure is adopted, coat seal glue
both
D and E joint face.
Cylinder hlock is made of high - strength cast iron, it has
3 Cylinder liner
6 Main bearing cap
Fig 1
good
strength and rigidity. For
13
B
3,4
and 6 - cylin-
on
Page 18
der engine, cylinder block has4,5 and 7 main bearings separately. The thrust ring isfitted on the first main
bearing (flywheel then
t"e
cap is turned for 90: Tightening order is
then tighten the bearing on both ends. For camshaft hearing holes
end)
is fitted with bronze camshaft bushing. There are oil hole in cylinder block in mounting, another one should engine and turbocharged and inter - cooled engine, a jet per cylinder is mounted on the right of cylinder block
(~ewed
end).
from flywheel
The main bearing cap is tightened by
end)
for cooling piston.
showninfig
two
holes in the bushing, one of them is aimed at the
be upwards. (shown in fig
MI4
-10.9,
the torque is about 70Nm and
2. First tighten the main bearing in middle,
in
cylinder block, only the last one (free
3).
For turbocharged
Fig 2
Camshaft bearingl
"'XA~:i'~:-'\
r:
"'<~>
i
l,
I>"",
\\
""''''.
"',.,.,.,
....
""
.~...........
"'"
I
v1'"
~
>-[
----
1 _
'"
--~~
Fig 3
""".,,"
'"
Fig 4
226B series diesel engine adopts wet cylinder liner. In order to guarantee sealing after assembling, there are two
rubber seal rings on the upper and lower locating positions of the liner respectively. The lower seal ring
is set up in the seal groove on cyHnder block and the upper one is set up in the seal groove on the upper end
14
Page 19
of cylinder liner. Before mounting, coat some lubricate grease on the seal rings
The front end and rear end of cylinder block are connected with gearbox cover and rear oil seal cover and fly­wheel respectively. When mounting, coat some Loctite 5910 tic) sealant on the contact surfaces of gear case cover, rear oil seal cover and cylinder block. The tighten force for gear housing bolts
There are SAEI ,SAE2,SAE3 and 135C flywheel casings are available for different engines and applications. There is a observation window on the top or the bottom of flywheel casing (fig. on flywheel and defining the wheel is fastened
(tighten force: 140
on
cylinder block with MI0 - 12. 9
+
(M8-8.8)
TDC
5Nm).
is about 20 - 25Nm.
and adjusting the fuel supply advance angle of injection pump. The fly-
(tighten
(Fig.
4).
(or
other alternatires of
force: 80 +
-the
same charas teris-
5)
for viewing the graduation
5Nm)
and
M12
- 12. 9 bolts
Fig 5 Oil sump has der block, gear case cover and lower bottom surface of rear seal cover are coated with Lotite 5910.
tightened through wheel with hydraulic converter, because there is oil leakage ofhydraulic converter, the flywheel sealing must
be
guaranteed.Sothe joint surface between oil sump and flywheel is sealed by sealing plate and coated with
sealing glue.
two
stru ctunil forms:cast and steel - punched. The connecting positions ofoil sump and cylin-
(fig
M8-8.8
1) .
bolts. Dust proof Flate is fitted between oil sump and flywheel housing. For fly-
15
It
is
Page 20
303
Crank
Crank shaft and connecting rod mechanism consists of crankshaft, flywheel, piston, connecting rod, vibra­tion
damper,
shaft
two
and
connecting
- stage balancing mechanism { for 4 - cylinder engine only) etc.
rod
mechanism
Crankshaft:
Crankshaft is forged gear is fitted on the front endofcrankshaft, tight fit is adopted.Inmounting, timing gear is heated to and it is aimed at the crankshaft dowel pin. MI6
-10.9 Crankshaft front oil seal is mounted between gear case and the positioning face. Another method of connecting timing gear case and crankshaft is pressed by hub direct-
ly.
bolts, the force is
part,
the balancing block is fitted on the crank arm and it is dynamic tested. Timing
Hub
240
+10Nm
is fitted on the frontofgear,
or
MI6
-12.9
bolts are adopted
hub,inmounting, lubricating grease is coated on
and it is tightened through
and
the force is
300
250CC
+ IONm.
Vibration
crankshaft, they are tightened through
adopted, 310mm cast into integral with hub.
damper:
the force is 65 + 5Nm. For 6 - cylinder engine, silicon oil damper is adopted, the diameter is
(for
engine speed
Vibration damper and pulley are fitted on the hub which is on the front end of
MI0
1500r/min
*8. 8 bolts, the force is 45 +5Nm. While MIO
-18oor/min).
4 - cylinder turbocharged engine adopts rubber damper
-10.9
bolts
the are
Flywheel:
Flywheel is fitted on the rear
70Nm and turned for tion and connecting method. On the flywheel, scale plate is stick to the side connecting surface of flywheel
and crankshaft. dead center mark and scale is marked on the flywheel circumference, and the inspection window is left on
the flywheel side surface.
(fig
90°.
6)
end
of crankshaft,itis tightened by 6 M16 -
Different types offlywheel canbeadopted according to different matching applica-
, the mark OT is the TDC mark of 1st
and
6th
10.9
bolts. Pre - tightened by
cylinder. For some models, OT top
r
L
Fig 6
16
Page 21
Two - stage balancing mechanism:
In ordertobalance the
- cylinder engine and decrease the vibration,
(1)
of transmitting
250CC
in mounting.
1" on the balancing shaft gear
"1
the mark
- 1" on gear mounting, the mark shaft. The gear side clearance is structed in mounting
two
- order reciprocating inertia force of piston and connecting
two
- stage balancing mechanism is mounted on the crank arm, it should be heated
"0-0"
markongear should be markedonthe specified position
(2)oftwo
(3).
Two
- stage balancing mechanism is mountedonthe main bearing
"0-0"
soasto
on gear ring should be matched with the mark on gear
O.
2mm and can be adjusted by gasket
ensure the lubrication of
rod
subassembly of4
two
- stage balancing mechanism is adopted. Drive gear ring
(fig
7).
The mark
- stage balancing transmitting mechanism should be matched with cap,
(2)
of the balancing
(fig
8).
Oil circuit should be unob-
two
- stage balancing mechanism bearing.
to
tI
in
Piston
group:
It consists of piston, piston ring , piston pin and lock ring.
For turbocharged and non - turbocharged diesel engine, the piston, piston ring and piston pin are
ferent
from
each other.
Crankshaft
Main bearing cap
Gear ring
3
Fig 7
Driving gear
2
Fig 8
Adjusting gasker
dif-
Combustion chamber and piston pin hole are off the piston center, mount the piston according rection. (Fig.
9)
to
the right di-
There are three piston rings on the piston. The first ring is of a ladder ring, and the second ring is of cone
(or
ring. The face with "TOP"
(Fig.
10).
The third ring is of a oil ring with a spiral spring. When mounting, the splits of three rings must
be staggered by a angle of 120°from each other, and the angle
factory mark) must be upwards (towardstothe piston top) when mounting
from
the split of first ringtothe edge of pin hole must not less than 30°. When mounting, coat some clean oil on the surlace of piston and cylinder liner.
17
Page 22
Connecting
small end bushing and connecting
6QOtooth.
torque of 30Nm, and then Caution: The connecting rod bolt can be used only once, or the potential fracture of the bolt damage of the machine and personnel casualty. The connecting rod marks on the body and cover. Connecting rod bearing shell: this bearing shell is made of lead - copper with steel back. The alloy surface is plateu with three - part alloy. For strengthened engine
and 132kW
bearing and anti - fatigue capabilities. The connecting rod bearing shell is located with a elastic cylindricalpin pin. Main bearing shell: this bearing shell is made of lead - copper with steel back. The alloy sunace is plated
,vith ternary alloy. There are oil
with spring pin. The lower half of this shell is of " quad - alloy - plated( optional)" and is corresponding with the connecting rod quad alloy plating,which is mainly applied in high power engine.
rod:
There are
/1500
for power generation) , the upper shell is of
made through mould forging, composed of c(lnnecting rod body, connecting
rod blot. The big end is 45°sectioned and the mating face is located with
two
connecting
turn
body
is machined with the cover, and they are not interchangeable. There are mating
rod
bolts
6000nce more.
(Fig.
9)
grooves
on the upper half of bearing shell. The main bearing shell is located
(M14
x
1.
5
-12.9).
(e.
"quad
g.
When mounting, tighten them with
may
the engine models of 120kW/15OOr/min
- alloy - plated layer" with bigger load
rod
cover,
canse the
.
--
I
@)
• 1
I
Fig 9
The
face
with "TOP" upwards
The
face
with "TOP" upwards
--
Fig 10
18
Page 23
3.4
Gear train
Camshaft timing
2=68
2=30
When the 18lcylinder piston is at TDC, the
"0-0"
ing with four MI0 x
to
the mark
mark on
two
tooth of camshaft gear, and the
"0-0"
1.
on injection pump gear
25 - 10. 9 bolts, and the four screw holes are uneven distributed for easy aligning of
mark"
Crankshaft
2=34
Fig.
11
0"
on
mark"
(see
fig.
gear
the teeth of crankshaft gear is corresponding to the
0"
on injection pump drive gear is correspond-
11).
Camshaft gear is fastened on the camshaft
marks on the cam and the gear. The tightening force of these bolts are 85
M8
is connected with camshaft gear by four pump drive gear and camshaft gear can be moved relatively. by
adjusting the injection
pump,
change the relative position of the
- 12. 9 bolts, and the tightening force is 85 + 5Nm. Injection
If
the injection advance angle
two
+5Nm.
gears.
Injection
2=45
pump
gear
Injection pump drive gear
cant
be reached
3. 5 Cylinder head and valve system Cylinder head:
valve). port respectively. For turbocharged engine, the intake valve seat cone angle is 120 seat cone angle is 90°(fig. all The width of valve seat face:
The injector is at the opposite side of intake/exhaust ports and forms an angle of 65°with the bottom face of cylinder head. There are other is
90
The
intake!
0
(
fig.
13)
at
the intake/exhaust port flange. The relationship of cylinder heads and diesel engines are as fol-
made of alloy cast iron, one cylinder one head (with one intake valve and one exhaust
exhaust ports are at the same side ofthe head. There is a seat ring on the
0
,
12)
. For natural aspiration engine, the intake/exhaust valve seat cone angles are
intake!
and the exhaust valve
.
2.0
-2.
7mm
(intake
1.
4 - 2.
two
water outlet ports available. One is on the top face of cylinder head and the
valve seat of turbocharged engine)
Omm
(other
valve
seat)
19
exhaust
Page 24
lows:
Cylinder head part No.
Water outlet position
Intake valve
cone angle
Top faceofcylinder
12212203
head
90
Top faceofcylinder
12214114
12214~78
head Intake/
exhaust port
120
90
flange
Intake/
exhaust port
12214132 120
flange
Valve
seat/valve
guide TD/TBD226B
Diesel engine structure
0
0
Natural aspiration, ter
outlet pipe are all separate parts
Turbocharged,
air
intake pipe and wa-
air
intake pipe and
-;
water
outlet pipe are integral cast
0
0
Natural aspiration, ter
outlet pipe are integral cast
Turbocharged,
outle"~
pipe are all separate parts
air
air
intake pipe
intake pipe and wa-
and
water
Valve seat/valve guide D226B
Seal
ring
1.4-2.0
Valve guide: made
of
haust valve guide length is
Fig. 12
phosphor cast
51.
5mm. Mounting position of valve guides are shown in fig 12 and fig 13. There
iron,
and phosphate coating. Intake valve guide length is58
Fig.
13
mm,
are grooves and a rubber seal ring on the inner wallofguide to prevent oil from entering into cylinder. Valve system: composed- of camshaft,
tappet,
push
rod,
rock
ann,
rock arm bracket, valve, valve spring
and some accessories.
Oil passage
The
oil came from cylinder block enters into tappet
grOC1r~
arm shaft to lubricate the friction surfaces of rocker
on the
of
valve system is shown in fig 14.
tappet,
and
then into the hollow push
and
the spherical surfaceofpush rod through the ring
rod,
the rocker arm adjusting screw, the rocker arm
ann
and
valve.
20
ex-
and
Page 25
Cold clearance of valve:
Inlet valve clearance:
Valve timing when the valve clearance is imm,Acceptable clearanle:
0.2mm;
exhaust valve clearance:
0.3mm.
±3°.
Intake valve open: 0045'CA after Intake valve close: Exhaust valve open: 32°45'CAbefore Exhaust valve close: 0°15
Coat some clean oil on the sunace of camshaft hole in cylinder block before mounting the camshaft. The fan-
like stop plate for camshaft should be mounted. The stop plate is fixed with ning force is
When mounting, coat some oil on the surfaces of rocker arm and rocker arm shaft. Rocker arm bracket is
fixed with MI0 ­with a nut by force of 20 +5
55+5Nm.
8.8
8°15'CA
'CA
bolt, tightening force is
Nm.
after
before
IDC
BDC
BDC
TDC
twoM8-12.9
40
+5Nm. Lock up the rocker arm adjusting screw
blots, it'tighte-
(M9
xl)
Oil inlet
Fig. 14
Valve: The valves for turbocharged and natural aspiration engines are made of different materials, they can
not be used interchangeably. For turbocharged engine, the valve rod and valve head are made of different materials. All valve rods are chrome plated. sinkage is about 1. 03 - 1. 42mm.
Mter
the valve is assembled on the cylinder
21
head,
the valve
Page 26
Mter
cylinder heads are mounted on cylinder block, all
&'~re
the sealing of intake/exhaust manifold. Cylinder heads is fixed with four.Ml4 oil (I.llolybdenum disulfide is not Pennissible). The bolts should Fig
15
by 3 times. First, tighten up with a force of 30Nm, then turn the nuts through an angle of 120
0
then turn the nuts through another angle of 120
intake/
exhaust flanges must beonone plane to en-
be
tightened accordingtothe sequence in
':'12.9
bolts coated with
0
,
and
Caution: The cylinder head bolt will be elongatedby0.2 the support face is up to
160.5mm,
the bolt must be changed.
Fig.
3.6
Fuel supply system
Fuel supply system is composed of injection
pipe,
pressure
low pressure pipe and some accessories.
pump,
governor, fuel supply pump, fuel filter, injector, high
-O.6mm.
15
(Fig.
16)
If
!be
length from the end of the bolt to
Injection pump and governor assembly:
Generally, injection pump, governor and fuel supply pump fall into one assembly. 226B diesel engine a­dopts type governors are also adopted
There is a mounting flange on the end face of injection pump and there is an The injection pump is fixed with 4 studs, and tightening force is 35 pump gear, the for injection pump (fig.
AD
and P Bosch injection pump and type
(see
"Fuel
system matching table" ) .
mark"
0"
on
injection pump gear should be faced with the
11).
RSV
governor, some other types of injection pumps and
0 - ring on the end face stop.
+5Nm. When mounting of injection
"0-0"
mark on the drive gear
22
Page 27
Fig. 16
23
Page 28
Check
and
adjusting for delivery beginning.
Correct delivery beginning can enable the· engine to obtain pertonnsnce. The crankshaft angle can be detennined by meas-
uring the displacement which the piston
be done by making use of the flywheel mark. It is recommen-
to
ded
use the fonner method for more precision.
from
TDC, also it can
good
When determining with the piston displacement,
you should:
( 1) Turn the crankshaft to let the piston of cylinder next
to the gearcase end at TDC position of compression stroke intake & exhaust valves are all
(
2)
Dismantle the rocker seat.
(
3)
Dismantle the valve spring of intake valve or exhaust
valve. The valve head falls on the piston in the meantime.
(4)
Set the dial gauge 1 with clamp at the top of valve
stem.
(see
Fig. 17)
(5)Turn the crankshaft along
measure the position of piston at TDC, and dial the hand of di-
closed).
CW
and CCW directions to
(the
to
al gauge
working direction, and let the valve drop to not more than 15mm.
Fig. 18)
mount the overflow pipe
delivery pump until
verflow pipe while turn the crankshaft slowly along its working direction. Stop turning crankshaft as soon as the dropping oc­curs, beginning for this cylinder. The delivery beginning angle can be found in the relationship between crankshaft angle and pis­ton displacement
0 graduation.
(6)Turn the crankshaft along the contrary direction
(7)
Pull control handle 4 to the middle position.
( 8) Dismantle the delivery valve 5 of injection pump and
6.
(see
Fig.
19,20)
(9)Get rid of the air in fuel piping with the hand pump of
no
bubble spills from the overflow pipe.
( 10)Pay attention to the moment of fuel dropping
and the crankshaft angle is the very position of delivery
(see
Appendix1)by comparing it with indi-
to
from
its
(see
o-
Fig.
17
,18,19,20
cated value
on
the dial gauge.
24
Page 29
(11) Adjustment should to be doneifthe measured angle differs
in
angle, which
the fuel system matching table.
from
the required fuel supply advance
Note: the valve might fall
turned.
IiI
ordertoprevent this situation occuning, clamp ring can be mounted in the groove of valve stem.
down
into the cylinderifthe turning angle is too big when the crankshaft is
Examining by the flywheel mark:
There are
on
the end face of flywheel is observed via the round hole 1
flywheel, lightening with flashlight, you can read the scale at the center of the circle. For the 8cale on the
circumferentia of flywheel, you can read it via the side window 2 on the flywheel housing ( see Fig. the pointer.
( 1) Get rid of the air (
2)
the high pressure pipe from fuel pump.
(3)
end) at compression stroke, when turning continuously near delivery beginning, you should slow down and
observe the fuel level from the port of delivery valve holder, stop turning as soon as the level rises. Read the degree of the angle scale before
vance angle
TDC
sign and scaleonthe end face or circumferentia of the flywheel
(see
Fig.
21)
below the starting motor on the
in
fuel piping.
Loosen the connecting nut between the high - pressure pipe and fuel pump at the
Turn the crankshaft along working rotating direction and make the piston of 1st cylinder (flywheel
TDC
from
the flywheel, adjustment should be donetothe fuel supply ad-
if
the degree is out of standard.
(see
Fig.
g~
6).
end,
The scale
22)
and
divorce
2
Fig.
21
Fig. 22
How to adjust fuel supply advance angle:
Loosen the tightening nut of the injection pump flange, and turn the pump. The fuel supply advance an­gle increases when the top end of injection pump is turned towards cylinder block, and the angle decreases when doing in reverse. Check according to the above method after adjusting, and readjust until the advance angle meet the stated requirement.
25
Page 30
The fuel supply advance angles for different models of diesel engine are listed in Fuel System Matching
Table.
Relationship among plunger diameter ofinjection
pump,
speedofengine
fuel supply advance angle:
1500
-1800
9
9.5
10
11
21
18
16
14
Injector assembly:
BOSCH S type nozzle is adopted for the diesel engine. Nozzles differ from each other in the number of
orifices, orifice diameter and angle of spray according
tem Matching Table for details.
The fuel rough filter should be set before the fuel entering into delivery pump from fuel tank
the delivery pump and the fuel fine filter.
to
different requirements of the engines. See Fuel Sys-
3. 7 Lubricating system
and
to
protect
the
The schematic diagram for lubricating system:
Opening pressure
540-750kPa
I I
I
l Fig. 23
Piston
jet
The lubricating system consists of strainer, oil pump, oil cooler, oil filter and pressure limiting valve
26
Page 31
etc.
The strainer is the intake opening of the oil pump, the connection between it and the inlet of oil pump is sealed by otherwise the ing burning the filter seat which has a safety valve (opening pressure is oil sump when the pressure of oil pumped from oil pump exceeds the opening pressure value of safety valve. There are sockets on the filter with the oil filter at the filter seat. The oil enters the oil cooler from filter turns the filter to
the actual need of different model, only one cooler can be used for the engine, also can be used gine, user may adopt out - connected cooler, be used instead of the former seat. The oil filter is of spin - on type, and can be used only once. In the lu­bricating system, pressure lubrication is adopted for the main bearing, connecting rod bearing, cam bearing, two
stage balance mechanism bearing, rocker bearing, injection
and splash lubrication is adopted for the connecting rod small
0 - ring,
air
and
seat,
in
series.Ifthe engine - mounted oil cooler
and
special attention should be taken to avoid leakage during installing the connector,
sucked in the oil pump will influence oil supply so astoresult in severe accidents like bear-
engine damage. The oil pump is of gear pump. The pumped oil from oil pump enters into
540
-750kPa)
seat
for pressure sensor and oil cooler. The oil cooler is con:nected in series
then enters the main oil passage. Each finned oil cooler has 9 cooling
cant
meet the requirement of oil cooling for the en-
but
the filter seat 12273108 with oil inlet & outlet
pump,
end,
gear
on it. The oil will be vented
seat,
through the oil filter and re-
chips,
two
or three coolers
jointsahould
turbocharger, air compressor etc. ,
train,
piston, cylinder liner etc.
according
3. 8 Cooling system
to
Besides becoming kinetic energy to do work, the heat energy produced by the fuel burninginthe com-
bustion chamber ofthe engine also heats up the cylinder head and cylinder liner etc. , therefore coolant cool-
to
ing should be used
3.8.
1 Schematic drawing of the cooling system The supercharged: inter - cooled diesel engine is equipped with supercharging air cooler( intercooler) ,
whichis positioned between the fan and radiator.
prevent them from overheating and guarantee me enginetowork reliablyinorder.
27
Page 32
Water
outlet
pipe
~
Q)
'0
o
u
~
Q)
§
I
W
~
Q)
'0
o
u
.......
Cylinder
head
o
cylinder
Fig. 24
3.
8. 2 Main componentsofcooling system
Water
mediate gasket, the water pump is integrated with the intermediate gasket and mounted at the front end face
of cylinder block. The cooling water enters into cylinder block through intermediate gasket. The impeller di-
pump:
the pump is of centrifugal type. The vortex passage of water pump is settled at inter-
block
ameter of water pump is 86mm or 110mm. Water pumps with different sizes should the applied speed and requisite cooling flow of
Water outlet pipe: the structure of water outlet pipe has
other is cast part connected with intake manifold, the latter is applied to the following arrangement, water outlet of cylinder head is located at the flange surface of intake and exhaust ports, and the adopted
built - in thermostat inside the water outlet pipe. There
the
diesel engine.
is
vent pipe
two
forms, one is welded
(dia:
the water outlet, this pipe should be connected with expansion
be
6mm)
tank
chosen according to
part;
and an-
i.
e. the
at
the top of
or
the cavity
of
upper water chamber of radiator, gas in the cooling system is guided out via this pipe to prevent water overheating due to
Thermostat:
type. Its opening temperature is temperature of the thermostat, thermostat, and the diesel engine needed under normal operation; when the temperature of outlet water is higher than opening temperature, the thermostat opens till full opening,
there are
temperatu":,,eof<:ooling
two
kinds of thermostat types, one is outboard type and anotherisbuilt -
75'C.
the
When the outlet temperature of cooling water is lower than opening
cooling water enters into water pump via the.outlet for minor circulation of
water is quickly raised to reach the water temperature which the
air
resistance.
all or partial cooling water enters the cooler to be
28
in
Page 33
cooled, and then enters into water pump.
Radiator
The radiator is fin al. The fan is made of pressed metal sheet or extruded plastic; its diameter is The fan can
3.9
Int9ke & exhaust system
This system includes air cleaner, intake manifold, exhaust manifold, exhaust muffler, exhaust turbo­charger connecting pipes.
3.9.
the resistance in intake pipeline should
corresponding capacity should be chosen for the engine with different power, and the cleaner with different model should
(for
1 Intake
The intake air for the engine should be clean and enough, therefore the intake air must be filtered and
Dry type paper element
and
fan:
(the radiator is supplied· according to users contract)
and
tube radiator, its capacity is configured according to the quantity of heat remov-
466,
be
mounted on ,water pump.
turbocharged diesel engine) , intercooler
be as small as possible.
air
cleaner is applied to 226B diesel engine for generating. The air cleaner with
be
chosen accordingtothe dust content of ambient air in actual working site.
(for
turbocharged and intercooled diesel engine) and
520,
540
and
600mm.
The dye type paper paper cartridge and safety element, as well stalled after the primary filter be too condition is 5kPa.
signal is given performance
ty. Otherwise largely increased oil consumption, crankcase blow ­exhaust and so on would occur because that the filter lose its effectiveness and is in short circuit leading early wear of the engine der
structures for to the cylinder used to jointed manifold.
big,
the allowable max. resistance under its unstained condition is
that
and
In mounting the air cleaner and connecting
liner and piston
The intake manifold of the engine is jointed by plates or cast by aluminum alloy, and there are various
ittosatisfy the requirements of different diesel engines. When the intake manifold is mounted
head,
ele~ent
There is maintenance indicator mountedatthe vent
means maintenanceorreplacement should be taken place in time, otherwise the
service life will be influenced.
and
could not achieve the specified service life. It even causes the serious wear of cylin-
ring,
compound material gasket is used to aluminum manifold, while stainless steel gasket is
The stainless steel gasket shouldbemounted
the cylinder head. The tightening torque
filter usually has primary filter ( it can make the air produce swirling flow) ,
as
auto dust - extracting valve or exhaust arresting device in-
to
take off the dust from filtering. The resistance of the air cleaner should not
pipe,
users should pay attention to its sealing
by,
decreased engine power, black smoke
and breakage of piston ring and cylinder scuffing.
with
for
tightening
nutofintake manifold is
3kPa,
and that under its stained
portofair
cleaner, when red
its convex surface facing to
45
± 5Nm.
and
reliabili-
3.9.2
Exhaust
29
Page 34
The three - cylinder or four - cylinder diesel engine adopts unitary exhaust
inder engine adopts inserted exhaust manifold which is made up of
wi.th
and sealed
narrow width ring. The
stainless steel gasket, the convex surface
joint
between exhaust manifold
of
which should face to the cylinder head. The
two
parts
m&nifol~,
(every
and
part for three cylinders)
cylinder head is sealed with
and
the six - cyl-
torque
for
tightening
must have sufficient diameter or area and with bends
be
will exhaust main and muffler should not be more than
5kPa for turbocharged engine.
should be wrapped with heatproof material and as well. In addition
Because the surtace temperature of the rear exhaust prevention measures should gen, amount will
3.9.3 Turbocharging
Turbocharger:
nutis45
The exhaust resistance of diesel engine should be as small as possible; therefore the exhaust manifold
influenced
In order
oxycarbide and carbonic smoke particle. Frequently breathing in those exhaust gas or particles in large
to
do
±5Nm.
<.IS
few
as possible, because the pertormanceofengine
Gbvio1:lsly
lower the surtace temperature of exhaust manifold and for safety reason, the exhaust manifold
to
hanntohuman,
and
Both turbocharging models and the turbocharging inter - cooling models of the 226B se-
if the exhaust resistance excee.ds a certain value. The sum of the resistances of
7.
5kPa for natural aspirated engl.tle, and notbemore than
cO\(ered
that,
some of the engines adopt water
be
provided. The exhaust gas of the engine contains nitrogen oxides, hydronitro-'
so such exhaust gas should be kept away
inter - cooling system
with armor plates, and high temperatare caution sign
jacket
pipe,
muffler, and expansion joint is very
exhaust manifold.
from
the personnels.
high,
external
ries engine employ the radial flow exhaust turbocharger. See the accessory list for the those models. The oil
the
lubricating and cooling back into the crankcase.
The exhaust turbocharger is a kindofrunning mechanismatits high speed The immediate
halt den. The right way other
5 -10minute so astoavoid any damage to the turbocharger bearing. After the turbocharger is
disassembled, someclean engine oil should be
air
Charging
The temperature will
er
of the 226B turbocharging inter - cooling engine features: air -
intake air temperature.
air
Air ­together with the circulating water radiator, cooled by fan. The intercooler can back of the radiator, determined by the wind direction of the fan. The intercooler could also line with the radiator, determinedbythe overall fitting mechanism.
cooler (intercooler)
cooling intercooler ( delivered conforming with the contract) , generally speaking, is assembled
turbocharger flows into the turbocharger from the main oil passage then directly
and
high temperature.
when the engine is runningathigh speed is
to decrease the load
and
the speed gradually
putatthe oil inlet during
goupafter the air goes through the turbocharger and gets pressured. The intercool-
and
with large load is strictly forbid-
and
let
the
engine
the
mounting process.
air
cooling. is used to lower the pressured
be
placed in frontoforatthe
run
idly for an-
be
30
placed
in
Page 35
The maximum acceptable
pressured air from the supercharger is passing through the pressure pipe should
flow
resistance (superchargertointercooler/ intercoolertoengines) when the
be
less than 2kPa. The
flow
resistance while going through the intercooler shouldbeless than 5. 0 - 5. 5 kPa.
tal resistance when the pressured air is passing through pressure pipe and intercooler is
3.
10
Electrical system
The system is consisted of starter, chargeable generator, control instrument and storage battery. The
12V,
service voltage is 24 V or
Starter:
rated power is
The starter is a
4kW
at the working voltage of 24V and 2. 7kW at the working voltage of 12V.
subjecttothe choice of the customers.
DC
motor controlled by electromagnetism. Without specific requirement, the
So
the limit value of the to-
7.
0 -7.5( kPa).
L
Fig 25
Generator: The generator is a kind of silicon rectifying generator equipped with transistor adjustor.
The rated voltage is 28 V or 14V. The generator is connected parallelly with the storage battery. The genera­tor is self- excited when working.
SC,hematic
diagram of the starter
31
J
Page 36
w
.8
ro
d----+-----lJ
Fig 26 Schematic diagram of the generator
Storage battery (generally self - prepared by the customers)
Storage battery capacity
B+
D+
Cylinder quantity Starter voltage V
3,4 3,4
6 6
Monitoring instrument:
accurately display the
to
toring light warning and distant transmitting. There is interface on the monitoring meter, through which a remote monitoring meter cording
above parameters accordingtothe setting of the customers and send signals like sound warning,
can
to
the contract. Refer to the monitoring instrument instruction for detailed information about it.
The monitoring meter isanautomatic diesel engine monitoring system, which
speed,
be connected ( they must be used together). The monitoring instrument is delivered ac-
oil pressure, water temperature and oil temperature. It can make timing moni-
24
12
24
12
Storage battery
capacity Ah
66
88 88
110
can
32
Page 37
Schematic diagram of the electric circuit connection
13
1. diesel engine
2. starter
3.
adjustor of the generator
4.
AC
generator
5.
the connecting wire from the
AC
generator to starter
6. storage battery
7.
the anode connecting wire to the starter
8. earth wire
9. connecting wire from starter to charging indicator
10. connecting wire from starter to ignition lock
11. connecting wire from starting button
12. meter cover
13. ignition lock
14. starting button
15. temperature warning light
16. oil pressure warning light
17. charging indicator light
18. temperature sensor
19. oil pressure sensor
33
Page 38
3.11Main bolts tightening torque
Name
No.
1 Cylinder head bolt 30Nm, tum
2
3
4 Flywheel pipe
5
6 MI0
7
of bolt Specification
Main
bearing bolt
Tightening nut of intake pipe and ex­haust pipe
Fastening boss of crankshaft boss
Fastening holt of the pulley on boss
Fastening bolt of the dampener
the
M14 M14
M14
M10
M16 M16
M16
MI0
M12
MID
MI0
-10.9
-12.9
-10.9
-10
-10.9
-10.9
-12.9
-8.8
-10.9
-8.8
-8.8
-10.9
Tighi:ei~ing
Maximum
Pre - tighten with a torque
120° Pre - tighten with a torque of
70Nm,turn 90°
45 50
285 295 240 250
300 310 45 65 70 85· 45 65
torque( Nm)
( max) Minimum( min)
of
1:1.00,then again turn
50
90 50 70
Tightening bolt of the camshaft gear
8 and the fastening holt of camshaft
gear and fuel injection pump gear Fastening bolt of the mounting gear at
9
the oil injector camshaft
Connecting rod bolt
10
Fastening bolt of the flywheel housing
11
and other fastening bolt and stud bolt
Fastening bolt of oil
12
cylinder - head bolt for bearing the oil pan. Fastening bolt of
13
mechanism Fastening bolt of oil pump and
14
stud bolt
with
self
pan,
two
stage balancing
-locking
hexagon
the Durlok
nut
Durlok
MI0 *
M14 M18*1.5
M12
M12 M12 M10 MI0
M8
M10
1.
*
M8
M8
M8
- 12. 9 55 60
25
*
1.
1.
5 - 12. 9
-12.9
-10.9
-12.9
-10.9
-8.8
-10.9
-8.8
M8
- 12. 9
-8.8
-10.9
5
85
85 100 110
Pre - tighten with 30Nm,turn 60°
140 110 120 80
60
20
30
35 40
30 40 20
90
100
a torque of
145
85 65
25
35
25
34
Page 39
Construction bolt of rocker
15
port
16
Adjusting nut of rocker
Fastening bolt of cylinder head hous-
17
ing Fastening support for tightening the
18
oil injection pump delivery valve Fastening bolt of high pressure fuel
19
pipe
20
Fastening nut of oil injector
ann
ann
sup-
MID
M9
M8
M12 MI4
-8.8
*1
-8.8
*
*1. 5
M8
40
20
10
33
1.
5
20 20
10
45
25
15
37 25
25
15
21
Fastening bolt of hydraulic pump
Fastening bolt of
22
AC
generator pulley
MIO
M8
-10.9
-10.9
MI4
60
30 35
65 35
40
35
Page 40
4. Operating requirement and procedures
4.1
Rules on the working fluid
and
the auxiliary material
4.1.1
oil
Quality class: Oil is classified according to its quality and characteristics, usuallyonthe basis of API . Oil which is allowed to use API class: CC
class oil should be selected for non - supercharged diesel engines while the
CC,CD,CD
charged ones. It is allowable for the
- n
,CE
CD
low
- quality oil to be replaced with high - quality oil.
class oil for the super-
Viscosity
The viscosity of the oil is ,
propriate oil viscosity class( SAE
to
a great extent, detenninedbythe temperature. Refer to the right figure for ap-
class).
Please refer to the right figure for the oil viscosity and select the most appropriate oil. The situation where
the environment temperature is close
to
the temperature limit will have some influence on the cold start per-
fonnance but not necessarily damage the diesel engine.
Do
not exceed the temperature limit
for
long timesoastokeep the abrasion within a minimum extent.
Multi - class oil could be used so that it wont be necessary to change the oil during the seasonal alternation
period.
be
The fuel consumption rate could
It
is recommended to use 15W/40 oil when
lowered by using multi - class oil
the
environment temperature is above -15CC
(light
oil especially)
and
use
5W
/30
when
it
is below -
15CC.
OF
-13
-22
-31
-40
86
77
68
+20
59
+10
50
41
32
0
23
-10
14
5
-4
-20
-30
-40
*
*
+
36
Page 41
4.
1.2
fuel
.This engine makes use of light diesel as the fuel.
Quality grade Sulfur content of specified brand· fuel is not allowed
to
exceed I% .
The fuel with following brand numbers is permissible:
-
DIN
51601
NATO
-
-BS2869:Al,A2
-
ASTM
- W
The waxiness producedbythe diesel under
CODES
0975
-F
-800C:DF
F54,F57,F76
(pay
attention to the sulfur content of the A2)
-81:1-D,2
-A,DF
- D
-1,DF-2 low
temperature will leadtothe
low
fluidity of the diesel and the
blockage of the fuel system and eventually result in the operating failure of the diesel engine.
So please use winter diesel when the environment temperature is blow
When the temperature is between and kerosene to meet the
low
In the case that the summer diesel has
60%
exceed
could be added, as is illustrated in the figure blow.
-15OC
and -
20CC
, the diesel engine could employ a mixture of diesel
temperature requirement. Refer to the right figure for the mixing ratio.
to
be used at a temperature of
+32
+23
0
-5
blow
oOC.
DOC
, some kerosene which
do
not
-10
+14
-15
+5
-20
-4
-25
-'13
-22
t t 0 10 20 30 40 50
OF
OC
I
'Ambient
temp
Mixing
ratio
60%
-.
Notice: the mixing process should he proceeded in the fuel tank. Fill in some diesel before adding enough kerosene.
4. 1. 3 cooling fluid
The cooling water of the diesel engine must be soft water and anticorrosive agent and anti - freezing agent must be added. Anti - freezing fluid
for
Please refer to the anti - freezing fluid instruction Longacting anti - freezing fluid
the mixing ratio of the longacting anti - freezing fluid.
37
Page 42
Glycol content %
33
50 56
Density( 15.
Boiling
Freezing
Min. temperature appropriate
The concentrationofthe anti - freezing agent should be checked once every 1 at
least one checkout in every season. The anti - freezing agent should be changed every
void corrosive damage. Anticorrosive agent Anticorrosive agent can sUmmer or autumn or in some areas with relatively high temperature). Cooling water The compositions of the cooling water are analyzed as following:
Water quality
6CC)
pointCC
pointCC
be added
1.05
104.5 ±1
-18
±1
CC
to
the cooling water when the environment temperature is above
-10
nun.
1.074 1.082
108.5 ±1
-36
±1
-26
()()()
max.
110.0
± 1
-
-45
±1
-35
hours. But there should
two
years80as to a-
5CC
I
be
(in
PH value The content of chloride ion
3
(mgldm
Content of carbonate Content of overall anion
Degree of hardness when using the anti - freezing agent
Degree of hardness of the carbonate
Degree chemical anticorrosive agent
Inner zinc - plated pipe is not appropriate for containing chemical anticorrosive agent80it cannotbeused as cooling water pipe.
4.
1.4
Waste fuel and oil should
)
(mgl
(mgl
hardness whenusing
of
Treating of waste fueVoil
be
stored in a special container. Because there exist poisonous substancesinfuel,
dm
3
dm
)
3
)
6.5
-
-
-
3
3
Notice, the instruction of
the supplier
0
I
8.5
100
100 150
12
-
10
Only the water with
compositions
the
specified content
·of
~
he added with addititin
agent
oil and coolant,
drink or contact with skin is forbidden.
38
Page 43
4.
2 swinging requirement
Inappropriate swinging might damage the diesel engine during the conveying process.
B
It is 'inappropriatetouse a rope and a triangle to sling the engine up. Becauseifthe slings, the cylinder
head bolt and the
s~inging
ring are not kept in a
line,
the cylinder head bolt might be damaged or even frac-
tured during the swinging process, which may eventually result in the failure of the engine.
4. 3 Preparation before the start
Notice: The engine should notbestarted until it has been installed in a appropriate placed in a final position. H the engine is operated in a closed environment, make sure there is good ventila­tion and that the exhaust gas is discharged into the atmosphere.
4. 3. 1 Engine oil filling
1. The oil must meet the specified requirement, otherwise, the oil pressure might fall short resulting in abrasion and starting difficulty. The oil must be very clean.
2.
Screw down the oil - draining plug
3.
Open the oil cap and fill in the oil. The oil must be filtered through a dross filter when it is filled in.
4.
Put the engine at a level position; pull out the dipsticktoexamine the height of oil level. Fill the oil
to
the upper limit of the dipstick,ifnecessary.
up
5.
Screw down the oil cap. Notice: The height of oil level must be checked out every time before starting the engine.
way
and
I
39
Page 44
4.3.2 Filling in the fuel
1. The
2.
diese~.
b~ing
used must comply with the regulation.
Pay attentiQntothe cleanness of the diesel; it had better be stored foratleast72hours before being filled into the engine. The diesel should be filled into the tank through a build - in dross filter. Notice: The diesel level should
4.3.3
Deflation of the fuel system
1. Unloosen the fuel bolt 1
be checked every time before starting the engine.
(at
the fuel outlet of the fuel supply pump) for half a round. Pump with the
hand pump 2 of the fuel supply pump 3 until there is diesel coming out; screw down the fuel bolt.
2. Open the deflating bolt 4 on the fuel filter
5.
Pump with the hand pump of the fuel supply pump until
there is diesel coming out; screw down the deflating bolt.
7.
3. Open the deflating bolt 6 on the fuel injection pump
Pump with the hand pump of the fuel supply
pump until there is diesel coming out; screw down the deflating holt.
4.
Continue pumping with the hand pump and check whether there is leakage in the fuel screw down the hand pump.
pipe,
then
4.3.4 The cooling fluid is compounded with softened clean water and anticorrosive agent(or anti - freezing
Filling in cooling fluid
agent).
The whole compounding process must be proceeded strictly in accordance with the regulations set by the
40
Page 45
manufacturer.
Notice: tion. as the cooling fluid system. Refer to the 4. 1 for the regulations ofthe operating fluid and auxiliary material, add anti - freezing agent. The liquid level of the cooling fluid level must be checked out every ti.:ie before starting the engine.
4. Refer to the storage battery instruction.
smoke
battery
mountofwater The operating sequence of c?arging process
Frequent
The
leakageofthe
muchaspossible
water
3.5 The charging of the storage battery
tank
Notice: around
has
water-adding
cooling system
and
avoid
can
be recycled
from
the water inlet of the radiator or heat exchanger and discharge the air of the cooling cycling
The
gas
produced
the
battery.
strong
corrosivity. H
immediately.
and
changing
after
during
Keep
any
itissplashedinthe
water
- changing
shouldberepairedassoonaspossible.
the
cooling
being
nltered
charging
open
fire
and
might
fluid,ifpossible.
through
proc~
spark
eyeoron
resultinthe
fabric
is
quite
away
froJJl
the
The
and
fine
explosive.
the
skin,
existenceofthe·
Add
clean
cooling fluid drained
structure
battery. wash
mesh. Fill in the
if
there is a need
So
itisforbidden
The
them
incrusta-
soft
acidofthe
with
large
water
from
1. Open the sealing cover.
to
to
a-
from
2. Fill into sulfuric acid
3. Fasten the sealing cover
4.
Coat the electrode of the battery with anticorrosive grease
S. Connect the connecting rod with the binding post, connect the anode first
6. It is not allowed to place any metallic object on the battery
7.
Check the sulfuric acid surface every day. Add distilled water if necessary.
4.4
Start
-rnfus~
the engine
1. Put the speeder rod in the central position
2. Connect through the power switch
3. Turn on the starting switch until the engine is started
ond).
4. gine and get rid of the failure.
S. Warm the engine up before operating at full load, check the cooling fluid circulation and whether the oil
the raw water pump of the marine engine with water. Rotate the crankshaft a
to
make sure there is no rotation obstruction.
Immediately check the oil pressure after the starting.ITthe oil pressure is less than lOOkPa, stop the en-
the filler port until the surface reaches the marker.
(The
maximum starting time every time is 6 sec-
few
round before starting
pressure is norntal.
6. Check the Three Leakage condition every time after the operation of the engine.
41
Page 46
Notice: When the engine is running,
it
is not allowed to remove the cables which are connected to
the voltage regulator and the battery anode. Differing from the DC generator, through voltage checking on the
AC
generator by the means of temporary earthing.
it
is forbidden to
4.5 Speed regulating
On the engine whose speedISvariable, the engine
. speed can be increased by turning the speeder rod in
the direction shown in Fig and loosen the locknut 4 tion. It is not allowed to open the lead sealed cover The speeder steel wire.
4.5.1 Speed fine - regulating mechanism The speed fine - regulating mechanism is used to the fixed - speed engine. Umoose the bllJcking speed, while turning counterclockwise will decrease it. Lock the nut 7 after speed regulating.
rod
1 can be pulled by pull rod or coated
2.
Screw out blocking nut 3
to
carry out idle speed regula-
5.
7,
rotate knurled screw 6toregulate the speed: turning clockwise will increase the
go
4. 6 stopping the engine
Do
not
try
to
stop the engine at full load. Decrease the speed before stopping'the engine and letitrun idly for
another 5 to 10 minutes. When trying to stop the engine manually, press the stopping rod 8 downwards until the flywheel stops rotating or the instrument board indicates lectromagnetic valve, the engine will stop the power off after the engine is stopped.
As for the engine whose circulating water is not added with anti - freezing fluid, in winter the cooling
water must be drained off after the engine is stopped so as to prevent the engine from being damaged
Dewatering outlet is on the oil cooler. The water inside the engine can be drained away by screw out
two
minutes after the switchover
42
"zero".
Engine stopping mechanism,ifusing
from
" open"to"close".
water-
Shut
e-
Page 47
discharging bolt. At the same time, the water - discharging bolt of the inter - cooler (regarding the super­charging inter - cooler engine) should also
4.
7 Operating
If
the environment temperature is above -15CC, the engine can be operated in a normal way.Ifthe tempei'-
ature is between the temperature is too high, the engine power should be modified. The engine is not anti - explosive, it
away from the inflammable explosive environment. The ambient illumination for engine should be more than 201ux. The engine is not suitable for underground operation.
enviro~ent
-15CC
and -
35CC
be
screwed outtodrain away the water inside the inter - cooler.
, it should be started with the help of auxiliary device.
If
the altitude or
so
keep
43
Page 48
5.
M'aintenance
5. 1 Time table for Maintenance
There is no needtorepeat after following the maintenance schedule
Working items
Re - tighten the connecting bolt and cylinder head bolt
Check the belt
Change the oil
Check valve clearance
Repeat the maintenance procedure following the timetable below
Working items
Cleanupthe air
Check and tension the V belt
Change the oil and oil filter element
Check valve clearance
Change the fuel filter element
Cleanupthe crankcase ventilation mechanism
and
and
oil filter element
filte~·
element
tension
1)
Operating time h
250
,
x x x
2)
Operating
time h
30 30 30 30
500
x x
125 125 125
1000
x
1) The change should be made earlier in dusty place. (at
Wet air filter should be cleaned every 200 hours
2)
Only under the circumstances where the crankcase ventilation mechanism does not intake the air.
the
The maintenance instructions for
backup
conditi~n
If the diesel engine does not operate for weeks(
Time period Requirement
Every month Trial running with load see
6 months
After 12
mounths nance procedure of this period must be carried out during this period.
If the running time does not reach 500 hours after 6 months,the required maintenance
procedure must be carried out during this period.
If
the running time does not reach 1000 hours after 12 months, the required mainte-
most) .
and emergency.
eg,
in winter) ,itmust be sealed
5.2.10
44
u..p(
see
5.2.
11).
Page 49
Overhaul
The reliablity of the engine might be affected because of abrasion and corrosion. In ordertoavoid any work­ing abnonnity of the engine, after the engine has runned for 2000 hours or after
Items Check the nozzle Check compressive pressure Check bearing clearance of the water pump Check supercharger Check fuel injection pump Check cylinder head Check cylinder liner Clear the water jacket space of the water cooling exhuaust pipe and check the corrosion Check connecting rod and main bearing Check pistion Check the crankshaft 10000 Check the camshaft 10000
we
recommend the following overhaul. The first overhaul should be proceeded
two
years( running time less than 2000
hours).
Running time
2000 2000 5000 5000
·5000 5000 5000
10000 10000 10000
Check the Check the drive gear Overhaul fuel injection pump Change oil pump
'Change water pump 10000
Change the oil sealing of the crankshaft Change
Above overhaul require expertise and shouldbecarried out by professionals.
two
- stage balancing mechanism
tb.e
damper
10000 10000 10000 10000
10000 10000
5.2 Maintenance procedure
5.2.1 cleaning up When the maintenance indicator of the filter shows a red signal or the engine perfonnance is affected because of the resistance of the filter, clean the filter
1. Dismount the main filter element
2. Lay the end surface downwards and flap the filter element carefully. Or put the filter element on ground and rollitto
dry
air filter
shake the dust
off.
or
change the filter element.
Do
not beat it forcibly.
dean
3.
Blow
from the inside and ouside the surface of the filter element with compressed air
45
(less
than
500kPa).
Page 50
4.
clean up me sealing packing. It shouldbechangedifthere is any damage.
5.
c~ck
the dust outlet in the dust - discharging valve.
6. Reinstall. when mounting the cover.
Notice: TIle main filter element of a filter can only ter a year, and should be immediately changedifthere is a damage. Mark the number of times which the main filter element has been cleaned or changed for in the exclusive marking column of the safe filter ele-
ment. The safe filter element must
1) Main filter element has been maintained for 5 times.
2)
It has been used for 2 years.
3)Assoon as the main filter element is maintained, the maintenance indicator will show immediately. Mter
4)
IT
the filter is mounted horizontally, place the dust - discharging valve vertically downward
be
cleaned up for at most 5 times. It mustbechanged af-
be
changed under following circumstances:
the operation with a defective main filter element.
5) Safety filter element is not allowed
5.2.2
Check the bolts for diesel engine, generator, injector and bolts and hoses, retighten them if necessary.
5.
Loosen the cylinder head bolts about a force of 200
Check connection bolt
2.2.
1 Tighten cylinder head bolts
+lONm immediately according
to
be cleaned.
1/4
of a rotation when engine warming, and then tighten them up with
to
the sequence as the following figure.
intake!
exhaust manifold and the connection of
46
Page 51
5.2.3 Check and tension the V - belt
~ess
the V - belt with
with a new one.
If
tension the belt through generator, loose bolt 1 and bolt 2 firstly, strain the generator outwards, then tight-
en tip bolt 1 and bolt 2 and check the belt by hand.
If
tension the belt through tension pulley, loose the bolt 3 and bolt 4 on bracket5,stain the tension pulley
hand,
the distortion should not be more than 10 - 15mm, otherwise change the belt
bracket, and then tighten up bolt 3 and bolt
Caution: Change the damaged or oiled belt.
5.2.4 a. Start the engine and stop it after reaching the operation temperature. b. Place an oil tank under the engine. c. Screw out the drainage screw plug d. Drain off all oil.
Change oil
1,
4 and then check the belt by hand.
pay attention the seal ring on the screw plug.
e. Screw on the screw plug 1 with seal ring.
f.
Fill up clean oil.
5.2.4. a. Disassemble the oil filter 1 with special wrench. b. Coat some oil c. Check the oil filter for tightness in running - in.
1 Replace oil filter
on
the seal ring 2 and tighten up the oil filter by hand.
47
Page 52
5.
2. 5 Check valve clearance
a. Remove cylinder head cover. b. Make the piston reached the firing TDC. c. Check the clearance between rocker arm and valve rod end with a
O.
2mm orO.3mm feeler gauge 1. Ad-
just the clearance according
d. Loose nut e. Holding the position of screw 3 and tighten nut 2.
f.
Check the other clearances with feeler gauge 1.
g.
Set up rocker arm cover and tighten the screws. The rocker arm cover seal side should be faced with the gasket. Caution: Adjust valve clearance according
5.
2. 6 Change fuel filter
1 Close the valve on fuel circuit.
2 Turn the special tools of fuel filter counter - clockwise. Disassemble the fuel filter 1. 3 Before mounting new filter, coat lubricating oil
4 Tighten the new filter by hand.
5 Open the valve on fuel circuit.
6 Degas the fuel system.
7 Check the sealing of fuel filter.
2,
adjust the clearance with screw
to
the following stepsifnecessary.
3.
to
the firing order to avoid turning crankshaft unnecessarily.
on
seal ring 2.
5.2.7 1 Loosen the hexagon nut or screw 1. 2 Loosen hose clip 2. 3 Disassemble breather body
4 Pay attentiontothe 0 seal ring.
5 Clean the breather body in diesel. 6 Mount the breather body, change 7 Tighten the hose clip 8 Tighten the hexagon nut or screw 1.
5.2.8
Clean breather body
3.
new
0 seal ring if necessary.
2.
Clean intercooler
if
In the operation of intercooler, affect the performance of diesel engine, the intercooler should
enlarged cooled air resistance and the decreased difference in temperature
48
be
cleaned.
Page 53
5.2.9 Run - in
If the engine is in standby or emergency state, run it once a month
1
Mter
starting, check the instrument meteratonce, put
2 After running for 10 minutes, increase
Mter
3
running for another 10 minutes, increasetofull load.
to
3/4
load.
4 Check the sealing of the engine.
1/3
5 Run the engine at
load for 10 minutes.
6 Unload and stop the engine.
5.2.10 Engine maintenance
If the engine stops
to
prevent it from corrosion damage:
for
a long
time
( for several weeks) , the following protective measures mustbetaken so as
Operating order:
1. Rinse the exterior of diesel engine.
2. Drain off the oil inside the engine and the fuel in iqjection pump.
3.
Add corrosion preventivetothe engine.
4.
Drain off fuel.
5.
Mix
fuel oil and corrosion preventive on the scale of 9: 1.
1/3
load on the engine.
soasto
prevent it
from
corrosion damage.
6. Fill the fuel tank with the mixture above.
7. Drain cooling water. to
8. Add emulsifiable corrosion preventive
the cooling water accordingtothe degree of
9. Add above compoundtocooling system, and vent air from the
~ystem.
5%.
10 . Start the engine and runitfor 10 minutes.
11. Stop the engine and turn flywheel for several circles to make the combustion chamber sufficiently wet.
12. Drain off cooling water.
13. Smear exposed parts of the engine with corrosion preventive grease.
14. Close the intake manifold and exhaust manifold.
15. Repeat the above operations after three months. When the engine is demanded to put into service, you should:
1. Drain off
C?orrosion
preventive and mixed fuel.
2. Add oil to the engine.
3.
Add fuel and coolant, vent air
4.
Remove corrosion preventive grease on the exterior parts.
5.
Open the ports of intake manifold and exhaust manifold.
from
the fuel system and cooling system.
49
Page 54
6. Trouble shooting:
W
me
eduult
~
~
~
~
~
~
~
~
~
~
InJufr
-icim
cil
IJ't':lIllIIl:
~
~
~
.~
mgine
lljlM1
~
~
t..
~
Unew:n
IIBJffi
The
Failure
-cimt
Il1lpJt
~
~
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~
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~
~
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~
IlIJIIing
d
the
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~
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to
sq.
llllIt
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Ul
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o
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L L
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Unew:n
OMhe
-aoo
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Cylirxlfr
kmc-
~
~
~
lit..
~
~
Cause
The
battery
comes
loose
Governor Stop
handleisnotinthe
leverisin Insufficient Incorrect Injector Incorrect Air
lub-oil
works
valve
cleanerisunclean
Compression
powerisinsufficient,
the
stop
position
fuel
grade
abnormally
clearance
pressureisinsufficient
connectorofwire
starting
Governerisoutoforder Fuel
filterisunclean
Over
oiling
Oil
filterisunclean
Oil
pressure
V
belt Insufficient Thermostatorwater Engineistoo Engine
Yalve
regulating
valveisopen
loosened
cooling
water
pump
works
abnormally
cold
overloading
phaseisincorrectorcamshaftisassembled
oroperlv Airinthe
Incorrect flow
turbochar(rer
Big Exhaust
fuel
system
fuel
supply
advance
pathofair
compressor
are
unclean
resistanceinintercooler,
resistanceistoo
big
angle
housing
low
cooling
Faultsinturbocharger Cooling
efficiencyoffreshwater
Air
sucked
into
Oil
strainer
clogged
the
cooling
up,
oil
cooler
system
suction
position
and
impellerofthe
efficiency
decreases
pipe
leaks
be-
im-
severely
Remedy
Check
and
charge
Turn
the
governor
Loosen
the
Add
fuel
Renew
the
Check
the
Adjust
accordingtorequirements Cleanorreplace Inspect
and
stop
lub -
handletothe
lever
oil
accordingtorequirements
starting
injector, repairorreplace it
it
adjust Repair Replace Drain
off
unnecessary
oil Replace Check
and
clean
it Tensionitaccordingtorequirements Add
cooling
water
Repairorreplace
Decrease Inspect Drain
Check
off
and
and
the
repair
air
correct
load
from
the
the
system
advance
angle Rinse Rinse
Find
out
the
cause
au-J
eliminate it
Replace
Clean
Drain
up
off
the
air
assembly
from
the
syEtem
and
oosition
clean
and
Inspect,
repair
position
eliminate
the
sucnon
Page 55
Appendix
1:
Relationship between crankshaft angle
<Il
and
piston displacement S
S(mm)
0.1
0.15
0.2
0.25
0.3
<1>(
2.90
3.56
4.11
4.59
5.03
0.35 5.43
0.4
5.81
0.45 6.16
0.5
6.50
0.55 6.81
0.6
0.65
0.7
7.12
7.41
7.69
0.75 7.96
0.8
8.22
0.85 8.48
0.9
0.95
1.0
8.72
8.69
9.20
1.05 9.42
1.1
1.2
1.3
1.4
9.65
10.07
10.49
10.89
1.5 11.27
)
S(mm)
3.6
3.7
3.8
3.9
4.0
4.1 18.72
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.0
<1>(
17.53
17.77
18.02 8.3 26.84
18.25
18.49 8.5 27.18
18.95
19.18
19.47
19.63
19.85 9.1
20.07
20.28 9.3
20.5
20.
71
1 20.92
21.
13
21.
33
21.54
21.
74
21.94 10.1 29.71 14.6
22.
14
22.34 10.3 30.02
22.53 10.4 30.17
22.73
)
S(mm)
8.1
8.2
<1>(
26.51
26.68
)
S(mm)
12.6
12.7
12.8 33.62 17.3
8.4
27.01 12.9 33.76 17.4 39.55
13.0
8.6
8.7
8.8
8.9
9.0
9.2
9.4
9.5
9.6
9.
7
9.8
9.9
10.0 29.56
10.2 29.86
27.34
27.50
27.67
27.83
27.99
28.
15
28.31
28.47
28.78
28.94
29.
10
29.25
13.
13.2
13.3 34.29
13.4 34.43 17.9
13.5
13.6 34.71 18.1 40.39
13.7 34.84 18.2
13.8 34.97
13.9 35.11 18.4
14.0 35.24 18.5
14.
14.2 35.51 18.7
14.3
29.40 14.4 35.77 18.9
14.5
14.7
14.8 36.29 19.3 41.81
14.9 36.42 19.4 41.93
10.5 30.32 15.0 36.55
<1>(
33.34
33.48
)
17.
17.2
<1>(
39.18
1
39.31
S(mm)
39.43
33.89
17.5 39.67
1 34.03 17.6 39.79
34.16
17.7
39.~1
17.8 40.03
40.15
34.57 18.0 40.27
40.51
18.3 40.63
40.75
40.87
35.38 18.6 40.99
1
41.
11
35.64 18.8 41.22
41.
34
35.90 19.0 41.45
41.
36.03
36.
16
19.1
19.2
19.5
58
41.69
42.04
)
11.
1.6
1.7
1.8
64
12.00
12.36 6.3 23.30 10.8 30.76 15.3 36.93 19.8 42.39
1.9 12.70
2.0
2.1
2.2
2.3
2.4
13.03
13.35
13.67
13.98
14.28
2.5 14.58
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
14.87 7.1 24.77
15.16
15.44
15.71
15.98
16.25
16.51
16.77
17.03
17.28
6.1
6.2
6.4
6.5
6.6
6.7
6.8
6.9
7.0
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.0
22.92 10.6 30.47
23.11 10.7
23.49 10.9
23.68
23.86
24.05
24.23
11.
11.
11.
11.
30.62
30.91
0 31.06
1
31.
21
31.35
2
3 31.50
15.
15.2
15.4 37.06 19.9
15.5 37.19
15.6 37.32 20.1 42.74
15.7
15.8 37.57 20.3 42.97
24.41 11.4 31.64 15.9
24.59
24.95
25.
13
25.30
25.48
25.65
25.83 12.2
26.
00
26.
17
26.34
11.
5 31.79
11.
6
11.
7
11.
8 32.22
11.
9
12.0
12.1
12.3
12.4
12.5
16.0
31.93 16.1 37.94
32.07 16.2
16.3
3.36
16.4
3.50 16.5
32.64 16.6 38.57
32.78 16.7
32.92 16.8
33.06
33.20
16.9
17.0 39.06
51
36.68
1
36.80
19.6 42.16
19.
20.0 42.62
37.44 20.2 42.85
37.69 20.4
37.82 20.5 43.20
20.6 43.31
38.07
38.
19
20.
20.8
38.32 20.9
38.44
21.0
21.
38.70
38.82
38.94
21.
21.
21.
21.
7 42.28
42.51
43.08
7 43.42
43.54
43.65
43.77
1 43.88
43.99
2
3 44.10 4 44.21 5
44.33
Page 56
Appendix
Wear LimitsofParts
of the Enl!lne
Dimension( mm)
No.
Crankshaft
Dia. of main journal
1
Dia. of conrod journal Length of thrust main journal Axial clearance measured after mounting
2 Main bearing All the
t-----+------------------+-----t-----l
3 Conrod bearing layer or guad alloy layer is
Thick of crankshaft thrust washer
4
Dia. of conrod small end bushing
5
Piston pinExternal cylindrical sunaceOutside
6
dia. of piston pin TD/TBD 226B Piston assembly
1st ring groove( trapezoid) 2nd 3rd ring groove
Piston pin bore
Contact sunace of piston skirt
7
End clearance of piston ring( all) 1st piston ring (trapezoid ring)
Clearance of Clearance of 3rd piston ring groove
Part name & measuring point
ring groove
2nd
piston ring in groove
(oil
ring)
Original state
Max.
wear limit
Max.
69.97
62.97
36.05
3.47
35.08
35.00
2.07
4.06
III
Min.
69.951
62.951
36.00
3.42
35.03
34.994
2.05
4.04
69.93
62.93
36.07
0.4
two
bearings must be
replaced if the plated trimetal worn down
35.15
Replaceifthere is scoring
34.990
Replace if there is wear
2.11
4.11
Replace if there is evident
clearance.
if
Replace
Replace if there is wear on
inclined end face of the ring
there is vertical
sconng
2.00
0.200. 15
D226B Piston assembly 1st ring groove ( trapezoid) 2nd
ring groove
3rd
ring groove
Piston pin bore Contact sunace for piston skirt
8
End clearance of piston ring( all) 1st piston ring (trapezoid ring)
2nd
Clearance of Clearance of 3rd piston ring groove
Cylinder liner Inside diameter
9
Honing sunace
piston ring in groove
(oil
ring)
Replace if there is wear
2.10
4.11
Replace if there is evident
clearance.
2.06
4.06
III
105.022
52
2.04
4.04
105.00
Replace
Replace if there is wear on
inclined end face of the ring
Replace if vertical scoring
if
there is vertical
sconng
2.00
0.20
0.15
105.250
exceeds
O.
05
Page 57
Dimension( mm)
Part
name·
No.
D/TD/TBD226B Valve and valve guide Dia. of valve stem Dia. of valve guide bore
10
Height between valve bottom face and cylinder head face
Rocker seat
11
Dia. of rocker shaft
12 Dia. of rocker bearing bore 16.018
Camshaft Intake Dia. of camshaft journal
13
Width of camshaft locating slot Axial clearance of camshaft after mounting
Dia. of camshaft bearing bore
cylinder block
Bore
14
Bore Inside dia. of tappet hole block
& exhaust cam face
with bearing mounted in (gear end)
without bearing mounted in
& measuring point
on
on
cylinder 17.518 17.500
Original state
Max.
8.970
9.015
1.42
15.984 15.966
46.960
7. 190
47.045
47.025
Min.
8.9"'j2
9:'JOG
1.03
16.000
46.940
7.10
46.990
47.000
Max.
wear limit
8.945
9.060
1. 80
15.950
16.040
Replace if there is wear
46.920
7.220
Axial clearance:
47.060
47.050
17.530
O.
40
Thick of tooth sector
15
location Outside dia. of tappet
16
Two
stage balance shaft assembly
Dia. of balance shaft journal
17
Axial clearance of balance shaft assembly after mounting
18
Inside dia. of balance shaft bearing bushing
19
Thick of balance shaft thrust washer
for
camshaft
7.005
17.494 17.483
33.975
34.050
3.55
6.850
33.950
34.010
3.45
6. 750
17.475
33.940
Axial clearance:
34.080 (after mounting)
3.35
O.
50
53
Page 58
~
17;
~~
Weirang Weichai Deulz Diesel Engine Company Ltd
Jt!!~I::
III
It!
111
IhIS!W:
Weirang Weichai Deulz Add:No.121 Beigong Slreel,Weirang
Tel:+86-0536-8679536 Fax: +86-0536-8679526 Poslac:
fJ,1'ii!ll;Jjj'j~tg*
i1;:
+86-0536-8679536
Jl:
+86-0536-8679526 261009
Shandong 261001,P.R.China.
261009
it
~tk~
I!j
121-<:-
Diesel
~~;;fj
Engine Company Ltd
f!l~;iJ
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