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WEICHAI R6160 Series Operating Instructions Manual
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WEICHAI R6160 Series Operating Instructions Manual

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R660系列柴油机维修保养手册
Maintenace Manual For R660 Series Diesel Engine
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
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.
第一章 柴油机使用说明
160
......
变型号Version No.
缸径 Cylinder bore
缸数 Number of cylinder
换代号 Generation code
--

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Summary of Contents for WEICHAI R6160 Series

  • Page 1 R660系列柴油机维修保养手册 Maintenace Manual For R660 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: …… 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...
  • Page 2 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 3 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 4 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 5 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 6 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 7 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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。...
  • Page 8 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 Maintenance of New Engine 一级技术保养 Level 1 Technical Maintenance 二级技术保养 1000 Level 2 Technical Maintenance 三级技术保养 3000 Level 3 Technical Maintenance 四级技术保养...
  • Page 9 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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。...
  • Page 10 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...

  • Page 11: Maintenance Of Diesel Engine

    R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 12 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 13 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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，...
  • Page 14 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 15 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine —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 - R e m o v e p l u g a n d b l o w i t w i t h compressed air from inside to outside;...
  • Page 16 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 17 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 18 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 19 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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”...
  • Page 20 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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) 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。...
  • Page 21 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 22 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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°...
  • Page 23 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.
  • Page 24 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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，...
  • Page 25 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 26 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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).
  • Page 27 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 28 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 s u r f a c e s h o u l d b e r e m o v e d .
  • Page 29 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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。...
  • Page 30 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 31 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 33 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 34 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 35 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 36 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 2．冷却系统 Cooling system 2.1 R6160A 系列柴油机冷却系统流程图 Flowchart for cooling system of R6160A series diesel engine 净水泵Treated water 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...
  • Page 37 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 38 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 2.3 陆机闭式循环 Closed circulation for stationary engine --...
  • Page 39 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 3．进排气系统 ntake & 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...
  • Page 40 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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) -0-...
  • Page 41 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 --...
  • Page 42 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 --...
  • Page 43 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 44 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 45 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 ～...
  • Page 46 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 47 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 48 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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，...
  • Page 49 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 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 The outer circle surface and lip for Molybdenum disulphide ointment Deep gray sealing ring of rotating shafts.

  • Page 51: Electric System

    R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.).
  • Page 52 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...
  • Page 53 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 54 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 55 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;...
  • Page 57 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 58 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 中冷器拆检 Disassembly and Check of Intercooler 中冷器型式为管片式， 散热面积 9m 和 12m 两种。 Intercooler is of gilled tube type, with a heat radiation area of 9m and 12m 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...
  • Page 59 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 拆下机油泵出油管 Remove oil outlet pipe for oil pump 拆下回油管 Remove oil return pipe --...
  • Page 60 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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;...
  • Page 61 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.
  • Page 62 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 -6-...
  • Page 63 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 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，...
  • Page 64 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 拆下与喷油泵连接的低压油管 R e m o v e t h e l o w p r e s s u r e f u e l p i p e connecting to injecto 松开中间法兰管与膜片的连接螺栓...
  • Page 65 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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。...
  • Page 66 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. -66-...
  • Page 67 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 68 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 -6-...
  • Page 69 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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).
  • Page 70 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 71 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 松开增压器进油管接头 L o o s e n o i l i n l e t p i p e n i p p l e f o r 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.
  • Page 72 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 a n d e x h a u s t e l b o w , a n d r e m o v e turbocharger.

  • Page 73: Diesel Engine Troubleshooting

    R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 74 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 75 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. 故障原因...
  • Page 76 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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.
  • Page 77 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 2．柴油机功率不足 nsufficient 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.
  • Page 78 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 故障原因 排除办法 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...
  • Page 79 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 80 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 故障原因 排除办法 Cause Remedy （1）燃油内有水 （1）更换柴油...
  • Page 81 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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...
  • Page 82 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. 故障特征 产生原因 排除办法 Failure Causes Remedy （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...
  • Page 83 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. 故障特征...
  • Page 84 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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）...
  • Page 85 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 故障原因 排除办法 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.
  • Page 86 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 7．突然停车 Sudden Stalling 故障原因 排除办法 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...
  • Page 87 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. 故障原因 排除办法 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...
  • Page 88 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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: 故障原因...
  • Page 89 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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. 故障原因...
  • Page 90 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 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 Failure Causes Remedy 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.
  • Page 91 R660系列柴油机维修保养手册 Maintenace Manual For R660 Series Diesel Engine 12．水泵不吸水或供水不足 Insufficient water supply or water pump failure 故障原因 排除办法 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).
  • Page 92 R6160系列柴油机维修保养手册 编校：刘国栋 2007年7月版...

This manual is also suitable for:

R6160a-5R6160a-6