WEICHAI R6160 Manual

R6160系列柴油机维修保养手册
Maintenace Manual For R6160 Series Diesel Engine
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:
R 6 160 ……
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.
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3．柴油机的启封
Unpacking the Diesel Engine
当您打开您柴油机的包装箱后，首先按文件清点柴油机及其随机附件，检查柴油机外表有无
损伤，连接部位是否松动，然后再安装入座台。
When you unpack your diesel engine, first sort and count the diesel engine and its accessories, inspect
the exterior surface of the diesel engine visually for damage and the connections for looseness, and then
mount the engine onto its seat stand.
4．柴油机的安装工作
Installation of Diesel Engine
机舱（机房）要求
Engine Room Requirements
管系要求
Piping Requirements
柴油机的起吊要求
Diesel Engine Lifting Requirements
柴油机的对中要求
Diesel Engine Alignment Requirements
机舱（机房）要求
Engine Room Requirements
机舱（机房）必须通风以散发发动机工作时产生的热量，避免机舱内温度过高。安装发动机时，
上方要留有足够的空间用于活塞连杆的拆卸，所需高度从曲轴中心算起，必须大于 1.4m，前方需
留出不小于 1.6m 的距离以抽出凸轮轴（从机体前端面算起）。
Engine room must be well ventilated so that it can radiate the heat produced while engine running in
order to prevent over-temperature in the room. When installing your engine, sufficient space must be
kept above the engine for removal and assembly of piston and connecting rod. The height required must
be more than 1.4m from the crankshaft centerline. A distance of at least 1.6m (from the front of the
engine block) must be kept in front of the engine to allow the pulling out of the camshaft.
管系要求
Piping Requirements
（1）排气管应通到室外，其内径不得小于 140mm，排气出口应有防雨防浪装置。排气管与增压
器不可刚性连接，中间必须装有膨胀管（随机配带）或其它形式的伸缩管。
The exhaust pipe should run out of the room. The inner diameter of the pipe must not be less than
140mm. The exhaust outlet shall be protected with rain-proof and/or wave-proof devices. No rigid
connection is allowed between exhaust pipe and supercharger, expansion pipe (provided with the engine
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in the package) or other telescoping pipes should be used.
（2）对于燃油箱，其容量应能满足柴油机在额定负荷下工作 8 小时，其放置位置尽量保证油箱
出油口高于高压油泵，燃油进油管内径不小于 10mm。
The capacity of fuel tank should be enough for the engine working about 8h at rated load. The height of
outlet of fuel tank should be higher than the injection pump. The inner diameter of fuel inlet pipe should
be more than 10mm.
（3）陆用开式循环冷却柴油机应使用冷却水池或冷却塔，冷却水池的容量应小于 25m3，水泵的
吸水高度应小于 25m3；
For land engine cooled with open circulation, water pool or tower with capacity of less than 25m3 should
be used. The suction head of water pump should be less than 2m.
（4）船用柴油机如果不配海淡水热交换器，用户需自配海淡水热交换器，禁止用海水直接冷却
柴油机
For marine engine without seawater/fresh water heat exchanger, the heat exchanger should be provided
by user. It is forbidden to cool the engine with seawater directly.
柴油机的起吊
柴油机在机体前后端各有一个起吊用的起重把，起吊应平稳，避免出现震荡、摇晃等现象。起
吊时允许有较小角度的倾斜，严禁倾斜角度过大，以免对柴油机内部结构造成相对位移。
柴油机的对中要求
柴油机作船舶主机安装时，柴油机曲轴和驱动设备必须对中。对中时用百分表来测量发动机
和被驱动装置的同轴度和端面跳动。如果是刚性连接，其同轴度应小于 φ0.08mm，如果是弹性连
接，其同轴度和端面跳动均应小于 0.2mm，若测得结果超出上述范围，必须进行调整。一般用不同
厚度的钢片进行调整，调整到规定数后，打上定位销以定位。
During installation of marine engine, the crankshaft of diesel engine and driven device must be well
aligned. Measure the coaxiality and face runout of the engine and driven device with a dial gauge
when making alignment. Coaxiality for rigid coupling should be less than 0.08mm, however for elastic
coupling, both coaxiality and face runout should be less than 0.2mm. Otherwise, carry out adjustment
with steel shims of different thickness, and secure with locating pins upon the completion of the
adjustment.
柴油机与发电机或动力输出装置必须采用弹性连接，采用弹性连轴结，其同轴度及端面的平
行度应小于 0.15mm。
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柴油机使用过程中，用户应定期按上述要求对机组进行检查，发现不合要求及时纠正，以保证
机组正常运行。
During operation, checking should be done according to the above requirements regularly. Readjust if
necessory.
注意：切勿使柴油机曲轴承受附加轴向力
Caution: Never allow engine crank shaft to bear additional axial force.
5．起动前的检查
Check before Start
旋开柴油滤清器的放污螺塞，放出燃油系统内的油封油料。
Unscrew the screw plug of diesel fuel filter to drain the preservative oil from fuel system.
将柴油机的开车手柄置于停车位置，并旋开气缸盖上的放气螺塞，然后盘动飞轮以驱尽气缸
内油封燃料。
Set starting lever of your engine to STOP position, unscrew the bleeding screw on cylinder head, and turn
flywheel to completely drain the fuel for oil sealing from cylinders.
如在寒冷季节，需取下气缸盖罩壳，用加热至 100 ～ 120℃的机油浇入气缸盖上的各运动部件，
使其防锈油料融化。
In cold season, it is necessary to remove cylinder head cover and pour engine oil heated to 100-120℃
onto moving parts on cylinder head to melt the antirust oil.
运行前必须检查所有的管路和螺纹接头、软管接头是否已经拧紧并处于完好状态。检查油门
控制和停车拉杆运动灵活性，监控和停车装置的功能以及线路状态。
Check before operation all pipelines, screwed connections and hose couplings for tightness and they
must be in good condition. Make sure that throttle control and shutdown control lever can move freely,
monitoring and shutdown devices can function properly, and circuits are in good condition.
向柴油机冷却系统内灌入冷却水。
Fill cooling water into cooling system of the engine.
加机油。对静止的发动机，由加油口向油底壳内加机油。直到油面达到油尺的上方标记。然后
用手压泵向管路系统和各润点供油至油压在 0.05MPa 以上。
（带电动预供油泵的机型在开车前自
行供油）。
Add engine oil. Add engine oil to your engine at stop state through oil filler into oil sump until oil level
reaches the upper mark of dipstick. After that, prime oil with hand pump to pipeline system and various
lubricating points (oil pressure: ≥0.05MPa). For engine with electric primary pump, the oil is supplied
automatically by the pump before starting.
在自备燃油箱内加注规定牌号的清洁柴油，并用手压输油泵向燃油系统内供油，同时，将柴油
滤清器顶部放气螺塞、喷油泵上部两放气螺钉和喷油器上的放气螺杆旋开放气，直至开始溢油并无
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气泡为止，然后旋紧。
Fill the self-provided fuel tank with specified and clean fuel and supply fuel to fuel system with hand
pump. Screw off the air release screw plug on the top of fuel filter, the release screws on the top of
injection pump and the release screw on the injector until there is fuel overflow without bubbles. Then
tighten them up.
采用气马达起动时，应先向起动空气瓶内充气，直至瓶内压力在 1.5MPa 以上。
When pneumatic motor is used for starting, charge the air bottle to above 1.5MPa firstly.
采用电力起动时，应先向起动蓄电池充电，保证蓄电池电压不低于 24V。
For the electric started engine, charge the battery firstly, and the voltage should not be less than 24V.
6．柴油机的起动
Engine Start
采用气马达起动时
Start with pneumatic motor:
将开车把手置于开车位置，首先旋开起动空气瓶上的控制小阀和中央大阀，然后再打开气马
达的开关阀，柴油机将能立即起动。起动后应立即关闭气马达的开关阀，并立即将空气瓶上各阀依
次关闭。
Open the control valve and central gate valve on starting air bottle, then open the switch valve of
pneumatic motor and the engine will be started immediately. Close the switch valve of the motor
immediately after the engine is started, and then close all valves on the air bottle.
如果气马达齿轮未旋出，关闭阀门，检查气马达；如果飞轮转动，但在三秒内未能起动，应立
即关闭阀门，停止喷油，并查找原因。
If the gear of pneumatic motor is not screw out, close the valve and check the motor. If the engine is not
started in 3s with the flywheel rotating, close the valves immediately and stop injecting and find out the
reason.
采用电马达起动时
Start with electric motor:
将开车把手置于开车位置，首先接通蓄电池开关，插入电路钥匙打开，然后按下起动按钮，柴
油机应能立即起动，起动后，应立即释放按钮，使起动电路迅速断开，并关闭电钥匙，断开开关。
起动时间不能大于 5 秒，若一次未能起动，再起动时应停 2 分钟。
Set up the start handle at the starting position. Turn on battery switch, insert the electric circuit key, press
start button, the engine should be started. After the engine is started, release the button immediately to
open the starting circuit and close the key switch. The starting time should not be more than 5 seconds. If
your engine can’t be started at one time, wait at least 2 minutes before trying again.
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带电动预供油泵的机型在起动时，电动预供油泵会向柴油机管路内充油，至规定压力后再接
通电马达回路起动柴油机。这个过程在柴油机首次起动时会持续 30 ～ 60 秒。所以首次起动时间
较长，属正常现象。
For the engine with electric prime pump, the prime pump will fill oil to the pipeline when starting (when
first starting of engine, it is about 30-60s), and switch on the electric motor to start the engine when the
specified fuel pressure is reached.
7．柴油机的运转
Engine Running
柴油机全负荷运转后，应先卸去负荷，逐渐降至怠速，待水温降至 60℃以下时再停车。严禁在
水温过高时骤然停车。凡是突然停机，应立即盘车 3 ～ 5 圈，避免活塞与缸套之间出现抱缸现象。
If your engine runs with full load, unload it and reduce speed gradually down to idle speed, do not
shutdown your engine until water cools down to below 60℃. Never shutdown your engine abruptly when
water temperature is too high. If the engine is stopped suddenly, rotate the crankshaft of the engine about
3-5 revolutions to avoid piston seizure.
经常注意机油压力和循环水温度，以免因控制系统失灵而造成事故。
Constantly pay attention to oil pressure and circulating water temperature so as not to cause any accident
due to control system failure.
经常注意油耗变化和排气烟色，以鉴别喷油器的工作性能和使用负荷的变化情况。
Constantly pay attention to variation of fuel consumption and exhaust smoke color to verify performance
of fuel injector and applied load.
注意柴油机在正常负荷下工作，避免柴油机超负荷工作。
Make sure that your engine runs with normal load. Never overload operation.
在寒冷季节（气温 0℃以下）停车后，应将冷却水放尽，以免冻裂柴油机机体、气缸盖等零部件。
放水应在停车半小时后进行，切不可停车后立即放水，否则，各摩擦表面温度很高，会将其间储存
的少量机油蒸发掉，造成再起动困难及不正常磨损，甚至能使活塞胀死在气缸内。
In cold season (air temperature below 0℃), drain cooling water completely to prevent frost crack of
engine block and cylinder head 30 minutes after shutdown. Never drain cooling water immediately after
shutdown, or the oil on the friction surfaces will be transpired and cause difficult starting and abnormal
wear.
注意：柴油机停车后，不得立即打开热交换器加水盖，以免被水蒸气灼伤。
Caution: Do not open water filler cap of heat exchanger immediately after the engine is
shutdown, so as to prevent being burned by hot vapor.
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2.柴油机维护保养指南
Maintenance Instructions For Diesel Engine
2.1 日常维护
Daily Maintenance
◆检查；
Inspection；
柴油机油底壳油面，加油达到油尺上最上刻线。
Oil level of oil sump, add oil to the upmost mark on dipstick;
冷却水面，按要求加水。
Level of cooling water, add water as required;
柴油机管路有无泄漏。
Diesel engine pipeline for leakage;
柴油机机油压力；排气温度、颜色是否正常，转速是否平稳。
Engine oil pressure, exhaust gas temperature and color, and engine speed (should be stable);
冷却水温度。
Temperature of cooling water;
空气滤清器外部脏污程度。
External cleanness of air filter;
检查“三漏”情况并排除
If there is oil, gas or water leakage, and remove if any;
外接件、附件的连接、紧固是否良好。
Connection and security of external connecting parts and accessories.
2．定期保养
Periodic Maintenance
定期保养按照下表进行，若柴油机使用工况变化比较频繁，需根据情况相应缩短保养周期。
Carry out periodic maintenance as per Table below. Shorten maintenance period as appropriate if your
engine operates at conditions changing frequently.
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2.1 维护保养周期
Maintenance Period
保养周期柴油机累计运行时间（h）
Maintenance Period Accumulated Running Time of Diesel Engine (hrs)
新机维护 50
Maintenance of New Engine
一级技术保养 350
Level 1 Technical Maintenance
二级技术保养 1000
三级技术保养 3000
四级技术保养 7000
2.2 保养项目
Maintenance
新机维护
Maintenance to New Engine
更换机油并清洗滤清器、机座。
Replace engine oil and clean oil filter;
清洗柴油滤清器，擦除气缸盖上平面的脏滞机油。
Clean fuel filter, remove the dirty oil on the upper face of cylinder head;
检查各紧固件、连接件是否有松动现象。
Check the connecting parts and tighten parts;
根据中速柴油机的工作特点，为了避免气缸盖漏气，保证柴油机可靠工作，投入使用累计运行
200 小时左右，将全部气缸盖螺栓松开，然后按照说明书要求分次重新把紧。
For engine worked about 200h, loose all cylinder head bolts and retighten them according to the
requirements specified in the Operation and Maintenance Manual to avoid gas leakage and ensure the
engine working reliably.
一级技术保养
除日常维护项目增添下列工作：
In addition to daily maintenance,
清洗柴油滤清器
Replace engine oil and clean oil filter and strainer;
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更换机油，清洗机油滤清器、滤网、机座。
Check the tension of belt, adjusting if necessory;
检查三角皮带的张紧程度，必要时进行调整。
Check intake/outlet valve clearance and advance angle, readjusting if necessory;
检查进、排气门间隙，及喷油提前角，不合规定时，进行调整。
Clean air filter;
清洗空气滤清器。
Check compressor impeller of turbocharger, the inner cavity of compressor casing, turbine and
清洗增压器压气机叶轮，压气机壳内腔，涡轮及涡轮壳等零件的油污和积碳。
turbine housing for oil dirty and carbon deposit;
清洗冷却水散热器中的沉淀物质。
Clean the radiator.
二级技术保养
除一级技术保养项目外另添下列工作：
In addition to Level 1 maintenance,
检查各缸工作的平衡性，如条件具备，必要时可调整喷油泵各缸喷油量的均匀性。
Check the balance of cylinders, adjust the balance of fuel injections of all injection pump cylinders if
necessory;
拆下各缸盖，清除燃烧室积碳，检查进、排气门及充气阀阀面以及气门锁夹、推杆和摇臂的配
合面的磨损情况，不合要求时，应进行研修。
Dismantle the cylinder heads, remove the carbon deposit in the combustion chamber. Check the wear
conditions of inlet/outlet valves and valve faces, valve collets, the contact faces of push rod and rocker
arm. Repair if necessory;
检查喷油器的喷油压力和喷雾情况，必要时进行调整和修理。
Check the injection pressure and spraying of injector. Adjusting and repair if necessory;
全面检查各油、水、气和电路件以及各紧固件的连接和紧固情况。
Check the connections of oil, water, gas pipelines and electrical parts and tightening parts;
检查柴油机与其配套工作机械的中心对正情况，并及时调整。
Check the center aligning of the engine and matched machinery. Adjusting if necessory;
检查连杆螺母和飞轮紧固螺母有无松动，不合规定时，应按规定扭紧力矩旋紧。
Check the connecting rod nuts and flywheel tightening nuts for loosing. Tightening according to specified
torque if necessory;
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检查水泵水封装置，及时研修或更换新件。
Check the water sealing of water pump. Repair or replace if necessory;
检查电起动机的起动电机齿轮磨损情况及其工作是否灵活。
Check the wear and working condition of motor gear of electric starter;
清洗机油、燃油系统管路，清除污物并应吹干净。
Clean oil and fuel pipeline, remove the dirt and clean by blowing.
三级技术保养
除二级技术保养项目外再加下列工作：
In addition to Level 2 maintenance,
检查活塞顶部积碳情况，必要时进行清理。检查活塞环、气缸套、连杆小头衬套及连杆轴瓦的
磨损情况，必要时更换。
Check the carbon deposit on the top of piston, cleaning if necessory. Check the wear of piston ring,
cylinder liner, connecting rod small end bushing and connecting rod bearing, replace if necessory;
检查喷油泵内出油阀的密封情况，必要时进行研修或更换。
Check the sealing of outlet valve if injection pump, repair or replace if necessory;
检查喷油器针阀偶件的工作性能，必要时换新。
Check the working performance of needle valve and seat of injector, replace if necessory;
清洗冷却系统内水垢。
Clean the cooling system, remove the scale in it;
根据运行情况，适当调整调速弹簧
Adjust the governing spring properly according to the operation conditions;
检查涡轮增压器中叶轮与壳体的间隙，喷嘴环表面烧损情况及其封、油封零件损坏的情况，必
要时修理或更换。
Check the clearance between the impeller and the casing of turbocharger, the surface ablating of injector
ring and the damaging of oil sealing parts; repair or replace if necessory;
检查机油泵工作情况，必要时进行调整。
Check the working of oil pump, adjusting if necessory;
放净起动空气瓶中压缩空气后，旋开底部的放污螺塞，放出瓶内积水及污物。
After release the air in the starting air bottle, screw off the drainage screw plug at the bottom of the bottle,
discharge the water and dirt.
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第三章柴油机保养内容
Maintenance Of Diesel Engine
1．每日保养
Daily Maintenance
预防性保养从每天作起，了解柴油机工作状况。
You should perform daily preventive maintenance to learn about operation conditions of your diesel
engine.
起动柴油机前检查：
Check prior to starting your diesel engine:
机油液面
engine oil level;
冷却液液面
coolant level;
泄漏
for any leakage;
易损件
vulnerable parts; and
柴油机上出现的任何异常
if there is any abnormal symptom on your diesel engine.
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检查机油液面
Check engine oil level:
从机体上抽出油尺检查机油液面。
当油面低于油尺下刻线或高于油尺上刻
线，绝不允许开动柴油机。
Pull out dipstick from engine block to check
engine oil level. Do not start your engine if
oil level is lower than Lower Limit mark or
higher than Upper Limit mark of dipstick.
如需在柴油机停车后检查油面，应
至少在停车 5 分钟后进行，以使机器内
的机油有充分时间流回油底壳。
If it is necessary to check oil level after
engine shutdown, wait at least 5 minutes to
let the engine oil in your engine return to
oil sump.
-12-
检查冷却液面
Check coolant level:
从海淡水热交换器上的水位窗检查
冷却液面
Check coolant level from observation
window on heat exchanger,
冷却液面冷却液面不够时，打开热
交换器顶部的水口盖加入冷却水。
and add cooling water from water filler on
top of heat exchanger if necessary.
注意：柴油机停车后，不得立即打
开热交换器水口盖，以免被水蒸气灼伤。
Caution: Do not open water filler cap of
heat exchanger at once after the engine
is shutdown, so as to prevent vapor from
burning yourself
检查三角皮带
Check the V-belt:
用肉眼检查三角皮带，有无裂纹或擦
伤，必要时应更换
Check the V-belt for cracks or abrade
visually, replace if necessory.
-13-
2．新机维护
Maintenance of New Engine
新机使用 50 小时后进行，除完成每
日保养外，增加下列工作项目：
Perform this maintenance after first 50h
running of new engine. In addition to daily
maintenance, you should:
更换机油
Replace engine oil.
新机经过磨合后，机油中会掺杂进
较多磨屑。此时应适时更换机油并清洗
机油滤清器，以保证机器在接下来的使
用中处于一种清洁的润滑环境中。
Run-in of new engine will result in more
abrasive dust in the oil. Replace oil and
clean oil filter is necessory to ensure proper
lubrication condition in future operation.
清洗机油滤清器
Clean oil filter
滤清器需分解逐层清洗：
The oil filter should be disassembled and be
cleaned according to the procedure below:
－旋下压紧螺母（7）
- Remove compression nut;
－取下壳体（2）
- Remove filter casing;
-14-
—取出滤芯（6）
- Take out filter element;
－拆分开滤芯
- Disassemble filter element;
－浸入油液中用毛刷刷洗干净
- Clean with brush in oil liquid;
－取下塞子，用压缩空气由内向外
反吹
- Remove plug and blow it with
compressed air from inside to outside; and
－重新进行安装
- Reassemble it.
将清洁的机油从加油口注入柴油机
到油尺的上限刻度。
Fill with clean oil from filler until oil level
reaches upper limit on dipstick.
-15-
用手压机油泵向管路系统和各润滑
点供油。预供油后，停一段时间（约 5 分
钟）油面达到稳定后，再加机油到油尺上
方标记，开机前必须预供油，直到油压表
开始动为止，然后方可开机（带预供油泵
的机型预供油到规定压力后机器自行起
动）。
Prime the pipeline system and various
lubrication points with hand oil pump. After
oil system is primed, wait for a while (about
5 minutes) until the oil level becomes
stable, add oil again to the upper limit mark
of dipstick. Prime the oil supply system
before each start until the needle of oil
pressure gauge starts moving. (For engine
with prime pump, when the oil pressure is
reached the specified value, the engine will
start automatically.)
-16-
清洗柴油滤清器
Clean fuel filter
滤清器需分解逐层清洗：
The fuel filter should be disassembled
and be cleaned according to the procedure
below:
－旋下紧固螺栓 3
- Screw off tighten nut 3;
－取下壳体 9
- Take off filter casing 9;
－旋下压紧螺母 4，取下芯盖 6
- Screw off compression nut 4, take off
cover 6;
—取出滤芯 7，
- Take out filter element 7;
－拆分开换滤芯，如有必要更换滤
纸。
- Disassemble filter element, replace filter
paper if necessory;
－浸入油液中用毛刷刷洗干净滤芯。
- Clean with brush in oil liquid;
－取下塞子，用压缩空气由内向外反
吹
- Remove plug and blow it with compressed
air from inside to outside; and
－重新进行安装
- Reassemble it.
-17-
检查各紧固件、连接件的紧固情况
Check the tightness of tightening parts and connection parts
应注意检查各连接紧固件的紧固情况，若有松动现象出现，应及时拧紧。以免造成意外的故障。
Check the tightness of tightening parts and connection parts If the tightening or connection part is loose,
screw it down in time to avoid accident trouble.
重新拧紧气缸盖螺栓
Retighten the cylinder head bolts
为了避免气缸盖漏气，保证柴油机可靠工作，投入使用累计运行 200 小时左右，将全部气缸盖
螺栓松开，然后分次重新把紧（把紧力矩及规范详见本手册第 5 章）。
After the engine is operated for 200h, loosen all cylinder head bolts and then retighten them according to
the requirement in chapter 5 to avoid gas leaking of cylinder head.
3．柴油机累计运行350小时的
保养内容
Maintenance of Diesel Engine after
350h operation
除完成每日保养后，增加下列
检查项目：
In addition to daily maintenance, the
following items should be checked:
检查气门间隙
Check valve clearance
拆下 6 个缸盖上的气缸盖罩
Remove the 6 cylinder head covers;
-18-
将柴油机的开车手柄置于停车位置
旋开气缸盖上的放气螺塞
Put the start handle of diesel engine at the
stop position;
使用盘车杆慢慢转动柴油机飞轮，使机后盖上的箭头对准飞轮上的“1-6”凹痕标记，此时柴
油机第一缸活塞处于上止点位置，第一缸的进排气门处于关闭状态（若第一缸的进排气门此时处
于开启状态，应继续盘动飞轮一周，使指针再次对准“1-6”凹痕标记，以便使第一缸的进排气门处
于关闭状态
Turn the flywheel with a bar and make the arrow pointer on the rear cover of the engine aligning with the
“1-6” mark on the flywheel housing. The piston of 1st cylinder is at TDC and the inlet/outlet valves
are closed at this time (if the inlet/outlet valves are open, turn the flywheel right along, and make the
pointer aligning with the “1-6” mark again to close the inlet/outlet valves of the 1st cylinder).
-19-
用塞尺检查气门间隙
Check valve clearance with feeler
gauge.
进气门间隙：
（0.4±0.05）mm
Inlet valve clearance: (0.4 ±0.05) mm
排气门间隙：
（0.5±0.05）mm
Outlet valve clearance : ( 0.5 ±0.05)
mm
注意：检测气门间隙时，柴油机应
处于冷态——低于 60℃，塞尺在气门桥
和摇臂间滑动，有阻滞发粘感觉时，所测
间隙为准确值。
Caution: Valve clearance shall be
measured with engine at cold state, i.e.,
temperature less than 60℃ . The measured
clearance is an exact value if a slight
resistance is felt when feeler gauge is
sliding between air valve bridge and rocker
arm.
第一缸活塞位于压缩冲程上止点位
置。
The piston of cylinder No.1 is at TDC
position of compression stroke.
如右表所示检查或调整气门间隙。
Check or adjust valve clearance as per
Table below.
6 5 4 3 2 1
进排进排进排进排进排进排
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet
√ √ √ √ √ √
-20-
用塞尺调整好间隙后拧紧摇臂锁紧螺母，并反复查气门间隙，直到达到要求为止。
Tighten rocker arm lock nut after clearance is adjusted with feeler gauge, repeatedly check valve
clearance until it meets the requirements.
用盘车杆再转动飞轮一周，使指针对准飞轮上的“1-6”凹痕标记
Turn flywheel one more revolution with barring rod to align needle with 1-6 dent mark on flywheel.
按右图所示调整气门间隙
Adjust valve clearance as per Table below.
同样松动摇臂锁紧螺母，用塞尺调整好后重新拧紧摇臂锁紧螺母。
Loosen rocker arm lock nuts, adjust the clearance with feeler gauge, and tighten these lock nuts.
6 5 4 3 2 1
进排进排进排进排进排进排
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet
√ √ √ √ √ √
安装气缸盖罩垫片和气缸盖罩
Mount cylinder head gasket and cover.
拧紧缸盖上进排气管的螺栓，检查所有的螺栓、螺钉联结、软管及密封状况。
Screw on intake/exhaust manifold bolts and check all bolts, screws, hoses and seals.
-21-
检查供油提前角
Check fuel advance angle
将油门置于最大油量位置，拆下第
一缸高压油管，将油泵足
Set the throttle at the max fuel quantity
position, dismantle the high pressure
fuel pipe of 1st cylinder, and pump fuel
sufficiently.
盘动飞轮到上止点前 30 度左右
Rotate the flywheel to 30° before TDC.
松开气缸盖放气螺钉，缓慢按柴油
机工作转向盘动飞轮，同时密切注意油
泵出油口的油面，当油面刚刚波动的瞬
间，就表示第一缸开始供油，此时机后盖
上箭头所对应的刻度即供油提前角。
Unscrew the release screw on cylinder
head, rotate the flywheel slowly with the
working direction and watch out for the fuel
level at outlet of fuel pump. When the fuel
level is just fluctuating, it means that the
1st cylinder begins fuelling. At this time,
the graduation indicated by the arrow on
the rear cover of engine is the fuel advance
angle.
若此角度与规定角度不符，则应调
整。
If this angle is not agree with the specified
value, it should be readjusted.
首先松开连接器的紧固螺栓
First of all, unscrew the bolt of connector.
-22-
若实际检查供油提前角大于规定值时，按曲轴旋转方向盘车到规定角度。
If the checked advance angle is bigger than the specified value, bar the engine with the rotating direction
of crankshaft to the specified angle.
若实际检查供油提前角小于规定值时，按曲轴旋转反向盘车到一大于规定值的角度，以消除
齿侧间隙，再按曲轴旋转方向盘车到规定角度
If the checked advance angle is smaller than the specified value, bar the engine with the reverse rotating
direction of crankshaft to an angle bigger than the specified value to eliminate the side clearance of gear.
Then bar the engine with the rotating direction of crankshaft to the specified angle.
调整完毕并检查无误后，拧紧连接器的紧固螺栓。
After the advance angle is correctly adjusted, tighten the bolt for the connector.
清洗空气滤清器
Check air filter
R6160 系列柴油机采用干式空滤器，
它利用空气通过带有孔隙滤芯的机械方
法，使空气净化。若滤芯的金属滤网积尘
过多，增加进气阻力，会影响进气效果。
For R6160 series diesel engine, dry air
filter is adopted. The air is filtered when
it is passing through the holes of the filter
element. If there is more dust on the metal
screen of filter element, the air intake will
be affected by the increased resistance.
-23-
检查三角皮带的张紧程度
Check the V-belt
传动用三角皮带，使用一段时间后，
应检查其张紧程度，过松时，应调整或更
换。
Check the tension of the V-belt when it is
used for a period of time. Adjust or replace
if necessory.
松开紧固张紧轮的螺栓，变动张紧
轮的位置，直至皮带张紧适中。拧紧张紧
轮紧固螺栓，固定好张紧轮。
Unscrew the bolt for tightening the tension
pulley, change the position of tension
pulley to adjust the tension of pulley. Then
screw down the tension pulley bolt and fix
the pulley.
-24-
清理增压器
Clean the turbocharger
清洗增压器压气机叶轮，压气机壳内腔，涡轮及涡轮壳等零件的油污和积碳。
Clean out the oil dust and the carbon deposit on the impeller of compressor, the inner cavity of
compressor casing, the turbine and turbine scroll.
增压器的拆装请参见本手册第八章第 4 小节。
Disassemble/assemble the turbocharger according to section 4 of chapter 8 in this manual.
增压器的维护请参见增压器使用说明书
For maintenance of the turbocharger, please refer to the Operation Manual of Turbocharger.
清洗冷却水水散热器
Clean the cooling water radiator
陆用闭式水冷却循环，采用水散热器冷却柴油机内冷却水，应适时清洗散热器，以保证其散
热效果。
For land engine cooled through close circulating water, the water inside the engine is cooled through
water radiator. So the radiator should be cleaned timely to ensure the cooling effect.
4．柴油机累计运行 1000 小时的保养内容
Maintenance of engine after 1000-hour’s operation
当柴油机累计运行 1000 小时时，除完成一级技术保养，再增加以下项目
In addition to the Maintenance 1, this maintenance also includes:
检查柴油机的对中
Check the alignment of diesel engine
检查对中时要用百分表测量柴油机
和被驱动设备的同轴度和端面跳动。如
果是弹性连接，其同轴度和端面跳动均
应小于 0.2mm，若是刚性连接，其同轴度
应小于 φ0.08mm，若是测量结果超出了
上述规定，用不同厚度的钢片进行调整。
The end face run-out and axiality of the
diesel engine and the driven equipment
should be measured by centigrade meter.
For flexible connection, the axiality and end
face run-out should be less than 0.2mm,
for rigid connection, the axiality should be
less than φ0.08mm; If the measurements
were beyond above-mentioned range, the
steel disc with different thickness is used to
adjust.
-25-
检查喷油器的喷油压力，清洗喷油
器的针阀偶件。
Check injection pressure of injector, and
clean needle valve and seat assembly of
injector
从机器上取下喷油器（操作方法详
见本手册第八章“更换喷油器”的内容）。
Remove injector as described in Para. 8.3.
如右图所示，将拆下的喷油器接到
试验器上。通过压动试验器的手柄来给
喷油器供油。
Connect this injector to the tester, and
operate the handle of tester to supply fuel to
the injector (as shown in right figure).
-26-
喷油器的雾化质量评价：
Evaluation on Atomization Fineness of Fuel Injector
好不良
Desirable Undesirable
慢的试验速度
每秒一次行程
Low test speed, one stroke per 喷油雾化细密，可听见喷射喷炬不雾化或无压力，无喷射
second 声，手柄处可感觉到振动。响声，手柄处无感觉。
Fine fuel spray atomization, No fuel spray atomization or
audible jetting, and perceptible pressure, no jetting sound, nor
vibration on handle. perceptible vibration on handle.
集中的燃料流，无雾化的喷
中等试验速度
炬，无响声，手柄处有均匀的
Middle test speed 喷炬雾化，又很显著的喷射
阻力，无振动。
声，在手柄处有显著振感。
Concentrated fuel stream, without
Sprayed fuel atomized, notable
atomized fuel spray and jetting
jetting sound, and perceptible
sound, with uniform resistance
vibration on handle.
force on handle, however without
vibration on handle.
快的试验速度
喷炬如左，但不带哨声。
每秒钟压手柄6～8次
喷炬强烈雾化，有喷射声，带 F u e l s p r a y a s s h o w n i n l e f t
High test speed, push handle 6 ~ 8
轻微哨音，手柄有振动 diagram, without whistler.
times per second.
Fuel spray intensively atomized,
with jetting sound and slight
whistler, and perceptible vibration
on handle
-27-
清洗针阀偶件必须在清洁的环境中
进行，不能使零件沾上任何的脏污。
The needle valve and seat assembly should
be cleaned in clean environment to ensure
no dirt on parts.
首先，将喷油器外表面的污物和积
碳清除干净，应注意只允许用汽油或煤
油将污物和积碳泡溶，或用软质木板擦
拭，禁用刮刀、锉刀及砂纸，也不允许用
棉纱擦拭。
At first, dirt and carbon deposit on injector
surface should be removed. During
removing, the injector must be soaked in
petrol or kerosene, then scrape the dirt with
soft wooden plate. Scraper, file, sand paper
and cotton yarn are forbidden.
夹紧喷油器体，松开紧帽，取出针阀
体和针阀，放入干净汽油或煤油中清洗
（偶件不能互换，应注意配对）。
Then grip injector with pliers, loosen the
screw, take out needle valve and valve body
(mated couple can not be exchanged), wash
them in clean petrol or kerosene.
检查喷油压力
Check injection pressure:
把压力试验器断开，压手柄若干次，然后接通试验器，慢慢压手柄直到带轻微喷射声的燃油从
喷油嘴喷出，指示的压力即为喷油压力。
Disconnect the pressure tester and push the handle several times, and then connect the tester again, push
the handle slowly until fuel ejects from nozzle with slight jetting sound. The pressure indicated now is
injection pressure.
新喷油器或新的喷油器弹簧最低 250bar。若测得的喷油压力低于此值，可通过更换调整垫片
来调整，大约每加厚 0.01mm，喷油压力上升 1bar。
The minimum injection pressure for new injector or injector spring is 250bar. If the measured injection
pressure is less than this value, adjust it with shims. A 0.01mm increment of thickness will increase the
pressure by 1bar.
-28-
调整垫片在备件箱中一套共 21 件，从 1 ～ 2mm，每隔 0.05mm 一档。

There is a set of adjusting shims in spare parts kit, 21 pieces in total from 1 to 2mm in thickness
with an increment of 0.05mm.
清洗热交换器芯。
Clean heat exchanger element:
注意：拆检热交换器前应放掉发动
机内的冷却水
Caution: Drain cooling water from
your engine before removing and checking
heat exchanger.
拆下热交换器端盖上的海水进水管、
出水管
To clean heat exchanger element,
remove seawater inlet pipe and outlet pipe
on heat exchanger cap,
松开端盖上的 6 个螺栓，拆下端盖
loosen 6 bolts on the cap, remove the
cap,
抽出热交换器芯子，进行清洗
and take out the heat exchanger
element
检查连杆螺母
Check connecting rod nuts
-29-
拆开机体上的观察盖
Remove the inspection window on cylinder
block
盘动飞轮，使连杆螺栓处在适当的
位置后检查，如发现有松动现象，应按规
定把紧（把紧力矩见本手册第五章）
Bar the flywheel to proper position and
inspect the conrod bolt. Tighten the
loosened bolt according to Chapter 5.
5．柴油机累计运行 3000 小时的保

养内容
Maintenance of engine after
3000-hour’s operation
当柴油机累计运行 3000 小时时，除完
成二级技术保养，再增加以下项目
In addition to the Maintenance 2, this
maintenance also includes:
更换冷却水节温器。
Replace cooling water thermostat.
拆开连接小循环水管与节温器的胶
管上的软管卡箍，并将胶管与节温器分
离开。
Remove clamp from the hose connecting
minor circulation water pipe to thermostat,
and disconnect hose from the thermostat.
-30-
拆开连接净水泵进水管与节温器的
胶管上的软管卡箍，并将胶管与节温器
分离开。
Remove clamps from rubber hose
connecting inlet pipe of treated water
pump to thermostat, and disconnect hose to
thermostat.
拆下连接出水总管与节温器体的 4
个螺栓，将节温器取下。
Remove 4 bolts for connecting water
outlet manifold and thermostat, and remove
the thermostat.
节温器的装配按照与拆卸相反的顺
序进行。
Mount thermostat in reverse order of
removal.
-31-
...
第四章柴油机几大系统流程图
Flowcharts Of Primary Systems Of Diesel Engine
润滑系统
Lubricating system
冷却系统
Cooling system
进排气系统
Air inlet and exhaust system
燃油系统
Fuel system
起动系统
Starting system
了解 170Z 系列柴油机的各大系统流程，将为您使用维护保养及排除故障提供帮助。
System flowcharts for 170Z-Series Diesel Engines can assist you to operate, service and troubleshoot
your engine correctly.
1．润滑系统
Lubricating System
-33-
1.1 R6160A 系列柴油机润滑系统流程图
Flowchart for lubricating system of R6160A series diesel engine
增压器Turbocharger 摇臂Rocker arm

挺柱Tappet 活塞Piston
凸轮轴Camshaft 机油泵Oil pump
机油冷却器Oil cooler 机油滤清器Oil filter
主油道Main oil passage 限压阀Pressure limiting valve
主轴承及连杆轴承Main bearings and 飞轮Flywheel
connecting rod bearings 回机座Return bed plate
电动预供油泵Electric oil pre-supply pump
机座Bed plate
-34-
1.2 R6160Z 系列柴油机润滑系统流程图
Flowchart for lubricating system of R6160Z series diesel engine
摇臂Rocker arm 连杆轴承Connecting rod bearings

挺柱Tappet 增压器轴承Turbocharger bearing
凸轮轴Camshaft 手压泵或电动预供油泵Hand pump or electric
机油泵Oil pump oil pre-supply pump
机油冷却器Oil cooler 传动齿轮Driving gear
机油滤清器Oil filter 传动轴齿轮Driving gear shaft
主油道Main oil passage 活塞销与轴套Piston pin and shaft casing
调节阀Adjusting valve 活塞与气缸配合面Matching surface of piston
主轴承Main bearing and cylinder
连杆轴承Connecting rod bearings 机座Bed plate
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2．冷却系统
Cooling system
2.1 R6160A 系列柴油机冷却系统流程图
Flowchart for cooling system of R6160A series diesel engine
气缸盖Cylinder head 净水泵Treated water

节温器Thermostat 生水泵Raw water pump
热交换器Heat exchanger 机体水腔Water cavity of cylinder block
生水腔Raw water cavity 机油冷却器Oil cooler
净水腔Treated water cavity 飞轮Flywheel
水源Water source
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2.2 R6160ZC 系列柴油机冷却系统流程图
Flowchart for cooling system of R6160ZC series diesel engine
气缸盖Cylinder head 生水泵Raw water pump

节温器Thermostat 机体水腔Water cavity of cylinder block
热交换器Heat exchanger 机油冷却器Oil cooler
生水腔Raw water cavity 飞轮Flywheel
净水腔Treated water cavity 中冷器Intercooler
水源Water source 水套排气管Exhaust manifold with water
净水泵Treated water jacket
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2.3 陆机闭式循环
Closed circulation for stationary engine
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3．进排气系统
Intake & exhaust system
其中，空气冷却器为 R6160Z 系列、R6160A-5、R6160A-6 型柴油机带
The air cooler is attached with R6160Z series diesel engine, Model R6160A-5 and R6160A-6 diesel
engine.
膨胀管Expansion pipe
排气管Exhaust manifold
进气管Intake manifold
空气滤清器Air cleaner
空气冷却器Air cooler
增压器涡轮机Turbine of turbocharger
增压器压气机Compressor of turbocharger
气缸盖Cylinder head
飞轮Flywheel
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4．燃油系统
Fuel system
喷油器Injector
高压油泵Injection pump
输油泵Transfer pump
滤清器Fuel filter
电磁阀solenoid valve
进油管（用户自接）Fuel inlet pipe (provided
by user)
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5．起动系统
Starting system
5.1 气起动系统
5.1 Pneumatic starting system
气缸盖Cylinder head
起动充气阀Starting charging valve
起动空气瓶Starting air bottle
空气压缩机Air compressor
减压阀Pressure relief valve
气压表Barometer
开关阀Switch valve
油雾器Fuel atomizer
起动气马达Starting pneumatic motor
飞轮Flywheel
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5.2 电起动系统
Electric starting system
与齿圈间隙Clearance to gear ring

起动电机Starting motor
接触器Contactor
电动预供油泵Electric oil pre-supply pump
观察盖Inspection cover
接蓄电池正极to battery positive pole
接蓄电池负极to battery negative pole
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第五章柴油机强力螺栓的拧紧力矩和拧紧办法
Tightening Torque And Method of Bolts And Nuts on DieseEngine
1．主轴承螺母
Main Bearing Nuts:
规格为 M18，共 14 个。
Size: M24; 14 used on 6-cylinder engine and 18 used on 8-cylinder engine.
拧紧次序按下图所示
Tightening order is as shown in the Figure below.
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拧紧力矩为（220~250）N.m。
Tightening torque is 220~250N.m.
拧入前螺纹表面涂乐泰 262 密封胶。
Before the nuts are screwed in, apply
LOCTITE 262 sealant on their thread.
2．气缸盖螺母
Cylinder head nuts
规格为 M27，每缸共四个螺母，拧
紧次序按右图所示
Size: M27, 4 nuts for each cylinder, the
tightening order is as shown in right Figure.
分三次均匀拧紧，拧紧力矩：220kW
以下机型为（600 ～ 650）N.m；220kW
及以上机型用（650 ～ 700）N.m。
Tighten the nuts uniformly for three times.
Tightening torque:600～650N.m for
engine which power is less than 220kW;
650～700N.m for engine which power is
220kW and more.
3．连杆螺母
Connecting rod nuts
300kW 及以上机型：规格为 M16，
每缸 4 个，拧紧力矩为 140N.m，分二次
对称拧紧：
For engine which power is 300kW and
more, the size is M16, 4 used for each
cylinder, tightening torque is 140N.m,
tighten in a symmetrical manner in 2 times:
第一次：80 N.m 第二次：140 N.m
First time: 80N.m; second time: 140N.
m.300kW 以下机型：规格为 M20，每缸
2 个，拧紧力矩为 250N.m，分二次对称
拧紧：
For engine which power is less than
300kW, the size is M20, 2 used for each
cylinder, tightening torque is 250N.m,
tighten in a symmetrical manner in 2 times:
第一次：130 N.m 第二次：250 N.m
First time: 130N.m; second time: 250N.m.
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4．飞轮螺栓
Flywheel bolts
规格为 M24，共 8 个，拧紧次序按
右图所示
Size: M24, 8 used; and tightening order is
shown in the right Figure.
拧紧步骤如下：第一次：30N.m；
第二次：430N.m ～ 470 N.m；
First time: 30N.m; second time: 430N.
m～470N.m.
拧入前螺纹表面涂乐泰 262 密封胶。
Before the bolts are screwed in, apply
LOCTITE 262 sealant on their thread.
5．机体与机座连接紧固螺栓
Connecting bolts between cylinder block and bed plate
规格为 M14，共 70 个，拧紧力矩为 90 N.m ～ 130N.m。分 2 次对称拧紧，步骤如下：
Size: M14, 70 in all, tightening torque: 90N.m～130N.m, tighten them symmetrically in 2 times:
第一次：用风动扳手拧紧第二次：90 ～ 130N.m。
First time: tighten with pneumatic spanner; second time: 90～130N.m.
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6．紧固皮带轮螺母
Tightening nuts for belt pulley
规格为 M72，共 1 个，拧紧力矩为
400 ～ 450N.m，一次拧紧，并加乐泰 262
厌氧密封胶。
Size: M72, 1 used; tightening torque is
400～450N.m; tightened at 1 time. before
it is screwed in, apply LOCTITE 262
anaerobic sealant on its thread.
7．减振器连接螺栓
Connecting bolts for damper
规格为 M12，共 10 个。拧紧力矩为
60 ～ 90N.m。分两次对称拧紧
Size: M12, 10 in all; tightening torque is
60～90N.m; tighten them symmetrically in
2 times:
第一次：风动拧紧
第二次：60 ～ 90N.m
First time: pneumatic tightening;
Second time: 60～90N.m.
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第六章柴油机所用的燃料油、润滑油、冷却水和辅助材料
Fuel Oil, Lubricating Oil, Cooling Water And Auxiliary Materials
1．燃料油
Fuel Oil
夏季：0 号轻柴油 GB252；冬季：-10 号轻柴油 GB252
In summer time: GB 252 Grade No.0 light diesel fuel; in winter time: GB 252 Grade No.-10 light diesel
fuel.
当冬季温度在 -20℃～ -10℃之间用 -20 号柴油；低于 -30℃用 -35 号柴油。燃油规格选择
不当或太脏均可能引起柴油机的故障和损坏，因此选择规格适当的燃油并确保其质量和清洁度是
很重要的。
Use Grade No.-20 diesel fuel if temperature is in the range from -20℃ to -10℃, and Grade No.-35
diesel fuel if temperature is lower than -30℃. Using contaminated fuel or fuel of improper grade may
cause diesel engine failure or damage. Always use high-quality and clean fuel.
2．润滑油
Lubricating Oil
R6160 系列柴油机推荐选用 15W/40 L-ECD 柴油机油 GB11122-1997
It is recommended to use GB 11122-1997 diesel engine oil 15W/40 L-ECD for 170Z-series diesel
engines.
全国夏季、长江以南地区全年也可选用 40 L-ECD 柴油机油 GB11122-1997
40 L-ECD diesel engine oil GB11122-1997 may be selected and used in summer in whole China and for
a whole year in the region south of Yangzi river.
机油在使用中不可避免地要受到从活塞环的缝隙中泄漏下来的高温燃气和从摩擦表面脱落的
金属磨屑的污染，而且在高温下机油会氧化变质。受这些因素的影响，油底壳和机油滤清器中会出
现大量的沉积物和泡沫等，因此必须定期更换机油。更换机油的时间取决于柴油机的使用情况，一
般看机油的情况而定，大约为每 500 小时左右更换一次。换油同时要进行清洁工作，同时检查机油
滤清器，如发现机油滤芯有脏污须清洗滤芯。
Engine oil will inevitably be contaminated during the operation by high temperature combustion gas
leaked from gap of piston ring and abrasive metal dust coming off from friction surface. Further more,
engine oil would become deteriorated as the result of oxidation at high temperature. Therefore, it is
necessary to replace engine oil at regular intervals to remove deposit and foam from oil sump and oil
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filter. The said time interval is usually 500 hours of operation depending upon the operating condition.
Check oil filter while replacing oil and clean filter element if it is found contaminated.
3．润滑脂
Grease
水泵油杯内注入锂基脂，规格为：SY1412-75。
Fill water pump oil cup with lithium based grease, SY 1412-75.
4．冷却水
Cooling Water
发动机用的冷却水必须是低硬度的洁净水。海水、含盐水、碱水、工业用水和废水等都不适用，
大多数城市的自来水使用前需进行脱氯处理。
Cooling water used in engine must be uncontaminated water with lower hardness. DO NOT use sea
water, saline water, water containing soda, industrial water and waste water. Tap water of most cities
must be dechlorinated before use.
冷却系统中可加入长效冷却液，用以防锈防冻。
（配比请参阅防冻液使用说明）
Cooling system can be added with long-term coolant to prevent rust and freezing. (As for mixture ratio,
see Operating Instructions of Antifreezing Fluid.)
注意：不加防冻液且气温低于 0℃时应将机器内的冷却水放尽。
Caution: Completely drain the cooling water in engine when antifreezing fluid is not used and air
temperature is below 0℃.
5．辅助材料
Auxiliary Materials
5.1 本机在装机过程中，可使用乐泰 510、242、271、277、262 等规格的密封胶和粘结剂。
When assembling your engine, the following materials will be used: LOCTITE 510, 242, 271, 277 and
262 sealants and/or adhesives;
5.2 细钼粉。
Fine molybdenum powder.
5.3 各种辅助材料的使用部位见下表
See Table below for application positions of various auxiliary materials.
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R6160系列柴油机所用辅助材料表
Table of Auxiliary Materials Used on R6160-Series Diesel Engines
序号名称颜色用途与应用
No Name Color Purpose and Application
各旋转轴唇形密封圈的外圆面和唇口
二硫化钼膏剂深灰色
1 The outer circle surface and lip for
Molybdenum disulphide ointment Deep gray
sealing ring of rotating shafts.
涂在螺纹部位起固持、密封作用
例：各种螺栓螺纹部位
乐泰242 兰色 Apply to thread position for fixation and
2
LOCTITE 242 Blue seal.
Example: thread positions of various
bolts
涂在螺纹部位锁紧密封、高力度
例：主轴承螺栓
乐泰262 红色
3 Apply to thread position for locking and
LOCTITE 262 Red
seal, high force
Example: Main bearing bolt
涂在金属表面起密封作用
乐泰510 红色
4 Apply to the metal surface for seal
LOCTITE 510 Red
functions.
涂在金属表面起密封作用
乐泰271 红色
5 Apply to the metal surface for seal
LOCTITE 271 Red
functions.
芯子与孔之间的密封
乐泰962 红色例：机体上的碗形塞
6
LOCTITE 962 Red Sealing between core and hole
Example: Bowl plug on the engine body
锂基脂红色水泵润滑脂
7
Lithium grease Red 3. Grease for water pump
本章注意：为确保您所购买的柴油机的正常使用，必须按本说明书中规定，使用正确牌号的
燃油、机油。
Caution: Use fuel and engine oil of proper grades as specified in THIS MANUAL to ensure
normal operation of your engine.
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...
第七章电器部分
Electric System
电器部分包括蓄电池、起动机、以及监控系统。
Electric system comprises battery, starter and monitoring system.
1．蓄电池
Battery
蓄电池提供工作电压应为 24V，容量约 280A.h。
（可选用 6-Q-140，6-Q-150，6-Q-180）
。
Battery provides 24V operating voltage and approx. 280A.h capacity. (6-Q-140, 6-Q-150 or 6-Q-180
is available.).
2．起动机
Starter
起动机船机为双线制，陆机为单线制，其型号为：ST710（陆机用）、ST712（300kW 以下船右
机用）、ST711（300kW 以上船左机用），功率为 11kW；工作电压为 24V。
There are 3 types of starters, ST710 (for stationary engine), ST712 (for marine right engine under
300kW) and ST711 (for marine left engine above 300kW), power is 11kW, operating voltage is 24V.
double-wire system for marine engine and single-wire system for stationary engine.
起动机连接蓄电池的主导线截面以大于 70mm2 为宜。
Cross section of main conducting wire connecting starter and battery is at least 70 mm2.
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3．安全保护装置
Safeguard device
R6160 系列柴油机的安全保护装置只应用在船用柴油机上，220kW 以上船用机型还带有超速
保护功能。此装置由温度报警器、机油压力报警器、油温报警器、转速传感器以及湿式电磁换向阀
（仅对 220kW 以上船用柴油机）、连接电线和柴油机保护装置组成。要求使用 24V 直流电源。
The safeguard device for R6160 series diesel engine is applied to the marine diesel engine only,
furthermore, the marine engine which power is above 220kW has overspeed protection. The device
is composed of temperature alarm, oil pressure alarm, oil temperature alarm, speed sensor, wet-type
solenoid switchover valve (only for marine engine which power is above 220kW), connecting wires and
protective device of diesel engine. 24V DC power is required.
安全保护装置都能准确地显示柴油机地各种参数，并在柴油机运行中出现异常情况时能进行
报警。
The safeguard device can display various parameters of your engine accurately, and give an alarm when
any abnormal condition appears during diesel engine operation.
功能
Functions
1．检测功能
Monitoring an measuring ability
船用柴油机一般使用安装在柴油机上的机械式仪表和测量保护装置形式（便于操作）。机械式
仪表可显示柴油机转速、水温、油温、机油滤清器前压力、主油道压力。测量保护装置可显示柴油
机转速、运行时间和报警信号。
Marine diesel engine is usually furnished with mechanical type instrument and measurement protective
device which are easy to operate. Mechanical type instrument can indicate diesel engine speed, water
temperature, oil temperature, pressure before oil filter and pressure of main oil passage. Measurement
protective device can display diesel engine speed, running time and alarm signal.
2．当柴油机的运行工况超越报警设定值时，监控系统会发出断续声光报警信号，直到按下消
音键后，才会消除报警信号。该报警型号提示操作者柴油机工况已经或曾经超越报警设定值。
When operating condition of your diesel engine exceeds the setting alarm value, monitoring system will
generate pulsed sound and /or visual alarm until you press silencing button. This alarm prompts you the
operating condition of your engine has already or on one occasion exceeded the setting alarm value.
当船用柴油机转速超过设定值时，保护装置自动进入“风浪”档工作状态，保护装置通过控
制停车电磁阀的开闭，使柴油机转速在规定的范围内变动，直到转速稳定。
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When speed of marine diesel engine exceeds the setting value, protective device enters “speed auto-
regulating” operating mode automatically so that the protective device will control speed of diesel
engine to vary within specified range by switching on and switching off the stop solenoid valve until the
speed is stabilized.
报警设定值见下表。
Setting alarm values are shown in the Table below:
测量保护装置传感器螺
报警设定值
序号保护内容报警形式纹
Setting alarm
No Items Alarm modes Measurement protective
values
device’s sensor thread
油压（MPa）Oil 声、光
1 ＜0.18±0.02 M12×1.25
pressure（MPa） Vocal and optical
油温（℃）声、光
2 ＞ 88+30 M18×1.5
Oil temperature（℃） Vocal and optical
水温（℃）声、光
3 ＞ 88+30 M18×1.5
Water temperature（℃） Vocal and optical
转速（r/min）声、光
4 ＞1200 M16×1
Speed（r/min） Vocal and optical
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3．远距离检测功能
Remote monitoring and measuring ability
通过远传电缆，监控系统中的保护显示器可放置在远离柴油机的地方，位置和远传距离由使
用者确定。
The protection display of monitoring system can be placed away from diesel engine by using a remote
transmission cable. The location and transmission distance are defined by user.
4．计时功能
Timing ability
监控系统有计时功能，能提示使用者柴油机实际工作时间，作为柴油机保养时间的依据。
Monitoring system possesses timing capability which may remind you of the actual running time of
diesel engine, providing you a time reference to perform engine maintenance accordingly.
注意：
Caution:
监控系统对电源有严格的要求，应控制在 18 ～ 31.2V 之间。
Monitoring system requires a power voltage from 18 to 31.2V.
柴油机停止工作后，应将电源切断，以延长监控系统的使用寿命。
To ensure longer service life of monitoring system, switch off power source after diesel engine stops.
各工作点已按要求调整好，用户切勿随意打开内部进行调整、修理。以免造成重大故障。
All operating points were pre-adjusted as specified in delivery. Do not attempt to adjust or repair any
internal parts, otherwise may result in severe trouble.
安装在机械仪表盘上的转速表为磁电式转速表。该表不通电时指针处于自由状态，指针不复
零，此为正常现象。
The tachometer mounted on the mechanical dashboard is of electromagnetic type. Its needle is in free
state when it is not energized. It is normal if the needle does not return to zero.
试验按钮不要经常使用，特别是在柴油机工作时不要进行。
Do not use test button frequently. Do not use it when diesel engine is running.
仪表箱电源线严禁连接在直流发电机或整流电源上！
Do not connect power cord of instrument box to DC generator or rectified power supply.
4．电动预供油泵
Electric oil pre-supply pump
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R6160 部分电起动机型带有电动预供油泵，取代了手压机油泵。由一套控制系统来实现在柴
油机起动前电动预供油泵向个润滑点预供一定压力润滑油的作用。其工作过程：按动电钥匙，先
接通电动预供油泵回路，电动泵开始供油，待油压达到设定限制，由油压传感器及内部电路控制，
接通电马达回路。柴油机开始起动。原理图如下所示：
Some models of the R6160 series diesel engine are equipped with electric oil pre-supply pump instead of
hand pump. before starting the engine, the pump supply oil to every oil site with certain pressure through
a set of controls: first, switch on the loop of electric oil pre-supply pump by pressing the electric key,
the electric pump start to supply oil until oil pressure reaches set value; then, the electric motor loop is
switched on via the oil sensor and internal circuit, and the engine begins to start. The principle diagram is
as below:
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...
第八章主要零件的调整与更换
Adjustment And Replacement of Main Assemblies And Parts
1．冷却系统
Cooling System
水泵拆检
Disassembly and Check of Water Pump
水泵包括生水泵、净水泵。均为齿轮驱动的离心式水泵。生水泵泵体外部设有油杯，由人工按
时添加润滑脂润滑，净水泵靠飞溅润滑。泵体上加工有泄水孔，如发现泄水孔漏水，应及时检修、
更换水封及静环组件。
Water pumps include raw water pump and treated water pump. Both are of gear driven centrifugal type.
Raw water pump is provided with an oil cup on its external body for the purpose of grease lubrication.
Manually fill the cup with grease periodically; The treated water pump is lubricated by splashing. There
are drain hole in pump body. If water leakage is found from the drain hole, duly locate the trouble and
repair it, or replace water seal and stationary seal ring assembly.
净水泵结构图生水泵结构图
Structural Diagram for Treated Water Structural Diagram for Raw Water Pump
Pump
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中冷器拆检
Disassembly and Check of Intercooler
中冷器型式为管片式，散热面积 9m2 和 12m2 两种。
Intercooler is of gilled tube type, with a heat radiation area of 9m2 and 12m2 .
中冷器芯子由黄铜管及散热片组成，芯子和外部端盖一起形成水腔和气腔。管外通水，管外通
气。在中冷器冷却水回流腔上部由放气螺堵，必要式可以旋开放气。另两个螺堵上装有两只锌块，
每隔 1000 小时左右，旋下螺堵检查锌块腐蚀情况，必要时换新。
Intercooler core is composed of brass tubes and radiation fins. The core together with external end cover
forms water jacket space and air chamber. Inside the tube is water, and outside is air. There is an air bleed
plug on upper part of cooling water backflow chamber of intercooler, which can be unscrewed to bleed
air if necessary. The other 2 plugs are fit with 2 zinc blocks which shall be checked every 1000 hours for
corrosion condition by screwing off plugs, and replace if necessary.
中冷器一般不必经常拆洗，如使用时间较长，冷却效果显著下降时，应清除散热片上的油泥和
管内的水垢及杂物。
Intercooler does not need frequent removal and cleaning. If cooling effect decreases remarkably due to
long operation, remove oil sludge from radiation fins and water scale and foreign objects from inside the
tube.
2．润滑系统
Lubricating system
机油泵的拆装及维护
Disassembly, assembly and maintenance
for oil pump
机油泵为单级齿轮式，安装在机器
前端的前盖上，由曲轴驱动齿轮驱动。
出油口一边装有压力调节阀。
The oil pump is single gear type which
is installed on front cover of the engine
front end and driven by the crankshaft
drive gear. A pressure regulating valve is
installed on the oil outlet side.
拆下机油泵进油管
Remove oil inlet pipe of oil pump
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拆下机油泵出油管
Remove oil outlet pipe for oil pump
拆下回油管
Remove oil return pipe
-59-
松开 4 个 M10 的螺栓，从机前盖上拆下机油泵。
Loosen four M10 bolts and dismantle the oil pump form engine front cover.
注意：出厂时已将油泵各处间隙调整好，并打上定位销，拆卸时要注意原有情况。
CAUTION: The clearances for oil pump have been adjusted well when the oil pump is delivered
from the factory and is fixed with the locating pins; pay attention to the original condition during
dismantling.
松开 6 个 M10 的螺栓，拆下机油泵盖
Loosen six M10 bolts and dismantle the oil pump cover
检查如油泵体和油泵盖上的轴套，如磨损过大则需要更换。
Inspect the bushings for oil pump body and cover, replace them if worn seriously
注意：轴套更换时应注意轴套的油槽开口，应与油泵体、盖上的直油槽对齐装配。
CAUTION: During replacing and assembling the bushings, the oil grooves on the bushings
should be aligned with the straight oil grooves on the body and cover.
按照装配顺序装好各件。
Assemble all parts as per assembly sequence.
注意：在机油泵体和机油泵盖之间薄而均匀的涂一层乐泰 510 胶，涂层厚度 0.06 ～ 0.1mm。
涂胶时，两结合面不得有油污、水、灰尘和铁锈等杂质，否则会引起漏油。
CAUTION: Coat LOCTITE 510 in thickness of 0.06-0.1mm on mating surfaces of oil pump body
and oil pump cover. Keep the surfaces clean while sealant is coated, oil stain, water, dust and
iron rust would result in oil leakage.
总装后，主轴应转动灵活，不得有丝毫卡滞现象，否则会导致严重事故。
After final assembling, main shaft should be able to rotate easily without any sticking, otherwise, serious
accident may occur.
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螺母的拧紧力矩为 100 ～ 140N.m。
The tightening torque for bolts should be 100~140Nm.
机油冷却器的拆装及维护
Disassembly, assembly and maintenance for oil cooler
R6160 系列柴油机采水冷式机油冷却器，冷却器芯子由一束回流的铜管组成，机油在铜管内
流动，收管外冷却水冷却，在正常条件下，可保证机油温度在 85℃以下。使用时间长了以后，管外
会结水垢，管内可能会有污物滞留，须进行必要的清洗，以保证水、油畅通，提高冷却效率。
R6160 series diesel engine adopts water-cooling oil cooler. The cooler element is composed of a set of
copper back-flow pipe, the oil flows inside the copper pipe that is cooled by cooling water outside the
pipe. In normal case, the cooler can ensure the oil temperature below 85℃.However, the scale and dust
may be deposited in the pipe after a long time, clean it as required to ensure the smooth flowing of water
and oil, and to enhance the cooling efficiency.
注意：拆卸机油冷却器前要放掉发动机内的冷却水。
CAUTION: Drain the cooling water from engine before removing oil cooler.
松开冷却器进水管
Loosen water inlet pipe of coole
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松开冷却器进油管
Loosen the oil inlet pipe of coole
松开冷却器出油管
Loosen the oil outlet pipe of cooler
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松开机油冷却器与机体相连的螺栓，
取下机油冷却器
Loose the bolts for connecting oil cooler
and
engine block, and remove the oil cooler
松开端盖与冷却器体相连的螺栓，
抽出芯子
Loosen the bolts for connecting end cap
and cooler body, and draw out the element.
对冷却器体进行清洗，
Clean the cooler body.
对冷却器芯子进行清洗
Clean the cooler element.
3．供油系统
Fuel supply system
更换喷油泵
Replace injection pump
拆下高压油管与喷油泵连接接头。
Remove the joint for connecting high-
pressure fuel pipe and injector
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拆下与喷油泵连接的低压油管
Remove the low pressure fuel pipe
connecting to injecto
松开中间法兰管与膜片的连接螺栓
Loosen the connecting bolts between
intermediate flanged pipe and diaphragm.
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拆下喷油泵与支架相连的螺栓，将
喷油泵拆下。
Remove the bolts connecting injector and
bracket, and then remove the injector.
将高压油泵端法兰从高压油泵上取下，对油泵进行检修或更换。
Remove the flange from the high-pressure pump, then check, repair or replace it.
检修完毕后将高压油泵端法兰安装在高压油泵上，并将喷油泵置于支架上，拧紧与支架的连
接螺栓。
After checking and repairing, install the flange onto high-pressure pump end, and place the injection
pump on its bracket, and then tighten connecting bolts.
注意：喷油泵安装时喷油泵凸轮轴与传动轴的同轴度不超过 0.1mm，如装配后测得值超出上
述范围，可用油泵支架定位圆弧面加垫片（往上调）和油泵支架与机体连接处加垫片（往外调）的
办法加以调整。
Caution: During installing the injector, the coaxiality of injection pump camshaft and driving shaft should
not exceed 0.1mm. After assembling, if the measured value exceeds the above-mentioned scope, it can
be adjusted by adding the gasket to the locating arc surface of the fuel pump bracket (adjusting upwards)
and by adding the gasket to the connection area of injection pump bracket and engine body (adjusting
outwards).
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将中间法兰管与膜片连接好。
Connect the intermediate flanged pipe and
diaphragm properly.
将油管连接到油泵上
Connect the fuel pipe to fuel pump.
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注意：重新安装高压油泵后需对供
油提前角进行检查，若有必要时进行调
整。
Caution: Check the fuel supply advance
angle and adjust it if necessary after
installing the high-pressure fuel pump.
更换喷油器
Replace fuel injector
松开喷油器上面的高压油管
Loosen the high-pressure fuel pipe on
injector.
松开喷油器上面的回油管
Loosen the return pipe on injector.
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拆下气缸盖罩壳
Remove the cylinder head cove
松开螺栓，拆下油嘴固定架
Loosen bolts and remove nozzle fixed
mount
-68-
用专用工具抽出喷油器，并根据相
应气缸做好记号，以便装配时按原顺序
安装。
Draw out the injector with special tool, and
mark symbol as per cylinder number to
later installation.
对喷油器进行压力调整，并对雾化
情况及漏油情况进行检查（参见第三章
第 4 小节中关于喷油器保养的内容）
Adjust injector pressure, and check fuel
atomization and leakage conditions (refer
to maintenance of injector in chapter 3
section 4).
将检查完毕的喷油器放好在缸盖
中。
Install injector into cylinder head
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把压板放在正确位置，用螺栓压紧
Place the pressure plates correctly and
tighten with bolts.
注意：压板位置一定要放正确，以
免产生初压力。
Caution: Pressure plate must be placed in
correct position to avoid generating initial
pressure.
装上气缸盖罩壳垫片 , 并将高压油
管、回油管装好
Assemble the gasket for cylinder head
cover, and mount the high-pressure fuel
pipe and fuel return pipe.
将检查完毕的喷油器放好在缸盖中。
Install injector into cylinder head
4．进气系统
Air intake system
更换涡轮增压器
Replace turbocharger.
松开压气机出气管处的橡胶软管卡
箍
Loosen clamp for rubber hose in position of
outlet pipe of air compressor.
and mount the high-pressure fuel pipe and
fuel return pipe.
-70-
松开增压器进油管接头
Loosen oil inlet pipe nipple for
turbocharger.
松开增压器回油管与增压器相连的
两个螺栓，拆下增压器回油管
Loosen two bolts connecting turbocharger
and its oil return pipe, remove the oil return
pipe.
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拆开增压器与排气弯管的连接螺
栓，取下增压器。
Remove the bolts connecting turbocharger
and exhaust elbow, and remove
turbocharger.
更换新的增压器
Replace new turbocharger.
注意：如果并不立即更换增压器，则应盖好各进出口，以防止由杂物进入。
Caution: All openings of turbocharger should be covered properly to prevent entering foreign objects if
turbocharger is not replaced immediately.
将换新的增压器安装到机器上，并连接好进出油管以及相应进气、出气管路。
Install the new turbocharger onto the engine, and connect oil inlet & outlet pipes as well as air intake &
outlet pipes properly.
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第九章柴油机典型故障及处理
Diesel Engine Troubleshooting
1．柴油机起动困难或不能起动
It is Difficult or Unable to Start Diesel Engine
完成柴油机起动的必要条件是：
（1）必要的起动转速。
（2）具有一定的压缩压力，从而使燃料
获得自燃所需的温度。
（3）向缸内喷入雾化良好的柴油，并供应燃料燃烧所需的充足空气。在环境
温度高于 5℃时柴油机一般能在 5 秒内顺利起动，有时需要反复几次才能起动，若有多次反复起动
柴油机仍不能着火，则为起动故障。
Necessary conditions to start your diesel engine are: (1) Necessary starting speed. (2) Certain
compression pressure such that diesel fuel can attain temperature required by self-combustion, (3)
Injection of well atomized diesel fuel into cylinder and sufficient air supply required by fuel combustion.
Your diesel engine should start successfully within 5 seconds if ambient temperature is higher than 5℃ at
one or several attempts. It is considered as start failure if your diesel engine cannot ignite after repeated
attempts.
当柴油机出现起动故障时，首先检查起动前准备工作是否完善，然后再查找柴油机有关系统
存在故障的原因。
If your diesel engine fails into start, check your pre-start preparations, and then identify possible fault
causes of systems related.
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1.1 起动系统故障
Starting System Failure
起动系统故障表现为起动转速低甚至不能驱动旋转，起动无力。
Symptom of st arting system problem is low starting speed or even failure to drive rotating parts, i.e.
weak start power.
故障原因排除办法
Cause Remedy
电马达起动
Start with electric motor:
（1）蓄电池电力不足（1）重新充电或更换蓄电池
Low battery. Charge or replace battery.
（2）起动系统接线错误或接触不良（2）检查线路是否正确和牢固
Wiring error or poor contact of starting system. Make sure wirings are correct and reliable.
（3）起动电机故障（3）修理或更换起动电机
Starting motor failure. Repair or replace starting motor.
气马达起动
Start with air motor:
（1）空气瓶内压缩空气压力太低（1）重新充气
Low air pressure in valve bottle. Re-charge air bottle.
（2）马达不能啮合或啮合太晚（2）修理或更换马达
Motor fails to engage or engages too late. Repair or replace motor.
（3）调压阀调整不当（3）工作压力调整为（0.7～0.9）MPa
Pressure regulating valve adjusted improperly. Regulate operating pressure to 0.7~0.9MPa.
（4）气马达内叶片损坏（4）更换叶片
Blades of air motor damaged. Replace blades.
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1.2 燃油供给系统故障
Fuel Supply System Failure
燃油供给系统故障表现为燃油系统不供油或供油不正常，柴油不着火或着火后不能转入正常
运转。
Fuel supply system failure exhibits that fuel system fails to supply fuel or supplies fuel improperly, fuel
does not ignite, or engine cannot be turned into normal operation after ignition.
Cause Remedy
（1）燃油管路堵塞（1）检查管路并清洗畅通
Fuel pipeline clogged. Check and clean pipeline.
（2）清洗滤清器，必要时更换滤芯
（2）燃油滤清器堵塞
Clean diesel fuel filter, and replace filter element if
Fuel filter clogged.
necessary.
（3）检查燃油管路接头是否松弛，旋开各部件
（3）燃油系统内有空气放气螺塞，排除内部空气。
Air in fuel system. Check joints of fuel pipeline for proper connection,
unscrew various air bleed plugs to bleed air.
（1）检查输油泵进油管是否漏气，或检修输油
（4）输油泵不供油或断续供油
泵
Fuel supply pump fails to supply or supplies fuel
Check fuel inlet pipe of fuel supply pump for air
intermittently.
leakage, or check and repair fuel supply pump.
（5）喷油泵故障：
供油提前角不正确
（2）
喷油泵弹簧断裂
重新调整供油提前角
喷油泵齿条卡死在停车位置
更换弹簧
出油阀卡住或出油阀弹簧断
检修或更换
Injection pump fails:
拆检清洗或更换出油阀及弹簧
Incorrect fuel supply advance angle.
Readjust fuel supply advance angle.
Injection pump spring broken.
Replace spring.
Injection pump pinion rack got stuck in stop
Repair or replace.
position.
Remove, clean or replace delivery valve and spring.
Delivery valve stuck or delivery valve spring
broken.
（6）喷油器故障（6）
喷油器喷孔堵塞清洗喷油嘴或更换
喷油器针阀卡死拆检清洗并研修喷油嘴偶件或更换新偶件
喷油压力太高或太低调整喷油器喷油压力
Fuel Injector Failure Clean or replace fuel injection nozzle.
Fuel injector nozzle orifice clogged. Remove, clean and/or repair, or replace fuel
Fuel injector needle valve stuck. injection nozzle coupling piece.
Fuel injection pressure too high or too low. Adjust fuel injector's injection pressure.
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1.3 压缩压力不足
Insufficient Compression Pressure
压缩压力不足，表现为气缸密封不严，漏气现象严重，人力转动曲轴时感觉压缩无力，并有
“吱、吱”漏气声。压缩比太学太小时也使压缩压力下降。
The symptoms of insufficient compression pressure are air leakage of cylinder due to improper sealing,
and perceptible weak compression with fizzing sound of air leakage when cranking manually. Too low
compression ratio can also result in decreased compression pressure.
Cause Remedy
（1）气门漏气
气门严重磨损，锥面密封不严
（1）研修密封面或更换气门
气门间隙太小
检查并调整气门间隙拆检清洗
Air Valve Leakage
Grind sealing surface or replace air valve.
Severe wear of air valve and/or improper sealing of
Check and adjust valve clearance.
conical surface.
Excessively small valve clearance.
（2）气缸盖、垫片漏气
气缸盖螺母扭紧力矩不足（2）按规定要求重新拧紧气缸盖螺母
气缸盖垫片损坏更换气缸盖垫片
气缸盖变形更换气缸盖
Cylinder head and/or gasket leakage. Re-tighten cylinder head nuts to specifications.
Inadequate tightening torque of cylinder head nuts. Replace cylinder head gasket.
Cylinder head gasket damaged. Replace cylinder head.
Cylinder head deformed.
（3）活塞与气缸套间漏气
（3）更换活塞环
活塞环磨损严重
视磨损情况更换活塞或气缸套
活塞与气缸套间隙过大
清洗活塞环，将各切口错开正确角度
活塞环卡住或各切口位置重合
Replace piston ring.
Air leakage between piston and cylinder sleeve.
Replace piston or cylinder sleeve depending upon
Severe scuffing of piston ring.
scuffing conditions.
Excessive clearance between piston and cylinder
Clean piston ring, and make notches stagger
sleeve.
properly.
Piston ring sticking or notch coincidence.
（1）更换气门弹簧
（4）气门弹簧折断
Replace valve spring.
Valve spring broken.
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2．柴油机功率不足
Insufficient Engine Power
2.1 配气机构及进排气系统故障
Air Distribution Device and Inlet and Outlet Systems Failure
配气机构及进排气系统故障：表现为充气效率低，进入气缸内的新鲜空气不足，而缸内废气
排不干净，排气出现冒黑烟现象等。
Symptoms of air distribution device and inlet and outlet systems failure are low air-charging efficiency,
insufficient fresh air inlet into cylinder, failure to fully exhaust waste gas, and/or exhausting black smoke.
Cause Remedy
（1）配气定时不正确（1）检查并重新调整配气定时
Air distribution timing incorrect. Check and readjust air distribution timing.
（2）气门间隙不正确（2）检查并调整至规定间隙
Valve clearance incorrect. Check and adjust to specifications.
（3）气门弹簧损坏（3）更换气门弹簧
Valve spring broken. Replace valve spring.
（4）空气滤清器堵塞（4）清洗空气滤清器
Air filter clogged. Clean air filter.
（5）进气管太脏，进气阻力大（5）清洗进气管
Air inlet pipe restriction. Clean air inlet pipe.
（6）排气管积碳严重（6）清除积碳
Excessive carbon deposit in exhaust pipe. Remove carbon deposit.
2.2 燃料供给系统故障 [ 详见本章 1.2 小节 ]

Fuel Supply System Failure (For detail, see Para. 1.2 of this section)
2.3 压缩压力不足 [ 详见本章 1.3 小节 ]
Insufficient Compression Pressure (For detail, see 1.3 of this section)
2.4 增压器故障 [ 详见废气涡轮增压器使用说明书 ]
Turbocharger Failure (For detail, see Operating Instruction for Exhaust-Gas turbocharger)
2.5 中冷器故障：通常是空气通路脏污、堵塞、空气冷却效果不足。排除方法：清洗
中冷器并检查水泵。
Intercooler Failure: Symptom is such as insufficient air cooling effect, possible causes are air
passage dirt and/or restrictions. Remedy: clean intercooler and check water pump
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3．工作不稳定有熄火现象
Unstable Operation, with Flameout
3.1 调速器故障
Speed governor Failure
调速器故障表现为转速不稳定
Symptom of governor failure is unstable speed
Cause Remedy
（1）调速弹簧变形（1）更换调速弹簧
Speed Governor spring deformed. Replace speed governing spring.
（2）飞铁移动不灵活（2）修理或更换
Fly-ball fails to move freely. Repair or replace.
（3）调速器拨叉固定螺钉松动（3）检查并拧紧螺钉
Retaining screws of governor fork loose. Check and tighten screws.
3.2 燃料供给系统
燃料供给系统故障表现为各缸工作不均衡，有个别缸产生熄火现象
Symptom of fuel supply system failure is operation of cylinders unbalances, and/or
flameout in individual cylinder(s).
Cause Remedy
（1）打开系统各部件放气螺钉放掉内部空气
（1）燃料供给系统内有空气
Bleed air by unscrewing air bleed plugs of the
Air in fuel supply system.
system.
（2）燃油泵各缸供油不均匀
（2）在喷油泵试验台上进行调整
Fuel supply from fuel pump of cylinders is non-
Adjust fuel injection pump on tester.
uniform.
（3）油量调节齿杆有卡滞现象（3）检查并排除卡滞现象
Binding of fuel-flow control toothed bar. Check and remove binding.
（4）按顺序停止各缸喷油器供油，以确定故障
（4）喷油器喷油质量不好或针阀卡住
位置，然后拆检清洗
Undesirable fuel injection from injector or needle
Stop each cylinder injector's fuel supply in sequence
valve got stuck.
to locate the failure, then remove, check and clean.
（5）喷油泵柱塞弹簧或出油阀弹簧损坏
（5）更换弹簧
jection pump plunger spring or delivery valve
Replace spring.
spring damaged.
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3.3 柴油质量不好，柴油中有水或水漏入气缸内造成工作不稳定，排除方法是更换合格柴油。
Unsatisfactory diesel fuel quality, unstable operation due to water content in diesel fuel or water leakage
into cylinder. Replace with qualified diesel fuel.
4．排气烟色不正常
Abnormal Color of Smoke Emission
4.1 排气冒黑烟
Black Smoke Emission
排气冒黑烟表示燃烧室内喷入柴油过多，在极端缺氧的情况下进行燃烧，造成燃烧不完全，而
出现黑烟现象。
Black smoke emission indicates that excessive diesel fuel is injected into combustion chamber causing
incomplete combustion under extremely oxygen deficiency condition
Cause Remedy
（1）柴油机负荷过重循环供油量过多（1）减轻负荷；并适当调整调速系统
Diesel engine is overloaded, and circulating fuel Reduce load, and adjust speed governing system
supply is excessive. properly.
（2）燃油质量太差（2）按规定选用合格柴油
Poor fuel quality. Use diesel qualified.
（3）空气滤清器或进气管部分堵塞（3）清洗空气滤清器和进气管
Air filter and/or air inlet pipe becomes restricted. Clean air filter and/or air inlet pipe.
（4）增压器压气机或中冷器脏污进气受阻（4）清洗压气机叶轮、进气管及中冷器
Air inlet of turbocharger compressor and/or Clean compressor impeller, air inlet pipe and
intercooler is restricted due to dirt. intercooler.
（5）检查喷油器喷油压力和雾化质量，清洗油
（5）喷油器雾化不良或滴油头、调整喷油压力
Insufficient atomization or diesel dripping of fuel Check fuel injector's injection pressure and fineness
injector. of atomization, clean injector tip and adjust fuel
injection pressure.
（6）检查并调整供油提前角
（6）喷油过迟，部分燃油在排气管中燃烧
Delayed fuel injection, causing partial fuel
Check and adjust fuel supply advance angle.
combustion in exhaust pipe.
（7）各缸供油泵供油不均匀
（7）调整各缸供油量
Fuel supply from fuel pump of cylinders is non-
Adjust fuel supply of each cylinder.
uniform.
（8）气门间隙不对，气门密封面接触不良（8）检查并调整气门间隙、消除缺陷
Valve clearance error, and improper fitting of air Check and adjust valve clearance, and remove
valve sealing surface. defects.
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4.2 排气冒白烟
White Smoke Emission
灰白色烟一般是柴油蒸汽，如果颜色很淡的话则是水蒸气。
Hoar smoke emission in most cases is diesel vapor, in some cases is water vapor if color is very slight
Cause Remedy
（1）燃油内有水（1）更换柴油
Fuel contains water. Replace diesel fuel.
（2）缸内漏水（2）检查漏水原因、及时排除
Water leaks in cylinder(s). Identify water leakage causes and duly remove.
（3）柴油机太冷（3）按规定温度运行
Diesel engine runs with temperature lower than Operate your engine at temperature as
specification. specified.
4.3 排气冒蓝烟
Blue Smoke Emission
蓝烟一般是机油蒸汽，由于大量机油窜入气缸，蒸发后未燃烧的结果。表现为机油消
耗量显著增加。
Blue smoke emission is usually oil vapor caused by blow-by of engine oil into cylinder
which is evaporated and unburned It results in remarkably increase of engine oil consumption.
Cause Remedy
（1）油底壳机油太多，机油压力过高
（1）放掉多余机油
Too much engine oil in oil sump and engine oil
Drain excess engine oil.
pressure too high.
（2）更换活塞环、纠正油环安装
（2）活塞环磨损或油环装错
Replace piston ring, and correct installation of oil
Piston ring scuffing or oil ring error.
ring.
（3）气缸套与活塞之间的间隙太大
（3）更换气缸套或活塞
Clearance between cylinder sleeve and piston is
Replace cylinder sleeve or piston.
excessively big.
（4）气缸盖处回油不畅，机油沿气门杆漏入气
缸内（4）疏通机油回路
Oil return is restricted in cylinder head, engine oil Make oil return unblocked.
seeped in cylinder along valve rod
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5．柴油机内有敲击声
Diesel engine knocks.
5.1 柴油机运动件由于磨损，间隙增大而产生的敲击声
Diesel engine knocks due to excessive clearance resulting from worn piston(s) and/or cylinder(s).
故障特征产生原因排除办法

Failure Causes Remedy
（1）在气缸套全长都能听到轰隆
而清晰的敲击声，在低速大负荷、
转速变化及冷机起动时更为显著
（1）活塞与气缸套间隙过大
Clear thundering knocks can be heard （1）更换活塞或气缸套
Excessive clearance between piston
from the full length of cylinder sleeve, Replace cylinder sleeve or piston.
and cylinder sleeve.
especially when engine runs at low
speed with heavy load, speed changes
or cold starts.
（2）沿气缸上下各处均有锤击声（2）活塞环与环槽间隙过大（2）更换活塞环，必要时更换活塞

Hammering sound exists at the full Excessive clearance between piston Replace piston ring, and replace
height of cylinder. ring and ring groove. piston if necessary.
（3）当柴油机转速变化时，特别
是由高速降到低速时，气缸上部可
（3）活塞销与连杆小头铜套间隙
听到尖锐的冲击声（3）更换连杆小头衬套
过大
Sharp impact sound can be heard from Replace connecting rod small end
Excessive clearance between piston
upper part of cylinder when diesel bush.
pin and brass bush of small end.
engine speed changes, in particular
when speed is reduced
（4）突然改变负荷时，可在曲轴
箱附近听到钝哑的敲击声，无负荷
时则不明显（4）连杆轴承间隙过大
（4）更换连杆轴瓦
Dull knocking sound is audible near Excessive clearance of connecting
Replace connecting rod bush.
by crankcase when load is changed rod bearing.
abruptly, however, not obvious when
no load.
（5）在曲轴箱下部可听到钝哑的
敲击声，在高负荷时更为明显
（5）主轴承间隙过大（5）更换主轴承
Dull knocking sound is audible from
Excessive main bearing clearance. Replace main bearing.
lower part of crankcase, especially at
high load.
（6）在齿轮室外可听到强烈噪
音，当柴油机突然降速时，可听到
（6）检查并调整齿轮间隙，必要
撞击声
（6）齿轮磨损，间隙过大时更换齿轮
High decibel noise is audible from
Excessive clearance due to worn gears Check and adjust gear clearance, and
external of gear box, and impact
replace gear if necessary.
sound can be heard when diesel
engine abruptly reduces its speed.
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5.2 由于柴油机安装调整不当，产生工作不协调或零件相互碰撞发生不正常响声。
Abnormal collision sound generated from poorly coordinated operation or knocks of parts due to
improper installation and adjustment of diesel engine.

（1）气缸内发出有节奏的清脆
（1）检查并调整喷油时间
的金属敲击声（1）喷油时间过早
Check and adjust fuel injection
Rhythmic and bell-like metal Fuel injection too early.
timing.
knocks from cylinder.
（2）气缸内发出低沉不清晰的
（2）检查并调整喷油时间
敲击声（2）喷油时间过迟
Check and adjust fuel injection
Deep and indistinct knocks from Fuel injection too late.
timing.
cylinder.
（3）在气缸盖罩旁可听到轻微
的金属敲击声，当柴油机低速
空装运转时，容易听到这种声
音（3）气门间隙太大（3）检查并调整气门间隙
Slight metal knocks are audible Air valve clearance oversized. Check and adjust valve clearance.
near by cylinder head cover, in
particular when diesel engine runs
with no load at low speed.
（4）检查碰撞原因，调整压缩
（4）气缸盖发出沉重而均匀，
余隙和气门间隙
有节奏的敲击声（4）活塞碰气门
Identify causes, and adjust
Heavy, uniform and rhythmic Piston knocks against air valve
compression clearance and valve
knocks from cylinder head.
clearance.
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5.3 由于柴油机零件损坏，柴油机工作时突然出现敲击声，遇到这种情况应立即停车检查，排
除故障后再使用，否则容易造成重大事故。
If knocks suddenly appear during engine running due to part damage, stop the engine immediately to
identify the fault, failure to do so may cause serious accident.

（1）连杆轴承发出强烈冲击
声，同时产生活塞顶撞气缸盖
的气门声，柴油机发出强烈振
动（1）连杆螺栓松动或屈服变形（1）紧急停车，更换连杆螺栓
S h a r p i m p a c t s o u n d f r o m Looseness or yield deformation of Stop the engine immediately, and
connecting rod bearing, and connecting-rod bolts. replace connecting-rod bolts.
sound of piston knocking against
cylinder head, and violent
vibration of diesel engine.
（2）气缸体下部听到清洗的敲击声
（2）主轴承烧毁（2）更换主轴承
Clear knocks audible from lower
Main bearing burnt. Replace main bearing.
part of cylinder block.
（3）在低速大负荷下，气缸体
内发出清晰的敲击声，但难以
听出响声出现的部位（3）连杆轴承烧毁（3）更换连杆轴承
Clear knocks from cylinder block Connecting rod bearing burnt. Replace connecting rod bearing.
at low speed and heavy load, but
hard to locate the sound.
（4）活塞碰击气门发出“当、
当”的响声，同时功率显著下
降，出现冒烟和振动
Sound of piston knocking against （4）气门弹簧断裂（4）更换气门弹簧
air valve, with power dropped Valve spring fracture. Replace valve spring.
remarkably, and smoking and
vibration happened at the same
time.
（5）紧固连接件松动后与各运
动件碰撞，发出刺耳的金属摩
擦声和敲击声（5）有关连接松脱
（5）检查并紧固
Connecting parts become loose Relevant connections become
Check and tighten.
and thus collide against moving loose.
parts, producing sharp metallic
grating and knocks.
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6．飞车
Run Away
飞车是指柴油机转速失去控制，大大超过规定的最高使用转速。飞车给柴油机带来极大危害，必
须紧急处理，设法迅速停车，办法有：
Runaway means that engine speed is too high and out-of-control. It exceeds the maximum operating
speed greatly. Runaway is extremely harmful to diesel engine. When it occurs, immediately stop the
engine as follows:
1）切断油路：将油门拉到停车位置，关闭油路开关。当油门失去对油泵柱塞控制时，拧开高
压油管联接螺母。
Shutoff fuel line: Pull throttle to STOP position, and turn off fuel switch. When throttle loses control to
fuel pump plunger, loosen fuel injection pipe coupling nut.
2）切断气路：柴油机有防爆装置等机构时，利用它将进气道迅速关闭，用棉衣抱住空气滤清
器。总之只要切断进气通道就能迅速停车。飞车时绝对禁止减小或卸掉负荷，停车后应分析和查找
原因，及时排除。
Shutoff air passage: You can use explosion-proof equipment if available on your diesel engine to close
air inlet channel immediately, and cover air filter with cotton quilted coat. In any case, engine can be
stopped immediately if air inlet passage is cut off. DO NOT attempt to reduce load or unload the engine.
You MUST analyze and identify the causes, and duly remove the failure.
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Causes Remedy
1）调速器故障
1）
（1）飞铁脱落
（1）检查修复
（2）调整器弹簧断裂
（2）检查更换
（3）限位螺钉变动
（3）检查调整
Speed Governor Failure
Check and repair.
Fly ball drop-out.
Check and replace.
Governor spring fracture.
Check and adjust.
limit screw is loose.
2）喷油泵故障
（1）油泵齿条在最大供油位置卡住 2）
（2）齿条与拉杆连接松脱（1）检查修理
（3）齿条和齿轮啮合位置装错（2）检查并重新调整后紧固
Fuel Injection Pump Failure （3）检查并重新调整
Fuel pump gear rack seized at maximum fuel Check and repair.
supply position. Check and tighten up after re-adjusted.
Disengagement between gear rack and pull rod. Check and re-adjust.
Engaging position error between gear rack and gear.
3）燃烧室内进入大量机油
3）
（1）油底壳内机油量过多
（1）检查油面位置，放掉多余机油
（2）活塞与气缸套磨损严重、机油大量上窜
（2）检查有关零件配合情况必要时更换
Excessive oil in combustion chamber.
Check oil level, and drain excessive oil.
Too much oil in oil sump.
Check mating condition of relevant parts, and
Worn piston and cylinder sleeve, resulting excessive
replace them if necessary.
oily smoke.
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7．突然停车
Sudden Stalling
Causes Remedy
1）超载而是柴油机憋死 1）减少使用负荷
Diesel engine stalling due to overload. Reduce operating load.
2）燃料供给系统故障
2）
（1）燃油箱内燃油用完
（1）添加燃油
（2）燃油中混入水
（2）更换燃料
（3）燃油油路堵塞
（3）检查清洗
（4）油管破裂或接头松动
（4）更换油管，旋紧接头
（5）油泵柱塞卡死
（5）拆检清洗
（6）油泵弹簧断裂
（6）更换弹簧
（7）调速弹簧断裂
（7）更换调整弹簧
Add fuel.
Fuel in tank use-up.
Replace fuel.
Fuel containing water.
Check and clean.
Fuel passage restriction.
Replace fuel pipe and tighten joint.
Fuel pipe fracture or loose connection.
Remove, check, and clean.
Fuel pump plunger binding.
Replace spring.
Fuel pump spring fracture.
Replace and adjust spring.
Speed governor spring fracture.
3）配气系统故障
3）
（1）气门弹簧断裂
（1）更换气门弹簧
（2）气门卡死在导管中
（2）检查清洗
（3）气门间隙过大或调整螺钉松动
（3）检查并重新调整
（4）进气管或空气滤清器堵塞
（4）检查清洗
Air Distribution System Failure
Replace air valve spring.
Air valve spring fracture.
Check and clean.
Air valve binding in conduit.
Check and readjust.
Excessive air valve clearance or loose adjusting screw.
Check and clean.
Air inlet pipe or air filter clogged.
4）机油压力过低，油压低自动停车装置发生作用
4）检查油压低之原因并排除
Low oil pressure, resulting in action of low oil
Determine and remove causes of low oil pressure.
pressure auto-stop device.
5）主轴承或连杆轴承烧瓦，活塞卡死在气缸中 5）拆检油管零件，更换修理
Burn of main bearing or connecting rod bearing Remove and check oil pipe parts, replace or repair
bush, and piston seized in cylinder. as necessary.
6）监控系统故障 6）见第11条
Monitoring System Failure Refer to Para. 11.
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8．柴油机过热
Diesel Engine Overheat
柴油机过热主要表现为水温过高，其主要原因是冷却效率低
The symptom of engine overheat is overheat of water. Its main cause is poor cooling efficiency.
Causes Remedy
1）燃料供给系统故障
1）
（1）燃油箱内燃油用完
（1）添加燃油
（2）燃油中混入水
（2）更换燃料
（3）燃油油路堵塞
（3）检查清洗
（4）油管破裂或接头松动
（4）更换油管，旋紧接头
（5）油泵柱塞卡死
（5）拆检清洗
（6）油泵弹簧断裂
（6）更换弹簧
（7）调速弹簧断裂
（7）更换调整弹簧
Add fuel.
(1) Fuel in tank run-out.
(2) Change fuel.
(2) Fuel containing water.
(3) Check and clean.
(3) Fuel passage restriction.
(4) Replace fuel pipe and tighten joints.
(4) Fuel pipe fracture or loose connection.
(5) Remove, check and clean.
(5) Fuel pump plunger binding.
(6) Replace spring.
(6) Fuel pump spring fracture.
(7) Replace and adjust spring.
(7) Speed governing spring fracture.
2）检查并调整
2）供油提前角过小
Replace and adjust.
Fuel supply advance angle excessively small.
3）柴油机长时间超负荷运行 4）降低负荷
Long time running of diesel engine with overload. Reduce load.
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9．机油压力过低
Low Oil Pressure
当柴油机压力低于规定压力范围时，首先通过调整机器一、二缸观察窗之间的限压阀，若仍不
能恢复，则需要按下列各方面内容检查原因。
If engine oil pressure is lower than specifications, firstly you may attempt to restore it by adjusting the
pressure limiting valve between cylinders No.1 and No.2. If this does not work, identify causes as below:
Causes Remedy
1）油底壳内油面过低 1）添加机油
Low oil level in oil sump. Add engine oil.
2）机油中混入柴油或水，使机油粘度过低
2）检查原因并排除故障，更换新机油
Engine oil containing diesel or water, resulting in
Identify causes and remove failure, and replace oil.
low oil viscosity.
3）机油泵齿轮磨损严重，装配不符合要求 3）检查机油泵工作性能进行修复或更换新泵
Worn oil pump gear, or improper installation. Check oil pump performance, repair and replace.
4）机油管连接头松脱；产生漏气或漏油现象
4）检查并紧固
Oil or air leakage due to loose connection of oil
Check and tighten.
pipe.
5）机油冷却器或机油滤清器堵塞 5）拆检清洗
Clogging of oil cooler or filter. Remove, check and clean.
6）主轴承击连杆轴承间隙太大
6）检查更换缸瓦
Excessive clearance between main bearing and
Check and replace cylinder bushing.
connecting rod bearing.
7）机油泵吸油管堵塞 7）拆检清洗
Oil suction pipe of oil pump clogged. Remove, check and clean.
8）压力表损坏 8）更换压力表
Pressure gauge failure. Replace pressure gauge.
9）调节阀弹簧断裂或弹簧变形 9）检查调节阀更换弹簧
Regulating valve spring fracture or distortion. Check regulating valve, and replace spring.
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10．柴油机振动加剧
Severe Engine Vibration
当柴油机压力低于规定压力范围时，首先通过调整机器一、二缸观察窗之间的限压阀，若仍不
能恢复，则需要按下列各方面内容检查原因。
Vibration is due to unbalance of structure or operation. Severe vibration is often accompanied with
abnormal sound and can be felt if you put your hand on engine block.
Causes Remedy
1）燃料供给与燃烧系统故障
1）
（1）各缸喷油量不均匀，喷油提前角不一致
（1）检查并调整各缸喷油量及供油提前角
（2）各缸喷油压力不一致
（2）检查并调整喷油器
Fuel Supply and Combustion System Failure
Check and adjust fuel injection amount and fuel
Non-uniform fuel injection amount of various
supply advance angle.
cylinders, and different fuel supply advance angles.
Different fuel injection pressure of various
Check and adjust fuel injector.
cylinders.
2）零部件加工精度或装备不合格
（1）曲轴弯曲变形 2）
（2）曲轴不平衡（1）修理或更换曲轴
（3）飞轮不平衡（2）检查并调整曲轴动平衡
（4）活塞连杆组重量不一致（3）检查并调整飞轮平衡
（5）轴承间隙过大（4）检查并调整活塞连杆组重量
Poor machining accuracy of parts or unqualified （5）检查并更换轴瓦
equipment. Repair or replace crankshaft.
Bent or deformed crankshaft. Check and adjust crankshaft dynamic balance.
Crankshaft unbalance. Check and adjust flywheel balance.
Flywheel unbalance. Check and adjust piston linkage weight.
Different weight of piston linkage. Check and replace bearing bush.
Excessive bearing clearance.
3）柴油机安装位置不正确
（1）柴油机曲轴中心与被驱动机械不同心
（2）柴油机安装基础底架不牢固，固定螺栓松 3）
动（1）检查并重新调整
Incorrect installation position of diesel engine. （2）加固基础底架，旋紧固定螺栓
Misalignment of diesel crank shaft and driven Check and readjust.
device. Reinforce framework, and tighten set bolts.
Installation framework of diesel engine is not strong
enough and set bolts are loose.
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11．监控系统常见故障及排除方法
Monitoring System
常见故障故障原因排除办法
电源断路查线路
保险丝断更换保险丝
数码管不亮，按动各按钮相应指示灯均电源极性反更换极性
不亮传感器插头坏更换新传感器
Digital display and indicators do not come Power circuit open. Check circuits.
on when buttons are pressed. Fuse blown out. Replace fuse.
Power polarity inversed. Change polarity.
Sensor connector failure. Replace sensor.
检显示暗，或电源指示灯亮，但无显示
电源电压偏低电源充电或更换蓄电池
Dim indication, or no indication when
Lower power voltage. Charge or replace battery.
power indicator is on.
电磁阀连接线断修复线路
电源电压低电源充电
急停灯亮，电磁阀不动作、不停车电磁铁失灵更换电磁铁
EMERGENCY STOP light comes on, but 电磁铁密封不严修复密封面
solenoid valve does not act and the engine Solenoid valve wire open. Repair the circuit.
does not stop. Low power voltage. Charge power supply.
Solenoid valve failure. Replace solenoid valve.
Poor solenoid valve sealing. Repair sealing face.
温度传感器接线断修复线路
按温度试验按钮，指示灯亮，但超温不报警
温度传感器失效更换新传感器
Press temperature test button, indicator
Temperature sensor open circuit. Repair the circuit.
comes on, but no overheat alarm is issued.
Temperature sensor failure. Replace sensor.
按压力试验按钮，指示灯亮，但柴油机
压力传感器接线断修复线路
运转时低压不报警
压力传感器失效更换新传感器
Press pressure test button, indicator comes
Pressure sensor open circuit. Repair the circuit.
on, but no low pressure is issued while
Pressure sensor failure. Replace sensor.
engine is running.
压力报警灯不灭，主机压力表显示正常压力传感器导线搭线修复线路

Pressure warning indicator does not go 压力传感器失效更换新传感器
off while the engine main pressure gauge Pressure sensor short circuit. Repair the circuit.
indicates normally. Pressure sensor failure. Replace sensor.
转速传感器插头内接线断、松脱、碰
转速表显示不正常线、连接线断、转速传感器装配位置不检查连线和接插件调整至正常间隙位
主机转速表同时显示不正常Indication 对或松动置：（1.5±0.5）mm
of both tachometer and the engine main Broken or loose connection in speed sensor Check wiring and adjust connector
tachometer are abnormal. connector, open or short wiring, improper clearance to (1.5±0.5) mm.
or loose speed sensor installation.
柴油机停车时，按“转速”试验按钮
时，油压报警灯光亮
油压传感器线路断修复线路
When pressing speed test button at engine
Oil pressure sensor open circuit. Repair the circuit.
shutdown, , oil pressure warning indicator
comes on.
传感器连线折断
显示停留在 “ 0 ” 或 “ 9 9 9 ” D i s p l a y 连接电缆上接插件接触不好检查连线和接插件Check wiring and
stays at “0” or “999”. Sensor open circuit. connectors.
Poor contact of connector of cable.
只显示部分参数Only displaying some 仪器未进入初始状态The display is not
按复位按钮Press reset button.
parameters. initialized.
-90-
12．水泵不吸水或供水不足
Insufficient water supply or water pump failure
Causes Remedy
1）水泵内或吸水管内有空气 1）灌入引水取出空气
Air in water pump or suction pipe. Fill water into pipe to drain off air.
2）清理或加入热水，或预加防冻液
2）水管堵塞或结冰（寒冷季节）
Clean and fill hot water or pre-fill antifreeze
Water pipe clogged or frozen (in cold weather).
liquid.
3）水泵密封装置或密封垫损坏漏气
3）检修或换新
Gas leakage due to sealing device or sealing gasket
Repair or replace.
for water pump damaged.
4）水泵皮带过松 4）检查并调整
Loose water pump belt. Check and adjust.
5）柴油机水泵内结垢严重 5）清除水泵
Too much scale in the water pump. Clean water pump.
6）水泵吸程大 6）按规定安装水泵
Excessive suction head for water pump Install water pump as per specifications.
-91-
编校：刘国栋
2007年7月版

WEICHAI R6160 Manual

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R6160系列柴油机维修保养手册

Maintenace Manual For R6160 Series Diesel Engine

换代号 Generation code

调整垫片在备件箱中一套共 21 件，从 1 ～ 2mm，每隔 0.05mm 一档。

5．柴油机累计运行 3000 小时的保

增压器Turbocharger 摇臂Rocker arm

摇臂Rocker arm 连杆轴承Connecting rod bearings

气缸盖Cylinder head 净水泵Treated water

气缸盖Cylinder head 生水泵Raw water pump

与齿圈间隙Clearance to gear ring

2.2 燃料供给系统故障 [ 详见本章 1.2 小节 ]

故障特征产生原因排除办法

（2）沿气缸上下各处均有锤击声（2）活塞环与环槽间隙过大（2）更换活塞环，必要时更换活塞

故障特征产生原因排除办法

故障特征产生原因排除办法

压力报警灯不灭，主机压力表显示正常压力传感器导线搭线修复线路

You might also like

WEICHAI R6160 Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WEICHAI R6160 Manual

Uploaded by

Copyright:

Available Formats

R6160系列柴油机维修保养手册

Maintenace Manual For R6160 Series Diesel Engine

换代号 Generation code

调整垫片在备件箱中一套共 21 件， 从 1 ～ 2mm，每隔 0.05mm 一档。

5．柴油机累计运行 3000 小时的保

增压器Turbocharger 摇臂Rocker arm

摇臂Rocker arm 连杆轴承Connecting rod bearings

气缸盖Cylinder head 净水泵Treated water

气缸盖Cylinder head 生水泵Raw water pump

与齿圈间隙Clearance to gear ring

2.2 燃料供给系统故障 [ 详见本章 1.2 小节 ]

故障特征 产生原因 排除办法

（2）沿气缸上下各处均有锤击声 （2）活塞环与环槽间隙过大 （2）更换活塞环，必要时更换活塞

故障特征 产生原因 排除办法

故障特征 产生原因 排除办法

压力报警灯不灭，主机压力表显示正常 压力传感器导线搭线 修复线路

You might also like

调整垫片在备件箱中一套共 21 件，从 1 ～ 2mm，每隔 0.05mm 一档。

故障特征产生原因排除办法

（2）沿气缸上下各处均有锤击声（2）活塞环与环槽间隙过大（2）更换活塞环，必要时更换活塞

故障特征产生原因排除办法

故障特征产生原因排除办法

压力报警灯不灭，主机压力表显示正常压力传感器导线搭线修复线路