Operation and Maintenan Anual: R Series Diesel
Operation and Maintenan Anual: R Series Diesel
Operation and Maintenan Anual: R Series Diesel
R series diesel engine covers 8 types as: both four-cylinder and six-cylinder with bore
of lOOmm,both four-cylinder and six-cylinder with bore of l05mm,and every style
has two models of matural aspirated and superchareged. RIOS series is bore -en-
larged from Rl00 series, besides piston, piston ring, piston pin, cylinder liner, cylinder
liner seal ring and injection pump, all other parts can be exchanged between both
two types of diesel engine.
R series diesel engine features easy adaptation to meet the various needs of
matched equipments,according to the requirement of users. It can be furnished with
hydraulic pump for Ifting and steering purposes, air compressor and vacuum pump
for breaking purposes and full power take-off from the front end of the crankshaft.
Through being changed for some of its parts accordingly, it can be used to match
with truck, tractor, small power generating station, engineering machinery, agricultru-
al machinery, irrigation machinery, drilling machinery and so on. The output range of
various version of R series diesel engine is 35 KW -125 KW , its rated speed is 1500r/
min -2800r/min. The moder, its make-up rule and the meaning of the symbol for ev-
ery type is as follows:
R 6 100 Z D 1 2
(1)@@ @@@ (j)
CD: distinguish symbol, Expressed with number sequence
~: Version symbol ,expressed with number sequence
@: application featrue symbol, expressed with alphabet
no alphabet: for common usage; T : for tractor; G: for engineering machinery; Q:
for vehicle; D :for generating set;
C: for marine usage; P: for power take-off unit
@: construction feature symbol, expressed with alphabet; no alphabet: for natural #85-
pirated model;
Z:for turbocharged model.
(S):cylingder bore( mm)
@:cylinder number
(J):series symbol;stand for imported from RICARDO
This operating manual mainly introduces common usage type. For various versions;
Being obtained as the accidental test result, the characteristic c.urves in the manual
are only supplied for reference.' And the picture in the manual cant be the accord-
ance of check upon delivery.
/ The manual is compiled by Wang Jinghai, Zhao Ruian, Yang Lin, Sun Chuanhai,
Wang Luhai, Dou Yuxiang, Jiang Bo, Yu Caihong, Liu Taicheng, Zhuang Longping,
Wei Zhiyou, Du Zhijun, advised by Li Peiyan, Chen Ling, Hao Sixian, and finally ex-
amined and approved by Chen Ling. For the limit of the compilers, there may be
mistakes in the manual, if you find any, please point out so that they can be correc-
ted. Also, it will be appreciated if you give your suggestions about our products.
The compilers
June, 2005.
•1•
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1200 1400 1600 1800 2000 2200 2400 2600 n T/min
Fig. 7 Speed and speed adjusted ~haracteristic curve for Model R6105G, R6105Gl,
R6105ZG and R6105ZGl diesel engine used for engineering machine
g/kW.h
360
340
~
320
\ \ 1500r/min
\ \ ~
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300
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20 40 60 80 Pe kW
• 10 •
glkw. h
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• II •
g/kW.h
380
360
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10 20 30 40 50 60 70 Pe kW
• 12 •
Naturally
6 Air Intake Mode Turbocharged
Aspirated
Rated Working
7 Ih OutpuVSpeed( KW/r/min)
Condition
• 13 •
3.93 4.33 3
16:1 17 :1 16: 1 17 :1 4
1-3--4-2 5
Naturally Na~urally
Turbocharged Irurbocharged 6
Aspirated Aspirated
55/2200 70/2200 7
~600 9
Etl.63 13
E;600 14
ElectrIC starting 18
• 14 •
Naturally
6 Air Intake Mode Turbocharged
Aspirated
Rated Working
7 Ih OutputiSpeed( KW/r/min)
Condition
• 15 •
4-105 x 125 2
4.33 3
17: 1 4
1-3-4-2 5
Naturally
6
Aspirated
E;600 9
:E: 1.63 13
~600 14
Electric starti'1Q 18
• 16 •
4 Pressure Ratio 17 :1
Naturally
6 Air Intake Mode
Aspirated
Rated Working
7 Ih Output/Speed( KW/r/min)
Condition
• 17 •
4-105 x 125 2
4.33 3
17: 1 16: 1 17 :1 4
1-3-4-2 5
Naturally Naturally
Turbocharged 6
Aspirated Aspirated
~600 9
258/1500 258/1500 10
~1.63 13
~600 14
ounter clockwise ( Facing to
15
the power output end)
Electric starting tg
4 Pressure Ratio 17 :1
Naturally
6 Air Intake Mode
Aspirated
Rated Working
7 Ih OutputiSpeed( KW/r/mln) 57/2200 51.5/2200 60/2200
Condition
• 19 •
6-105 x 125' 2
6.49 3
17 :1 16:1 17 :1 4
1-5-3-6-2-4 5
Naturally Naturally
Turbocharged 6
-Aspirated Aspirated
=e:600 9
=e= 1.63 13
E;600 14
ounter clockwise( Facing to
the power output end) 15
~
Forced Water Cooling 16
Electric starting 18
I I
-~
• 20 •
4 Pressure Ratio 17 :1
Naturally
6 Air Intake Mode
Aspirated
Rated Working
7 Ih OutpuVSpeed( KW/r/min) 85/2600
Condition
6-105 x 125 2
6.49 3
1-5-3-6-2---4 5
Naturally Naturally
Turbocharged Turbocharged 6
Aspirated Aspirated
65/2000 *** 53/1500 *** 88/2000 *** 72/2000 58/1500 68/1800 84/1500
Ei600 9
10
~1.63 13
~600 14
Electric s~erting 18
530
I 580 660 525 525 570 19
Turbocharged
6 Air Intake Mode TUrbocharged Turbocharged
Intercooled
Rated Working
7 Ih OutputlSpeed( KW/r/min) 110/2400
Condition
• 23 •
17: 1 16:1 17 :1 4
1-5-3--6-2--4 5
Naturally Naturally
Turbocharged 6
Aspirated Aspirated
8512200 90/2200 7
Ei600 9
~600 14
Electric starting 18
• 24 •
O. 30 - O. 50MPa
Lub oil pressure
;==O.OIMPa,when at idling speed'
NOTE: The injector of vehicle diesel engin~ should adopt fuel delivery advancer
• 25 •
9 the second compression ring and ring gra 0.040 -0.080 0.30
Gap of second compression ring in cylin- Gauge .100 +0.000 0.30 -0.50 3.00
12
dar Gauge .105 +0.000 0.30-0.50 3.00
Gauge .100 +0.008 0.20 -0.40 3.00
13 Gap of oil compression ring in cylinder
Gauge 41105 +0.008 0.20 -0.40 3.00
Shaft .54 :~:=
14 Camshaft journal neck and bUshing 0.062 -0. 125 0.25
Holet .54 ~~:::
Shaft clJ6 o- o.os axile clearance
15 Camshaft thrust plate and journal meek 0.40
Holet 4X5 o+ o -m 0.05-0.15
axial clearance
18 Idler and idler shaft
0.038 -0.095
clearance of tooth
19 Contacting clearance of various timing ge 0.60
flank 0.10 -0.15
(delective fitted)
23 Cylinder liner over the cylinder block surface
0.050 .wO. 120
back clearance
24 Water pump impeller and pump body
0.08 -1.27
Adjusting
25 Water pump impeller and packing block
clearance
• 27 •
Rl00 series diesel engines have the same kind of cylinder head with RI05 series
diesel engines.
Cylinder head is a single piece casting structure, with independent intake, and ex-
haust ports on both sides. The intake port is a helicoid type designing. In order to de-
crease the heat load of cylinder head, and consider of the supercharged condition,
the cylinder head base wall theicknessis different at the area of valve distance' and
injector seat hole, and cooled by inject cooling water. The valve guide and intake &
exhaust valve seats are interference fit with cylinder head very tightly. Valve seat ring
is made of heat resisting and wear - resisting Chrome - molybdenum casting.
Intake & exhaust valve and valve seat have been run - in when using, remember the
number of cylinder when disassembly and assembly. When sealing condition be-
tween valve and valve seat is not good, lapping is necessary, and should be clean be-
fore assembly. After long time operating, the width of valve seat contacting area may
be over 2. 5mm ,or valver seat damaged or non - round, reaming should be done, or
change valve seat if necessary. When assembly ,cylinder head should be heated at a-
bout 2000C ,then the valve seat can be in - laid, after that ream and lap it at the con-
tact area and make it at 1.3 -1.5 mm in width, valve setting value is 0.6 ..., 1.0 mm
down.
A copper - asbestos gasket is fitted between the cylinder head and the cylinder
block. The cylinder ead is tightened on the cylinder block by 18 (for four - cylinder
diesel engine) or 26 (for six - cylinder diesel engine) strengthen bolts and quenched
bolt gaskets. The cylinder head bolts should be tightened evenly by three times one
by one in regulated order and torque. (Fig. 1)
Fig. 1 The sequence of tightening cylinder head bolts
• 28 •
The cylinder blockofR series diesel engine is short skirt construction without side 0-
pening. The main oil distrib~ting passage is at the left side of cylinder block ( view
from flywheel end) , the fuel injection pump, oil filter, fuel filter and oil cooler are at
this side as well. The push - rod chamber are located at the right side of cylinder
block, crankshaft case ventilator, generator, starting motor, air compressor and hy-
draulic pump as well.
A laser quenched wet cylinder liner is fitted in the upper part of cylinder block. In or
der to press it tight enough, its upper end is 0.05 -0. 12mm, higher than that of cyl-
inder block.
The main bearing at the lower part of cylinder block is a full supporting type. The
main bearing cover is positioned horizontally by shoulders at sindes of cylinder block,
and is machined together with cylinder block, thus can not be changed each other.
For this reason, each main bearing cover has its sequential number and a triangle
symbol, the arrow of triangle is to the front. Each upper mainbeatihg half has oil
holes on it. The bearings are all made of steel back aluminum alloy. The' 'clearance
between main bearing and crankshaft journal is not adjustable. Whenever the clear-
ance is over limited value after bearing worn, it must be to change the bearings.
When tight the main bearing bolts, each two bolts at one same bearing. should be
tightened gradually and al~ernately
into specified torque. As there is anti .... loose
quenched gasket, the main bearing bolts bave no locked gasket.
3. Camshaft assembly
The camshaft of R series diesel engine is full supporting, the cam is function cam, to
adapt different working speed. Camshaft is driven by crankshaft timing gear through
idling gear and camshaft timing gar. There are engage marks on the timing gear, the
marks should be aligned when assembly. There assembled a camshaft thrust plate
between camshaft timing gear and shaft collar, to control the axial clearance of cam-
shaft.
• 29 •
specified range.
The side of the first and second piston rings with the word' top' on it, should be
faced at top side when assembled. The scraper ring is a component with inner spiral
spring. As assembling scraper ring, the opening of the inner spiral spring maintain
reed should be at the opposite sid~ of the opening of scraper ring. When piston is
assembled, the arrowhead on it6s top should be at the same side with the word
, front' on connecting rod, i. e. the arrowhead on top of the piston should be to the
• 30 •
The piston pin is full floating type, and can be rotate in piston pin hole as it getting to
certain working temperature, to make wearing .evenly. But it is cool, it· is interference
fit between piston pin and the piston pin hole. So when assemble and disassemble
the piston pin, the piston should be preheated to 80 - 90OC. Assemble piston pin by
. force at cool temperature is prohibited, othervise the pinhole may be ruined. Piston
.. pin should stagger 1mm to non - pressure plane relative to piston center, to de-
crease piston knock.
Connecting rod body and connecting rod cap are positioned by single - tooth, and
hav~ marking numbers at same side, when assembled, the number must be
regisered. The small end bushing of connecting rod is wrapped bush by bimetal ma-
terial ; the oil holes on the bushing should be right alingned to the oil gathering hole at
the top of connecting rod small end, to lubricate piston pin and bushing. Connecting
rod bolts should be tightened evenly with specified torque strictly, connecting rod
bolts are self - locked by friction force. The mass difference of connecting rod for
one same diesel engine is less than 12g, and that of piston and connecting rod as-
sembly for one same diesel engine is not bigger than 20g.
Connecting rod bearing of R series diesel engine is usually made of steel - backed a-
luminum alloy material. Connecting rod bearing of strengthen diesel engine is made
of steel - backed copper - lead alloy. It is unadjustable for the gap between shaft
bearing shell ad shaft neck ,when wearing capacity is over limited value, the bearing
shell must be changed.
The crankshaft is made of OT800 - 3 high strength modular cast iron t and is full sup-
• 31 •
The outside of flywheel is marked TDC point, and also the scale range of 0 - 300C of
advanced used to adjust advanced angle of supplying fuel. Each scale means 10
crankshaft angle of turn. For some models of engines, the TDC point is marked at
the flywheel end face of crankshaft pulley..
6. Transmission system
• 32 ·
, Crankshaft pulley is consisted of two A - type V - belt to drive water pump pulley
and alternator pulley. Dfferent of V - belts are used because of the different position
of water pump and alternator. V - belt is tensioned by alternator adjustment mecha-
nism. When press the center of V - belt by finger, 10 -15mm depth should be availa-
ble.
Crankshaft timing gear drives idling gear, idling gear drives camshaft timing gear, fuel
injection pump timing gear and oil pump gear. Camshaft timing gear may drve air
compressor gear of work pump gear and bydraulic pump gear if necessary. Hydraulic
pump gear may drive the front and the rear hydraulic pump through the transmission
splined hobs of hydaulc upmp or one of them.
7. 1 Air filter
When the diesel engine is working ,clean and fresh air is required to be supplied by
the air filter, this can assure to reduce the wear of cylinder liner, piston t piston rings,
valve and other parts.
For the air filter equipped with R series diesel engine, besides one or two types are
equipped by OEM, the common two structure styles are as follows single stage pa-
per filter element style ang double stages paper filter elemenl style
7 . 2 Silencer
In order to reduce the noise and improve the operator's working environment,R se-
ries diesel engine adopts exhaust silencer. The exhaust gas of the diesel engine ex-
pands through the holes of the silencer inner pipes and the noise is reduced. If the
• 33 •
The construction of silencers used for four cylinders and six cylinders diesel engine is
just the same, only the capacity is different. according to the matched requirement,
the connecting pipe can be lengthened or prepared by users.
According the matched requirement, the main installing mode of silencer for R series
diesel engine is horizontal style and vertical style.
7. 3 Turbocharger
R series diesel engine is made by adding a turbocharger between the intake and ex-
haust pipe of the natural aspirated type diesel engine. Through the turbine, the turbo-
charger transforns the exhaust energy of the diesel engine to the rotating mechanical
energy of the rotor, then the blower is driven to rotate at a high speed and compress
the fresh air coming from the air filter, then delivery it to the cylinder. Through suppl-
ying more air to the diesel engine, more fuel will be burned thoroughly and the out-
put of the diesel engine will be increased accordingly.
The turbocharger is combined with constant pressurt single inlet turbine bousing or
pulse double inlet turbine housing, turbine ass embly, blower pump impeller, blower
housing and so on.
The turbocharger is a high speed - rotating machine t its rotating speed will influence
the superchargine effect of the diesel engine directly. In order to assure the diesel
engine working normally, the lubricating oit supplied to the turbocharger "must be
double stages filtered. When being used, the turbocharger must be technically main-
tained in time strictly according to the stipulation on the turbocharger - operating
manual. The blower must be cleaned regularly according to the operating require-
ment. The turbocharger should be dismantled by skilled professional technical work-
ers. A point should be paidattention to that when the lock nut on the end of the blo-
wer is being tightened, the reticule on the nut should be aligned with the reticules on
the rotor shaft cscrew and blower impeller. This can protect the running balance of
the rotor from being damaged and assure it working normally.
8. Fuel system
When the diesel engine is working fuel flows through fuel tank, inlet pipe, fuel delivery
pump into the fuel filter, after being filtered, it enters into the injection pump, then be-
ing compressed with plunger mate to high pressure, through fuel cock and high pres-
sure fuel pipe, it enters into injector. When the pressure is high enough to open the
needle valve nate of the injector, the fuel will be sprayed into combustion ch~mber in
the form of atomization. After spraying, the pressure will gets lower, the needle valve
returns to the seat under the force of spring, the injecting hole no sprays again.
The extra fuel that the fuel delivery pump supplies more than the injection pump
used ,also with the fuel that the injector needle valve mate leaks and the returning
fuel of the fuel filter and the injection pump will flows back to the fuel tank.
The purpose of the fuel delivery pump is to keep the low - pressure fuel pipe full of
pressed fuel. In order to remain the pressure stable, the piston of the fuel delivery
• 35 •
The hand press is used to make the fuel deliver pipe full of fuel and to wipe off oir
before the engine starts. When the engine is not at working situation, the handle nut
should be tightened.
8. 2 Fuel filter
In order to meet different requirements, there are three types of fuel filter:
CS0708BI , CS0712Bl, COS10S, the former two are single stage type, C0810S is
double stages type.
The purpose of the fuel filter is to filter the tiny impurity out of fuel to reduce the
wear of the precise mates inside the hing pressure and injector.
After the fuel being fitered with element,dirt is kept on the element outer surface.
Being made of fuel filter paper, the e~ement should be maintained and replaced regu-
larly. For the fuel filter with water deposited cup, the water in the cup should be
drained off regularly.
There is type A of high - pressure pumps: The body of the type A pump is an all - in
- one - piece style, as shown in Fig. 7.
The quantity of fuel delivered for the fuel pump varies according to the load of the
diesel engine. This is achieved by the rotating of plunger made by the shaft rotating
movement of the adjusting rod gear. The injected fuel rate can be changed byadjus-
ting the cam working section and the diameter of the plunger so as to meet the dif-
ferent requirement of the diesel engine characteristics. The front of the fuel pump is
fixed on the gear housing by the fuel pump fixing flange. When installing, please
match well with the gear so as to ensure the fuel delivery advance angle correct.
The adjusting method of the fuel delivery advance angle is to discharge the fuel
pump on the gear housing cover and check the cover timely; loosen the platen
screw fixed on the fuel pump gear hub; turn the hex head bolt on the end of the fuel
pump bearing; turning clockwise will add the fuel delivery advance angle while turn-
ing anticlockwise will reduce the fuel delivery advance angle. After adjusting proper-
Iy, fasten the four platen screw and the six hex head bolt on the and of the fuel
pump bearing to avoid them loosening.
• 36 •
The quantity of fuel delivered by the bigh pressure pump has been adjusted before
letting released from factory. It's forbidden to open the high pressure pump inspec-
tion window cover to rotate the plunger so as to prevent the delivered fuel quantity
and the fuel quantity in cylinders from being changed, if necessary, the adjustment
should be o'perated on a high pressure pump test bench.
8. 4 Governor
There is a RSV mechanical full range· type governor. Vehicle diesel engine is equipped
with a RFD full full range - double poles type governor.
The function of the RSV full range type governor is to keep the speed of the diesel
engine varying in the scope of fluctuating rate when the load doesnt change and var-
ying in the scope of stable speed adjusted rate when the load changes sQ,that it can
work stablv.
The high speed position limiting bolt and low speed position limiting bolt are used to
. ~
adjust the highest idling speed and the lowest idling stabJespeed separately. The fu-
el quantity limiting screw is used to adjust the quantity of fuel detivered to the fuel
• 37 •
8.5 Advancer
A-M8
/-u
70
8. 6 injector
9. Lubricating System
The engine is lubricated by pressure oil combined with splash oil., the layout of lubri-
cating system is shown in fig. 6
The oil is sucked into the oil pump through the strainer and the enters into the main
oil passage after being cooled and filtered. The oil in the main oil passage of the cyl-
inder block is ·delivered to the main bearings, connecting rod bearings, camshaft
bushings t high pressure pump, air compressor, vacuum pump. The oil passing J
through the camshaft bushings, high pressure pump, air compressor, vacuum pump.
The oil passing ~hrough the camshaft bushing flows through the oil passa~e in cylin-
der block and cylinder bead to lubricated the valve mechanism. Piston ,piston pin, cyl·
inder liner are all· splash lubricated by the·oil· spilled from the bearings.
1. crankshaft and bearing;2. piston sooling injection nozzle4;3. oil temperature gauge;4. piston and connecting
rod assembly,S. oil sump,6.oil strainer,7.oil pump,8.oil filter and cooler,9.centrifugal bypass type oil filter;10.
idling gear shaft and bushing, 11. oil fine filter, 12. oil pressure gauge, 13. turbocharger, 14. push rod, valve tappet,
15. rocker arm and arm shaft, 16. valve and valve guide, 17. main oil passage, 18. camshaft and bushing, 19. piston
injection cooling oil passage.
For the supercharged engine, there is a special oil passage in the cylinder block for
cooling piston, the oil injected into piston through oil passage and injection nozzle for
cooling piston.
For lubricating turbocharger, portion of oil from oil main passage flows into turbo-
charger through another oil filter to lubricate and cool its bearing, then the oil flows
• 40 •
Four and six cylinders engine all use gear type oil pump. The structure of four cylin-
der engine is show in Fig. 11.
The oil pump should be installed in the tunnel on the upper part of the main bearing.
The oil pump transmission gear is driven by the crankshaft gear trough the idling
gear. The turning speed is the same as the crankshaft.
'When the oil pump is being mounted,. not too hard or deviated stress on it, the seal
ring should be coated with lubricating oil so as not to be damaged.
The overload overflow valve should be installed in the oil groove of the engine block,
as seen in Fig. 12, to limit the low temperature and the high viscosity of the oil,
protect ·the oil pressure gauge, thus assure the oil pump and the lubricating tube
work normally. The overload overflow valve has been adjusted through the, special
test platform before use, so you neednt adjust again on general.
If the oil pressure is too low, you should regulate the regulating valve in the oil filter
first, then youtest and regulate this pressure regulating valve, it's 'opeing pressure is
O.8MPa.
2 3 (1)
6. Bolt 7. Gasket
8. Driven gea~s subassembly
The structure of JX0811a, JI012B and J0506 type oil filter is shown in Fig. 13 and
Fig. 14.
B D
3
A-A
(2)
c-e D-D
.)1>
6
7
8
There are pressure limiting valve and bypass valve. When the oil filter or the viscosity
of the oil is too high, the bypass valve will open, and the oil will enters into the main
passage without bing filter ed through oil cooler or filter to ensure the engine running
safely. The bypass valve shouldn't be dismantled and adjusted without authorization.
The paper element should be maintained and replaced periodically.
9. 4 Oil cooler
R series diesel engine adopts. pipe & shell type oil cooler, which is shown as
Fig. 15.
The cil cooler is usually installed at the side of the oil filter, oil from oil pump enters
into oit' cooler through the inlet hole of the shell. Through the hose ,the cooling water
enters into the cooling element from the special outlet hole at the left of the cylinder
block. Because the water and oil has a different temperature and keep flowing, they
exchange heat inside the cooler and th~ oil is cooled then. The cooling water from
the cooler flows back into the cylinder head through the hose and the cooled oil fol-
ws into the main oil passage through the oil filter.
When using the engine, we. should often observe whether there is engine oil mixed
in the cooling water cycle system. If find water mixing with oil obviously, we should
check immediately whether the seal ring of .the oil cooler still work or whether the
cooling element leak. If find any trouble, we must resolve it.
When changing the engine oil every time, we should change the oil filter wick at the
same time.
The engine adopts close type forced circulation water cooling system, is shown in
Fig. 16
The cooling water in the radiator is forced by the water pump into the main water
passage, which link up front ar,td rear parts located at the left of the cylinder block. It
flows into all cylinders evenly to cool the liners, most of water flows through all holes
into cylinder head, the others enter into the rear.. of the cylinder head through oil cool-
era If the oil cooler is not installed ,;the all cooling water will flows into cylinder head
through cylinder block. About 35 % of all ~ate'r in the cylinder head flow~ transversely
through the hole. at the bridge of the nose ,and it cools the heavy thermal duty angle
• 43 •
The 4& 6-cylinder type R series diesel engine all adopts the same water pump. The
temperature gauge of R series diesel engine can be chosen by users and can be
• 44 •
The diesel engine adopts centrifugal water pump which is installed at the front of the
engine block and driven by the crankshaft belt wheel through the V belt.
The water pump bearing is supported by the two dustproof bearing in the shell and
rotates in the water pump. The vane wheel is installed at the end of the water pump
bearing. There-s china ring on the vane wheel neck, and between it and the pump
shell there ~ water seal subassembly used to avoid water from leaking out of the
pump block. To avoid the water leak into the rotating bearing, a water - relief hole is
drilled under the seat hole of the pump bearing and a water throw ring is installed on
the bearing to make the water leaked into the seal hole of the bearing spill over from
the water - relief hole. If find the water - relief hole dripping water seriously, you
should change the water seal.
Radiator connector can be added on the water pump shell and the cylinder head to
supply heating for customers.
10.2 Fan
The diesel engine adopts vane axial - flow cooling fan which is installed at the front
of the water pump belt wheel and rotates synchronously with the pump bearing.
According to the different application of the diesel engine and the surrounding tem-
perature and wind quantity t the fan can be chosen as four or six leaf blades, wind
absorbing or wind ejecting type.
10.3 Thermostat
Marine diesel engine adopts sea water and fresh water heat exchanger. The struc-
ture is shown as Fig. 17.
11
Above the exchanger, there is a inflation compensating water tank. The sea water
entered from the sea water pump cool the fresh water flowing by the internal groove
of the exchanoer wick and thAn cool thQ exhaust manifold; the f"'e~h vvcater in the
compensating water tank enter into the water pump through the exchanger wick and
do the fresh water cycle.
The electric system of the R series diesel engine has two tYP8S:12Vand 24V,all are
single wire system with negative pole grounded, can be chosen by users. shown in
Fig. IS
The common and for tractor using diesel engines adopts 12V electric system;for en-
gineering and truck using diesel engines adopts 24 V electric system, can use more
powerful24V starting motor to improve starting capacity. The rated voltage of the
motor and other electrical equipment must meet the voltage pequirrement of the e-
lectric system. In order to improve the diesel engine' 5 coaly starting capacity , the
coolly starting equipment installed at the air inlet pipe can be used by user's need.
11. 1 Battery
The battery for start is a power device of the diesel engine, its performance influence
the start of the diesel engine directly, suitalbe capacity battery should be chosen ac-
cording to the starting motor's specific property. The battery should be installed near
the starting motor so as to shortem the length of the cable between the battery and
the starting motor to avoid the voltage drop too hard when the engine starting, the
section area 36mm2 low voltage connecting cable should be adopted.
When the starting current is highest,for 12V and 24V starting motoft the VQItage drop
should be less than O.5V and tV respectively.
JF series silicon rectified dynamo is adopted in the diesel engine, there are many
types of JFl312YE ,JF2312YE ,JF2512YE ,JFZ1512YE, BJFW23B ,and etc.
The diesel engine for tractor adopts JF1312YE type of 12v, the oter engines usually a-
dopt dynamo of 24V;the engine with vacuum pump adopts BJFW24B type, six cylin-
ders engine for truck adopts JF2512YE type.'
The use of this voltage regulator is to keep the voltage at the range of 13.5 -14. 5V
or 27 -29V respectively when the speed of the 14V or 28V generator changed. These
two types of generators adopt FTIII, FT211 AND FT226 voltage regulators respec-
tively, the FT226 type regulator can be connected to a charging indicator.
When the FTIII type and FT211 type regulators are used, the key swich should be
turned off as soon as the engine stops in case the battery discharge to the magnetic
coil and make the battery insufficient, this will influence the next starting.
The regulator is a precise instrument and not be dismatled and regulated at will, if it
is necessary to be adjusted, it should be done at specicl equipment.
The starting motor is full closed direct current .series excitation motor, the engine of
12V s'yIStem adopts OD1518E.OD154.0154C types.and the~engine of 24V system a-
dopts QSZ637E type starting m~tor. In oreder to improve the starting capacity,
QDl54C type motor adopts 9 teeth,and the OD154 adopts 11 teeth.
• 48 •
The key switch has thr~ working positions, at the center position, the whole circuit
will be turned off , turning the key clockwise, the preheating - starting switch, Voltage
regulator and other electric equipment will all be switched on and the diesel engine
will etarts. After the engine starts, the switch should be turned counterclockwise to
the end to tum off the preheating - starting switch and in case of any trouble.
If the preheater be used,a preheating - starting switch should be adopted. The pre-
heating - starting switch has four working positions. At the "Preheat" position, only
the preheater or electric plunger be turned on. At the" preheat - start" position, both
the preheater and the starting motor wUI be turned pn. At the "start" position, only
starting motor will be turned on. To loose the switch ,it will.automatically moves back
to the" 0" position -and the whole circuit will be cut off.
To meet the requirement for the break and aeration for tire of tractors, some types
of vehicles and engineering machines, the relevant diesel engine derived products
have installed LC126 type air compressor.
The structure
.
of LC126 type air compressor is shown
.
as Fig. 19.
It~ structure is single cylinder piston type with a bore of 6511Jm and stroke of 38mm.
The displacement of piston is O. 126L working displacement;a=lOOUmin, exhausting
pressure;;'0.6Mpa, full load consumption power=S:1.4KW.
The air compressor is driven by gear. When the air compressor is running, the pis-
ton is going down. ·the air opens the inlet valve and enters the cylinder through the
air filter. When the piston is going up, the air will be compressed and push open the
outlet valve and enter the air storage tu~. According to the different load discharge
. me~hod, there are two kinds of air compressor for customer~ cnoice.
1. Inlet load discharge air compressor
Theres a pressure releasing valve installed on the cylinder of the inlet load discharge
.- 49 •
necting rod 6. 'Connecting flange 7. Crankshaft 8. Crankshaft tank 9. Bearing 10. End cover
• 50 •
The diesel engine adopts open, piece and dry type clutch, a disc type spring is adopt-
ed .as elasticity compensation, shown in Fig. 20
• 51 •
When the clutch is engaged, the friction disc is pressed between the fixed pressure
disc and the front moving pressure disc. The power of the diesel engine is transmit-
ted from the inner teeth ring to the moving pressure disc assembly and then to the
splined thaft of the clutch, it is outputted from the belt pulley. Aflat belt pulley, v -
belt pulley or a coupler can be installed at the oudpud end.
When the clutch is disengaged, the friction disc is combined with the inner teenth
ring and be rotating with the flywheel, other moving parts of the clutch is motionless
and the workless state of the clutch is improved.
According to the inner teeth engaged with the outer teeth, the friction disc assembly
can rotater with the flywheel and can slide axially. The fixed pressure disc is con-
nected with the shaft of clutch by the rectangle spline, the front moving pressure
disc is also engaged with the fixed pressure disc by the inner teeth and the outer
teeth. Through the rear moving pressure disc moves axially with the pressure lever,
the engagement and disengagement of the clutch is achieced.
The engagement of the clutch is kept with the self - lock of the pressure lever sys-
tem, so the engagemrent of the clutch is very reliable.
The front end of the clutch output shaft is supported on the flywheel bearing, the
rear end is supported on the bearing of the rear bearing seat inside the clutch hous-
ing. The clutch is connected with the diesel engine through the clutch housing com-
bined with the diesel engine flywheel housing by the rabbet.
When you want to connect the clutch with the diesel engine, you can move the fric-
tion discs to the rabbet of the clutch housing all around evenly so that the friction
discs are in the middle symmetrical state. After you move the lever to enaaae the
clutch, you can connect and fast~n it with the diesel engine.
When you want to dismantle the clutch from the diesel engine, you should engage
• S2 •
After the clutch be used for some time, if it's performance turns worse because of
the wear of the friction discs, users can adjust it as follows:
( 1) Put the clutch to the disengagement state, open the upper window, rotate the
clutch shaft, peep at the lock pin of the adjusting plate, press the lock pin, rotate the
adjusting .plate clock wise, the adjusting plate will be pressed about o. Imm per 12 0
gap. After the adjustment is finished, insert the' lock pin into the corresponding gap.
(2 ) ~ush the clutch to the engagement state, use a special rule to test whether the
distance be~een the rear moving pressure disc and the top end or the sleeve fixed
bolt is 1 -2mm.
1) When the clutch is engaged and to out.,. put power, the time of engagement
should be very short or it will burn the friction discs.
2) The asbestos friction di.scs must be protected from being dirtied by oil dirt.
3) There is a dirt - drained plug at the bottom of the clutch housing, the oil dirt and
deposited water should be often drained off.
The window should be often opened when working, the safe pin of the opratin sysy-
en should be tested to keep it in good condition.
S) Lubricating grease should be perodically filled into the oil cup as stipulated.
When the diesel engine is transported, the front and rear lifting bracket should be
used to lift the engine and close attention should be paid to protect the appearance,
accessories and oil pipes of the diesel engine from being damaged.
If the diesel engine will be transported for a long distance, the air filter and silencer
should be dismantled, use plugs and plastics to seal the air intake and exhaust hole,
water pump inlet and outlet hole, fuel inlet and outlet hole. If necessary, use plastic
cover and wooden case to pack the 'diesel engine.
If the diesel engine is used for stationary application, the foundation must be firm t
the mounting surface must be kept horizontal, the driving equipment should conform
to the requirement of stipulation, the working place should be spacious, well Nenti-
lated ,clean and rain - proof.
If the diesel engine is going to be laid up for a long time, it should be preserved and
stored as the below methods;
2) Remove the inje,ctor assembly away from the engine, fill to each cylinder with
200kg dehydrated chlean oil (it means: keep the oil heated at 100 - 2000C until n9
bubble remains, rotate the crankshaft to let the lubricating oil coat evenly on the sur-
faces of the valves, cylinder liners and pistons, etc. ; then clean the appearance of
the nozzle assembly, smear lubrdcating oil on it and then re - install it to the engine.
3 ) wrap up the air filter with plastic film, dismantle the silencer and stop up the ex-
haust hole with wooden plug.
4 ) wipe off the oil dirt, dust and rust from the outer surface of the engine, smear the
unpainted parts ·surface with thin layer of anti - rusting grease ( such as calcium type
lubricating grease) ,then cover it with paper.
• 54 •
Downloaded from www.Manualslib.com manuals search engine
6) the preserved engine should be stored in well ventilated t dry and clean room, it is
strictly forbbidden to be putted together with corrosive substances. The effective
time of this method is 3 months , when the time exceeds the period, please repeat
this procedure.
The diesel engine should adopts diffeent brand of light diesel oil according to the at-
mospheric temperature ( GB252 - 81)
. The diesel engine should adopt different brand L - ECC diesel lubricating oil accord-
ing to different area and atmospheric temperature.
AREA Winter In Cold Area All Year In Common Area Summer In The South
The turbocharged diesel engine should adopts L - ECD type diesel lubricating oil
(GB11122 - 89)
The lubricating oil rnu5t be filter-ed before it i~ filled into die::iel engine "other brand lu-
bricating oil is forbidden to be used for -engine so as to protect the parts such as
bearing and piston ring from being darmaged.
• 55 •
The diesel engine should adopt clear soft water such as tap water, rain water and riv-
er water ,etc.. If hard water is adopted such as well water and spring water which
contains much more minerals, the hard water should be softened, of there will be
scale on the water passage of the engine and block the water ;weaken the cooling
effect and recult in the engine too hot.
(2) Fill20g Na3 P0 3 on each IOkg water ,precipitated and piston rin"g fom being dam-
aged.
When the temperature is below ooc ,antifreeze mixture can be used for cooling me-
dium. The antifreeze mixture can be mixed with water and alcohol according to the
below ratio.
When compound and fill the antifreeze mixtrue, pay attention to:
( 1) The antifrezed mixture is poisonous, never drink it.
(2)When the engine is working, the temperature of the antifreeze mixture doesn't
exceed 900C so as to avoid the alcohol volatilize.
(3 ) test the volume of the antifreeze mixture each 25 - 30hrs ,compensate it if not e-
nough.
( 4 ) the volume of antifreeze nixture should be 6 % less than the water, because the
antifreeze rni~ture preventive liquid will exqands at nlgn temperature.
2.4Auxiliary material
The types of glue R diesel engine adopt is as the following table:
• 56 •
(1) When the·tem,perature is below sOC, the cooling water should be drained 'after
stopping the engine.
( 2) When the temperature is below 0, we should check the consistency of anti-
freeze for those adopt it..
3. 1 The diesel engine should be thoroughly checked before starting. Closed attention
should be paid to see whether foundation bolts and the connection'with the driv-
en equipment is rigid and reliable, and whether the transmission parts and con-
trol systems are sensitive and so on. The engine won't be started unless every-
thing is all right. "
3. 2 Check and replenish the oil sump to keep the oil surfpce between the top and
bottom carved line, fill up cooling water and fuel oil, open the switch of the fuel
tank, check the fuel system for leakage and eliminate it if there is any.
3. 3 It is recommend to vent the air out of fuel system step by step as follows:
At first loosen the venting screw on the filter, pump the fuel with priming
hand pump t vent out the air from the fuel passage between the fuel tank and the
filter t then loosen the venting screw on the injection pump until the fuel flows.
out without bubbl.es.
3. 4 Check the batt~ry be sufficien or not t connect· the_battery to the circuit and see
whether it is electrified.
The diesel engine shouldn't be started until the preparation is completed and meets
the requirement. When starting, the clutch should be apart, operate as following
steps:
4. 1 Set the control handle of the fuel valve to the position where the fuel will be de-
livered rather more..
4.2 Turn the circuit switch clockwise and close the circuit.
4. 3 Turn the starting switch to the "starting position" ,after the crankshaft is spee-
ded up by the starting motor, the engine is started then.
4.4 For the protection of the starting motor and battery, the starting time shouldn't
exceed lOs. If need to start continucously ,the interval time should be more than
2min.lf can't start for continuous 3 times, then don't start until the trouble is
found out and elininated.
4. 5 As soon as the engine starts, turn the starting switch back to the' previous posi-
tion. Set the control handle of the fuel valve to the idel speed position, turn the
circuit key switch counterclockwise to the charging position.
4. 6 Check the oil pressure after the engine starts the oil pressure in ilde speed nev-
t
er be lower than O.lmpa. After the engine starts for 5min,stop it and wait for 15 ,~
min, check the surface of the oil when the oil flows back to the oil sump, if nec-
essary ,add oil to the required level.
5. running
5.1 After being started, the engine shouldn't operater at full load immediately. It
should be warmed up at low speed without load, only after the temperature of
the cooling water reaches to 6OOC, it can be speeded up to the highest speed
and operates at full load.
5. 2 When operating, the engine's speed and load should be increased and decreased
gradually. In general,shouldn't increase or decrease rapidly.
5. 3 When the engine is working, should often pay attention to oil pressure, oil tme-
perature, cooling water temperature, charging current, should also observe the
color of the exhaust smoke, listen attentively to the voice inside. If any trouble
such as overheating, black smoking, knock and others, should stop the engine to
check and remedy immediately. It is forbidden to let the engine operate with
• S8 •
6. Stopping
6.1 Before stopping the engine,unload first,decrease the engine to the idling speed
gradually, when the water temperature falls down below 700C , turn the stopping
lever to stop- After the engine stops, take out the switch key and close the fuel
thak valve.
6.2 It is forbidden to stop the engine suddenly at high water temperature.
6.3 It is not permitted to stop the engine by shutting off the valve of the fuel tank so
as to preventiong the air from entering into the oil passage.
6.4 When it is belowSOC, if the antifreeze mizture is not used, should drain off the
cooling water so as to avoid the cylinder block and water pump being frost
crack.
6.5 The found trouble should. be remedied after every stopping, and should often
check the engine.
New and repaired diesel engine (including those have taken third grade technique
maintenance and have changed piston t piston ring, cylinder liner, main bearing and
connecting rod bearing) must have a long period of wearing from low load to high
load gradually. Wed better make the various operations match well to.avoid abnor-
mal damage. EXperience provea tnat tne life of the diesel engine, its liability and t r
conomy are largely determined by the wearing in an the initial· stage, so the custom-
ers should follow the wearing in instruction strictly.
8.1 It' forbidden to let the person who don't know the operating technique to oper-
ate the engine.
8. 2 The engine can be started only after all the starting preparation has been com-
pleted.
8. 3 Pay close attention to prevent fire, it' 5 forbidden to let the naked flame near the
working engine. If the engine is working beside inflammable substanc8,a fire ex-
tinguisher system should be installed on the exhaust manifold.
8. 4 When the engine is working, never to dismantle or adjust, the operator don 't
leave the working site.
8. 5 It! s forbidden to let the engine working under no oil pressure, low oil pressure or
whith abnormal noise inside. If you meet with these cases, the engine should be
stopped urgently.
8. 6 If the engine happens to be overspeed, you should turn the stopping hanlde to
stop it to have a test. If the stopping handle malfunctions, you can stop the en-
• 60 •
1. 1 Check the oil surface in the oil sump, oil bath type air filter and the power output
gear box, if the oil surface is higher, find out the trouble and eliminate it; if the oil
is insufficient, the refill it to the required amount.
1. 2 Check the cooling water surface in the water tank, if insufficient, fill it up . If the
air temperature will be under + SOC, then drain off the cooling water after sto~
ping.
1.3 Check and fasten the shown bolt and nut, eliminate the leak of oil,water and air.
1. 4 During working at the dusty plac~, use the compressed air to clean the air filter
element.
1. 5 Clean the mud, dust and oil dirt on the appearance of the engine.
1. 6 When the engine is working, listen to the voice, observe the smoke color and e-
liminate the troule and abnormal appearance.
• 61 •
adjust it.
3. 10 Fill the lubricating grease to the filling boles of the clutch, test the gap between
the releasing lever and the releasing bearing.
3. 11 Check and adjust the contack working gap and iron core gap every two mainte-
nance period
4.1 Perform the full items on the "second grade technique maintenance".
4. 2 Clean the cooling system, wipe off the scale.
• 62 •
ting grease.
4. 12 Check the turbocharger, clean the parts, wipe off the cabon deposit, and test
the rotor freedom allowance.
If the temperature maybe lower thanSer:, the engine must be maintained specially.
~. 1 Must use the winter used oil and fuel, note the damp in the fuel so as to protect
the fuel passage from being jammed.
5. 2 It's better to fill the antifreeze fluid to the cooling system, or must drain off the
cooling water after its lemperature is lower than 40 - 50OC.
5. 3 On the cold dseason or area, it's better to prevent the diesel engine ( or vehicle
from being deposit in the open air, or wh~n starting, it's need to heat the cooling
water to· preheat the engine body.
CHAPTER V Troubleshooting
1. Start failures
Touble cause and its feature Remedy
1. 1 Troubles in fuel system 1.1
• 66 •
When the engine works normally, the smoke color is light grey, when the load is
higher at low time, it 'color is onlt dark grey, when the exhaust smoke is blue, white
or black,then the smoke color is abnormal. Blue means burning oil;white means fuel
fog no burns thoroughly inside the cylinder or water trapped inside the cylinder; black
means injecting fuel too much to burns thoroughly. Thouble cause· ahdits feature
5.1
Blue smoke Remedy
( 1 ) Lubricating oil flees, piston ring ( 1) Check piston ring and eliminate
installed inversely, choked or the fault
worn out to badly
(2) Clearance between valve and (2) Replace the parts and assure the
pipe hole too large stipulated lash
5.2
White smoke Remedy
( 1) Fuel spray be atomized not well, ( 1) Check the injection pressure and
fuel drips the seal of the mate, adjust and
clean or replace
( 2 ) too much water trapped in the fuel ( 2 ) Test the fuel quality
(3 ) Water trapped in the cylinder (3) Inspect the seal of the cylinder
gasket ;,check the water leakage of
the cylinder head and cylinder
liner, repair or replace
5.3
Black smoke Remedy~·c.
( 1) Engine is ouer - loaded ( 1) Adjust to the stipulated load
• 67 •
4. Oil pump driving and driven gear worn 4. Replace driveing and driven gear
out
5. Strainer screen and oil filter element 5. Clean or replace
blocked
6. Pressure limiting valve and pressure 6. Inspect and replace
regulating valve spring broken
7. Oil passage choked or oil leaks 7. Checkand eliminate
8. Lash between the bearings too large 8. Test the matching lash
• 68 •
• 71 •
• 72 ..
broken, qylinderlinerwornoutoroil
ret\Jfn pipe choked
3. Abnormalsoundcanbeheardwhen ~ 3. Check and repair, etaan off corbon
working because of thaft an'd deposit, replace; parts.
bearingwornoutorpistontouches
cylinder head
,.
'~'--J;-=, =. =-_-_-_-. .~__:.=_;
Fig. 21
Attention:
1. The installation of cooling tank of the diesel engine should follow the structure of
the layout. An absorber or damping gasket should be installed on the supporting
section.
2. When the diesel engine is connected with alternator, air compressor etc. , if we
adopt steel adaptor, an absorber or damping gasket should be installed on the sUJr
porting section.
3. When the diesel engine is connected with alternator, air compressor etc., a
clearance of 3 - Smm should be kept between the diesel engine flywheel and the
connecting disc of the applied machines in case the pull power or push power dam-
age the diesel engine and the applied machines.
4. When the diesel engine and the applied machines are transmitted by V belt or flat
belt, we shouldnt fasten the belt pulley on the flywheel or the gear box putout shaft
dirQctly 7 othorvviso, it vvill dan-.ogo the nevv \JrClnk~hClft or bccaring.
5. The diameter of the wind directing cover' should match with the diameter of the
fan. The diameters of the two have a difference of 20 -40mm in general.
Wrong connection
x
Fig.22
. • 77 •