WEICHAI R6160 Series - User Manual

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R660系列柴油机维修保养手册
Maintenace Manual For R660 Series Diesel Engine
R 6
……
160
第一章 柴油机使用说明
Operating Instructions For Diesel Engine
1．R6160系列柴油机代号的含义
Composition of type and its signification:
变型号Version No.
缸径 Cylinder bore
缸数 Number of cylinder
换代号 Generation code
2．新柴油机使用须知
Cautions for Operating New Diesel Engine
新机初期磨合期为 100 小时。
Initial run-in period of a new engine is 100 hours.
新机经初期使用磨合后，需要更换机油并清洗机油滤清器，否则可能造成柴油机零件的过度
磨损或损坏。正确的维护保养将使您的柴油机有更好的性能、更经济的运转及更长的寿命。
After initial running in of a new engine, replace the engine oil and clean oil filter. Failure to do so may
result in excessive wear or damage of diesel engine parts. Proper maintenance is necessory for better
performance, more economical operation and longer service life.
每日检查油温表、油压表、报警装置和其它仪表，确保它们正常能工作。
Check oil temperature gauge, oil pressure gauge, alarm device and other instruments daily for proper
operation.
按说明书中要求进行日常维护和保养。
Perform daily maintenance work as specified in this manual.

WEICHAI R6160 Series Specifications

General

Brand	WEICHAI
Model	R6160 Series
Category	Engine
Language	English

Summary

Operating Instructions For Diesel Engine

R6160 Series Diesel Engine Model Designation Meaning

Explains the meaning and significance of the R6160 series diesel engine model designation.

Cautions for Operating New Diesel Engine

Provides initial operating precautions for new diesel engines, including run-in period and daily checks.

Unpacking the Diesel Engine

Installation of Diesel Engine

Engine Room Requirements

Specifies ventilation and space requirements for the engine room during installation.

Piping Requirements

Outlines requirements for exhaust and other piping systems.

Diesel Engine Lifting Requirements

Diesel Engine Alignment Requirements

Check before Start

Engine Start

Start with Pneumatic Motor

Explains the procedure for starting the engine using a pneumatic motor.

Start with Electric Motor

Details the process for starting the engine using an electric motor.

Engine Running

Maintenance Instructions For Diesel Engine

Daily Maintenance

Outlines daily inspection and maintenance tasks for the diesel engine.

Periodic Maintenance

Introduces periodic maintenance schedules and procedures.

Maintenance Period

Maintenance

Maintenance to New Engine

Details initial maintenance tasks for a new engine after 50 hours of operation.

Level 2 Technical Maintenance

Level 3 Technical Maintenance

Maintenance Of Diesel Engine

Daily Maintenance

Specifies daily preventive maintenance tasks to understand engine operating conditions.

Check engine oil level

Check coolant level

Check the V-belt

Maintenance of New Engine

Clean oil filter

Prime the pipeline system

Clean fuel filter

Check the tightness of tightening parts and connection parts

Retighten the cylinder head bolts

Maintenance of Diesel Engine after 350 h operation

Check valve clearance

Explains how to check valve clearance by setting the engine to TDC.

Check valve clearance with feeler gauge

Adjust valve clearance as per Table below

Mount cylinder head gasket and cover

Check fuel advance angle

Check air filter

Check the V-belt

Clean the turbocharger

Clean the cooling water radiator

Maintenance of engine after 1000-hour s operation

Check the alignment of diesel engine

Details procedures for checking engine alignment using a dial gauge.

Check injection pressure of injector, and clean needle valve and seat assembly of injector

Evaluation on Atomization Fineness of Fuel Injector

The needle valve and seat assembly should be cleaned in clean environment

Check injection pressure

Clean heat exchanger element

Check connecting rod nuts

Remove the inspection window on cylinder block

Maintenance of engine after 3000-hours operation

Remove clamps from rubber hose connecting inlet pipe of treated water pump to thermostat

Flowcharts Of Primary Systems Of Diesel Engine

Lubricating System

Presents the flowchart for the engine's lubricating system.

Flowchart for lubricating system of R6160 A series diesel engine

Flowchart for lubricating system of R6160 Z series diesel engine

Cooling system

Flowchart for cooling system of R6160 A series diesel engine

Flowchart illustrating the cooling system for R6160A series diesel engines.

Flowchart for cooling system of R6160 ZC series diesel engine

Closed circulation for stationary engine

Intake & exhaust system

Fuel system

Starting system

Pneumatic starting system

Flowchart of the pneumatic starting system.

Electric starting system

Tightening Torque And Method of Bolts And Nuts on Diesel Engine

Main Bearing Nuts

Specifies tightening torque and order for main bearing nuts.

Cylinder head nuts

Connecting rod nuts

Flywheel bolts

Connecting bolts between cylinder block and bed plate

Tightening nuts for belt pulley

Connecting bolts for damper

Fuel Oil, Lubricating Oil, Cooling Water And Auxiliary Materials

Fuel Oil

Specifies recommended diesel fuel grades for different ambient temperatures.

Lubricating Oil

Recommends specific grades of lubricating oil and their replacement intervals.

Grease

Cooling Water

Auxiliary Materials

Table of Auxiliary Materials Used on R6160-Series Diesel Engines

Electric System

Battery

Specifies the operating voltage and capacity of the battery.

Starter

Describes different starter types and their specifications.

Safeguard device

Monitoring an measuring ability

Details the monitoring capabilities of mechanical and protective devices.

When operating condition of your diesel engine exceeds the setting alarm value

Describes alarm functions and automatic speed regulation.

Setting alarm values are shown in the Table below:

Remote monitoring and measuring ability

Timing ability

Some models of the R6160 series diesel engine are equipped with electric oil pre-supply pump

Adjustment And Replacement of Main Assemblies And Parts

Cooling System

Focuses on the water pump disassembly, check, and maintenance.

Disassembly and Check of Intercooler

Lubricating system

Disassembly, assembly and maintenance for oil pump

Explains the disassembly and maintenance of the oil pump.

Remove oil outlet pipe for oil pump

Remove oil return pipe

Loosen four M10 bolts and dismantle the oil pump form engine front cover.

Loosen six M10 bolts and dismantle the oil pump cover

Disassembly, assembly and maintenance for oil cooler

Loosen the oil inlet pipe of coole

Loosen the oil outlet pipe of cooler

Loose the bolts for connecting oil cooler and engine block, and remove the oil cooler

Fuel supply system

Replace injection pump

Instructions for replacing the injection pump.

Remove the low pressure fuel pipe connecting to injecto

Remove the bolts connecting injector and bracket, and then remove the injector.

Remove the flange from the high-pressure pump, then check, repair or replace it.

Connect the intermediate flanged pipe and diaphragm properly.

Caution: Check the fuel supply advance angle and adjust it if necessary after installing the high-pressure fuel pump.

Replace fuel injector

Remove the cylinder head cove

Loosen bolts and remove nozzle fixed mount

Draw out the injector with special tool, and mark symbol as per cylinder number to later installation.

Adjust injector pressure, and check fuel atomization and leakage conditions

Place the pressure plates correctly and tighten with bolts

Assemble the gasket for cylinder head cover, and mount the high-pressure fuel pipe and fuel return pipe

Air intake system

Loosen oil inlet pipe nipple for turbocharger

Loosen two bolts connecting turbocharger and its oil return pipe, remove the oil return pipe

Remove the bolts connecting turbocharger and exhaust elbow, and remove turbocharger.

Replace new turbocharger

Diesel Engine Troubleshooting

Difficult or Unable to Start Diesel Engine

Discusses causes and solutions for difficult or failed engine starting.

Starting System Failure

Fuel Supply System Failure

Insufficient Compression Pressure

Insufficient Engine Power

Air Distribution Device and Inlet and Outlet Systems Failure

Covers faults in the timing and air intake/exhaust systems.

Intercooler Failure

Discusses intercooler faults and their remedies.

Unstable Operation, with Flameout

Speed governor Failure

Lists faults related to the speed governor and their troubleshooting.

Fuel Supply System Failure

Details fuel supply system issues causing unstable operation or flameout.

Unsatisfactory diesel fuel quality

Abnormal Color of Smoke Emission

Black Smoke Emission

Discusses causes and remedies for black smoke emission.

White Smoke Emission

Blue Smoke Emission

Diesel engine knocks

Diesel engine knocks due to excessive clearance resulting from worn piston(s) and;or cylinder(s).

Details knocks from worn parts and excessive clearances, with causes and remedies.

Abnormal collision sound generated from poorly coordinated operation or knocks of parts due to improper installation and adjustment of diesel engine.

If knocks suddenly appear during engine running due to part damage

Run Away

Speed Governor Failure

Fuel Injection Pump Failure

Excessive oil in combustion chamber

Sudden Stalling

Diesel Engine Overheat

Low Oil Pressure

Severe Engine Vibration

Monitoring System Common Faults and Troubleshooting

Insufficient water supply or water pump failure