WD615系列柴油机使用与维修 Operation and Maintenance of WD615 Series Diesel Engine

主要内容 WD615发动机外型图

WD615系列增压机型外形图

WD615系列增压中冷机型外形图

斯太 尔系列柴油机横剖 图

斯太尔系列柴油机纵剖图

目录 Catalogue 第一章、WD615系列柴油机型普及基本参数。 Basic parameter and type of WD615 series diesel engine 第二章、WD615系列柴油机的构造 The conformation of WD615 series diesel engine 第三章、保养规则 Maintenance rules 第四章、常见故障及排除 Trouble shooting 第五章 、 附录 Addendum

Basic parameter and type of WD615 series diesel engine 第一章 WD615系列柴油机型普及基本参数 First Chapter Basic parameter and type of WD615 series diesel engine

Displacement/one cylinder 1、WD615系列柴油机机型的基本含义： The basic signification of WD615 series diesel engine W D 6 15 ×× - 水冷 Water cooled 柴油机 Diesel engine 六缸 Six cylinders 单缸排量约1.5升 Displacement/one cylinder 基本型产品。 Rudimental product 如56、50等 For example 50、56 and so on. G-工程机械； G—construction machinery Q—汽车 Q--motorcar C—船机； C--watercraft D—发电机； D--generator CD-船用辅机 CD-accessorial manchinery 序列号。 Sequence No. 如28、29、36等 For example 28、29 and so on

2、WD615系列柴油机型号含义： The type No 2、WD615系列柴油机型号含义： The type No. signification of WD615 series diesel engine DH 615 × ×××× 订货号的汉语拼音首字母 WD615系列柴油机 WD615 series diesel engine G—工程机械； G—construction machinery Q—汽车； Q--motorcar C—船机； C--watercraft D—发电机； D--generator 顺序号。 Sequence No. 如0001、0002、0209等 For example: 001、002、0209 and so on

3．WD615系列柴油机型谱-基本参数。Basic parameter 数值(numerical value) 型式(type) 四冲程、水冷、直列、直喷、干式缸套 four-stroke、water-cooled、in-line、direct-injection、dry-liner 缸数\缸径\行程mm) Cylinder No/bore/stroke 6/126/130 排量 (L)/displacement 9.726 点火顺序/旋转方向 Firing order/ratatingdirection 1-5-3-6-2-4 /顺时针（从齿轮室端看） 1-5-3-6-2-4/clockwise(view from free end) 冷态气门间隙(mm) Valve clearance at cold state 进气/intake 0.3 排气/exhaust 0.4 配气相位/valve phase Intake valve open：BTDC34°-39°Intake valve close ：ABDC61°67° Exhaust valve open：BTDC76°-81°Exhaust valve close:ATDC26°-34° 起动方式/starting method 电启动/electric start 润滑方式/lubricating method 压力润滑 /pressure lubrication 冷却方式/cooling method 水冷强制循环/water-cooled force circulation 机油压力(Kpa)/oil pressure 350—500 润滑油容量 L/oil sump capacity 20 涡轮后排温℃ /eshaust tep. ≤550

3．WD615系列柴油机型谱 The type chart of WD615 项目(ITEM) 56 58 50 31 额定功率Kw/rate power 190 175 206 225 额定转速r/min/rate speed 2600 2200 2400 最大扭矩Nm/Max. torque 830 1000 1070 1250 最大扭矩转速r/min Speed at max.torque 1600~ 1700 1300~ 1400 排放指标 Displacement standard EURO Ⅱ 活塞平均速度 m/s Mean piston speed 11.27 9.53 10.4 压缩比/compression ratio 16:1 15.5:1 吸气方式 /intake mode 增压/Turbocharged 增压中冷/turbocharged & intercooled

3．WD615系列柴油机型谱 The type chart of WD615 项目(ITEM) 64A 61A 67A 68A 50 44 46 额定功率kW/rate power 175 193 206 225 201 236 266 额定转速r/min/ rate speed 2200 最大扭矩 Nm/ Max. torque 1000 1100 1160 1250 1110 1460 最大扭矩转速r/min Speed at max.torque 1300~1600 1100~ 1600 1400~1600 排放指标 Displacement standard EURO Ⅱ 活塞平均速度 m/s Mean piston speed 9.53 压缩比/ compression ratio 15.5:1 吸气方式 /intake mode 增压中冷/turbocharged & intercooled

The conformation of WD615 series diesel engine 第二章 WD615系列柴油机的构造 Second chapter The conformation of WD615 series diesel engine

目录 Catalogue 第一节 气缸体 Cylinder block 第二节 主要运动件（曲轴和连杆活塞） Main moving parts（Crankshaft & connecting rod ,piston) 第三节 气缸盖和配气机构。 Cylinder & Valve train 第四节 供油系统： Fuel supply system 第五节 润滑系统： Lubricating system 第六节 进排气系统： intake and exhaust system 第七节 电气系统： Electrical system

第一节 气缸体Cylinder Block 气缸体、曲轴箱 Cylinder block、crank case 齿轮室 Gear case

一、机体与曲轴箱 Cylinder block &Crank case 1、WD615系列柴油机则是主轴承盖与曲轴箱（亦称框架）铸为一体，以曲轴中心线水平分开成为上下两部分，上部为机体，下部为曲轴箱，机体与曲轴箱之间没有垫片，在连接前须将结合表面擦净，整体结合面涂密封胶（乐泰510）。机体前、后分别与正时齿轮室和飞轮壳连接，其结合面处涂以乐泰510密封胶密封。 The main bearing cover and crank case of WD615 series diesel engine is cast in one piece,is separated into two parts of cylinder block(upper) and crank case (lower).there is no gasket between them,before mounting,clean the joint faces and coat with Loctie 510 sealant thoroughly.The front end and rear end of cylinder block connect separately with the timing gear case and flywheel casing.Loctite 510 sealant should be coated on the joint faces before mounting.

2、机体上有七道主轴承、宽度全部相同。止推片置于第二道主轴承两侧。 There are seven main bearings with same width.the stop ring is set in the two sides of the 2nd main bearing seat. 3、机体采用干式缸套结构。气缸套与机体缸孔间为过渡配合。薄壁气缸套系用耐磨的高硼或铜硼铸铁制造，壁厚仅为2mm，对其检测需用专用测量工具。气缸套内表面为特制的平台网纹，对加快磨合和耐磨性能均有良好的效果。安装前去油脂并涂上一层薄薄的钼粉，用手或工具即可平稳压入。 The thin wall(only 2mm) and dry liner is made of wear-resisting high boron or copper-boron cast iron,special measure device should be used during inspecting.And transition fit is adopted to the liner and cylinder bore.platform net lines are specially made in the inner face of the cylinder for speed up wear-in and improve wearability.Before mounting,remove away the oil or grease on the surface of cylinder bore and/or the outer face of liner and coat with a layer of Molykote powder.the push the liner into cylinder bore smoothly by hand or special tools.

4. 机体右侧腰部有一贯通主油道。左侧腰部有一副油道（不贯通），它是为六只机油喷嘴供油，有效地冷却活塞。 There is a main oil passage through the waist of right side of cylinder block.And an auxiliary oil passage(not through) is provided at the left side to deliver oil to the six nozzles. The pistons are cooled effectively with oil injected by the oil nozzles. 6.七道凸轮轴轴承座位于机体右内侧。机体的右侧面有一个安装机油冷却器的水室，其内下部有6个通道是冷却水进入机体缸筒水夹层的入口。机体总成下部（在曲轴箱上）有一个安装机油滤清器的结合面，机油滤清器总成通过4只M8螺栓压紧，压紧前结合面需涂密封胶。 The seven camshaft bearing seats are located in the inner right of cylinder block. At the right side of cylinder block, a water chamber is provided for oil cooler, and six passages are designed under the water chamber for cooling water entering into the narrow space between the cylinder block and liner. There is a joint face for mounting oil filter on the crankcase, the oil filter assembly is fixed by four screws(M8) at the joint face coated with Loctite510 sealant.

主轴瓦 气缸套外表面涂钼粉 Molykote powder 止推片 Stop ring 主油道 Main oil passage

传动齿轮 Transmission gear 喷油泵齿轮 Injection pump gear 水泵蜗壳 Water pump carapace 中间齿轮 Intermediate gear 凸轮轴齿轮 Camshaft gear 曲轴齿轮 Crankshaft gear

WD615系列车用柴油机中传动齿轮系由8个齿轮组成。在安装时仅凸轮轴齿轮上有一处记号须比正时齿轮上刻痕记号约超前半齿，如图F（第1缸活塞须处于上止点位置即飞轮刻度为0º）即可。喷油泵齿轮毋须对记号，可通过松开传动轴端角度调节板拉紧螺栓来调整供油提前角。调整时，先把需调的飞轮上的角度值与飞轮壳上的记号对准，然后 松开拉紧螺栓，使油泵上的记号与连接器上的记号对准，或松开第一缸油泵上的高压油管，盘车直至出油阀油面波动即停，然后紧固拉紧螺栓至130N·m。在安装凸轮轴齿轮紧固螺栓和中间齿轮盖板时，注意切记用乐泰242涂在紧固螺栓螺纹部分。在安装中间齿轮盖板和凸轮轴齿轮螺栓时，注意切记用乐泰242涂在紧固螺栓螺纹表面。 The gear train of WD615 series diesel engine is composed of eight gears,When mounting,the mark on camshaft gear should be half tooth advanced the cut in gear case(the 1st piston should be at TDC,I.e. the flywheel graduation is of 0º).The delivery advance angle can be adjusted only by loosen the tension screw for the angle regulating plate at the end of transmission shaft.It does not need to align mark for the injection pump gear.During adjusting,align the graduation on the gear needed to be adjusted with the mark on flywheel casing firstly,and then loosen the tension screw and align the marks on the fuel pump and the connector,loosen the pressure pipe of the 1st cylinder of injection pump,turn the crankshaft until fuel over-flows from the delivery valve ,now stop turning. And then tighten the tension screw to 130N•m when mounting the intermediate gear cover and camshaft gear bolts,Loctite 242 sealant must be coated at the thread of the screw.

齿轮室各齿轮的安装。Fitting of gears in gear case B C D E F

第二节主要运动件 Main moving parts 1）曲轴 crankshaft WD615柴油机曲轴为钢质模锻件。根据不同强化要求选用二种材料，额定功率在220kw以下的机型采用45号钢，额定功率大于220kw的机型采用42CrMo钢。曲轴有12块平衡块。曲轴主轴颈为Ø100，连杆轴颈为Ø82 ，曲轴经软氮化处理，有较好的疲劳强度和耐磨性。曲轴前端有一个法兰，法兰外圆为曲轴油封的密封面，法兰的八个M10镙孔用于连接减振器，皮带轮。曲轴齿轮在装配时须加热到180ºC后装入曲轴，法兰须加热到290ºC后装入曲轴。曲轴前端装有95x115x12骨架橡胶油封，后端油封是115x140x12骨架橡胶油封。 There are two kinds of steel forging crankshaft for WD615 diesel engine according to the requirements.High-quality 45# steel crankshaft is used for the engine that rated power is lower than 220kw and 42CrMo steel crankshaft for the engines of 220kw or more than 220kw.There are twelve balance blocks on the crankshaft.The widths of main journal (Ø100) and connecting rod journal (Ø82),The fatigue strength and wearability of crankshaft are increased greatly by heat-treated with soft nitrogen.there is a flange at the front of crankshaft and the outer surface of the flange acts as the sealing face of oil seal of crankshaft.The vibration absorber and pulley are connected with the flange through eight screwed holes(M10).before assembling,crankshaft gear and the flange should be heated respectively to 180ºC and 290ºC.the front end oil seal of crankshaft is of 95x115x12 skeleton rubber oil seal,and the rear is of 115x140x12 oil seal

Connecting rod journal Ø82 连杆轴颈 Connecting rod journal Ø82 曲轴齿轮 Crankshaft gear 主轴颈Ø100 Main journal Ø100 法兰flange 减振器 vibration absorber

活塞 Piston 采用马勒124铸造铝合金制造。活塞销孔直径Φ50mm，为了 改善活塞销座上应力分布，在活塞销座加了减压槽，活塞裙部采用复杂的型线，保证了活塞与气缸套有良好的接触，在裙部表面喷涂厚0.01mm的石墨层起较好的减磨作用。 活塞装入气缸后的压缩余隙为1mm。相对柴油机强化程度要求，机油喷嘴尺寸不同。同一组活塞质量差规定是10g以内。 Piston The piston is made of Mahle 124 cast aluminium alloy; The diameter of piston pinhole is 50mm.In order to improve the stress distribution on the pin seat,the pin seat is designed with a pressure-reducing groove. And complex shape line skirt is effective on the fine contact of the piston and the cylinder liner.For reduce wearing,a layer(0.01mm) of graphite is sprayed on the surface of the skirt. The clearance between cylinder head and the piston TDC is 1mm.According to the diesel engines,the oil spray holes differ in size, the weight differences of pistons in the same group must be less than 10g.

活塞环：活塞上有两道气环和一道刮油环，第一道是铸铁镶圈环槽内的双面梯形桶面环，上部带有切口，工作表面喷钼，有利于磨合及抗拉毛和减磨作用。第二道气环是镀鉻锥面环，第三道环是撑簧铸铁油环，双刃表面镀鉻。 Piston ring:There are three rings on one piston(two compression rings and one oil ring).The first ring is of double-side ladder cylindrical ring with a cut on the top end.A layer of molybdenum is sprayed on the surface of this ring for improve wear-in and scratch resistance and reduce wear and tear.The second ring is of chromium-plated cone ring and the third ting is of a spiral spring oil ring that is made of cast iron,the outer surfaces are chrome-plated. 连杆：连杆螺栓扭紧时须按转角扭紧法规要求，连杆螺栓只允许使用一次后即调换，不许超限使用。 Connecting rod:Tighten up the bolts according to the corner tighten criterion,The connecting rod bolts can be used only one time.

2.连杆活塞 connecting rod & piston 梯形环 ladder ring 锥面环 cone ring 油环oil ring 活塞销 piston pin 活塞 piston 连杆衬套 connecting rod bush 连杆瓦 connecting rod tile 连杆connecting rod

气缸盖 Cylinder head 1-cylinder head 2-intake valve seat 3-exhaust valve seat 4-valve guide 5-seal washer 6-Nozzle holder insert 7、8、9、10-Core hole plug 11-cylinder gasket 12-Cylinder head cover 13-Cylinder head cover gasket 16－Cylinder head clamp 17－Collar nut 18－Clamping yoke 19－Eye screw 20－Valve guide bush 21－Cylinder head bolt 22－Clamping yoke 24－hexagon bolt 25-Wave spring washer

第三节气缸盖 Cylinder head (1)由合金铸铁材料制成，一缸一盖，气缸盖上布置一个进气门和一个排气门，进排气道分布于两侧。冷却水流进气缸盖后，全部通过气缸鼻梁热区的水腔，然后掠过喷油器铜套进入出水管。气缸盖总高125mm，气缸盖上进排气口均镶有特殊材料的气门座，进气门座面角为110°，排气门座面角为90°。气门装缸盖后下沉量不得超过1.8mm。 The cylinder head with one inlet valve and one outlet valve is made of cast alloy,and one head for one cylinder.The intake and exhaust manifold are designed separately at the two sides of the head.The cooling water enters into cylinder head,then to the water cavity in the nose bridge of the head.by brush through the copper sleeve,the water gets into outlet pipe.the cylinder head is 125mm in height,valve seats made of special cast iron are inlaid at the inlet and outlet valve ports,the cone angles of inlet and outlet valve seats are 110° and 90° respectively.the sunk height of valve after fitted in the head should be not more than 1.8mm. (2)为了防止机油从气门导管间隙中进入气道，在气门导管上安装了密封套。 A sealing bushing is set to the top end of valve guide to prevent oil get into the gas passage from the gap of the valve guide.

（3）气缸盖 每个气缸盖上有4个M16的气缸盖主螺栓及6个M12的与邻缸共用的双头螺柱，副螺母通过具有V型压紧面的夹紧块压紧，在两端头处采用悬挂式压紧块。气缸盖主螺栓及副螺母均采用转角扭紧法拧紧。 （3）CYLINDER HEAD each cylinder head is pressed against the block by four bolts(M16),and the two adjacent cylinder heads are held down by six studs(M12) with help of a set of lock nuts and other parts. The main bolts and the nuts should be tightened up according to the following table.

Valve train 配气机构 1、camshaft 2、Camshaft gear 3、Thrust flange 4、Idle gear axle 5、Idle gear 6、Axle 7、Guard plate 8、Sealing ring 9、Cover 10、Rocker arm support 11、Rocker arm (intake) 12、Rocker arm (exhaust) 13、Valve cap 14、Valve cone 15、Spring cup 16、Outer valve spring 17、Inner valve spring 18、Spring seat (intake) 19、Intake valve 20、Valve tappet 21、Push rod 22、Valve setting screw 23、Hexagon nut 24、Spring seat (exhaust) 25、Exhaust valve 26、27Hexagon bolt

配气机构 Valve trains （1）凸轮轴材料为高碳钢，有七道轴承，整体式的摇臂轴座，整个配气机构刚度较高，配器机构润滑比较充分，机油通过挺柱孔中的小斜油孔从主轴颈引油，当挺柱工作面上凹槽与油孔相接时机油从挺柱筒支承面中心通孔经空心推杆和空心摇臂螺钉到摇臂轴承，另外有部分润滑油经摇臂顶部线槽去润滑摇臂头部。 （1）The camshaft of the engine is made of high-carbon steel, there are seven main bearings and with integral rocker shaft seats,the whole valve train has high rigidity. The lubricating oil is intaked from the main journal through the small inclined passage in the tappet hole. When the concave face of the tappet is connected with oil passage, the oil is delivered through the center through hole in the tappet barrel, the hollow pushing rod and the hollow screw to the rocker bearing. And some oil is delivered to the top of the rocker.

WD615柴油机气门间隙 : 进气门（冷态）0.3mm 排气门（冷态）0.4mm 气门间隙测量，应在气门摇臂头部R面与气门杆端或气门杆帽之间的间隙，通过调整摇臂上调螺栓来达到。 在进行拆装后或二级以上保养中，都应检查气门间隙，检查时应保证该气门处在完全关闭状态。 Valve clearances of WD615 diesel engine are follow: Inlet valve(at cold): 0.3mm Outlet valve(at cold): 0.4mm The valve clearance between rocker arm head R face and valve end or valve cap, should be adjusted by regulating the adjusting screw on rocker arm. Valve clearance should be checked in second order maintenance or after reassembly, pay attention to that the valve should be in full closed status in inspection.

柴油机冷态下打开缸盖上的气门摇臂罩，拆开飞轮壳下部的观测孔盖，按柴油机旋转方向将机器盘车至一，六缸上止点，飞轮壳刻线与飞轮上OT线对齐，判断第一缸还是第六缸处于压缩行程，处于压缩行程的气缸两气门都有间隙，确定处于压缩行程的气缸后，按下表顺序对各缸相应气门进行检查调整。 When the diesel engine is at cold state, open the valve rocker arm cover on cylinder head, dismantle the cover of inspection hole below flywheel, turn the flywheel positively to TDC of cylinder 1 and cylinder 6, align the scale on flywheel housing with the OT line on flywheel, judge which cylinder, the cylinder 1 or cylinder 6, is actually at its compression stroke, both the two valves of the cylinder at compression stroke have clearances. You can check and adjust the relevant valves of each cylinder according to the sequence in following table.

按柴油机旋转方向将机器盘车至一，六缸上止点，飞轮壳刻线与飞轮上OT线对齐，确定处于压缩行程的气缸后，按下表顺序对各缸相应气门进行检查调整。 turn the flywheel positively to TDC of cylinder 1 and cylinder 6, align the scale on flywheel housing with the OT line on flywheel, You can check and adjust the relevant valves of each cylinder according to the sequence in following table.

Cylinder 1 at compression stroke 第1缸 Cylinder 1 第2缸 Cylinder 2 第3缸 Cylinder 3 第4缸 Cylinder 4 第5缸 Cylinder 5 第6缸 Cylinder 6 第1缸处于压缩行程 Cylinder 1 at compression stroke 进排气门 Intake valve& exhaust valve 进气门 Intake valve 排气门 Exhaust valve 进、排气门均不能调整 Intake & exhaust valves can not be checked 第6缸处于压缩行程 Cylinder 6 at compression stroke

WD615柴油机要求进气门0.3mm,排气门0.4mm ，用塞尺检查气门杆端部与气门摇臂之间的间隙，若间隙过大或过小可通过调整摇臂上的调整螺栓来达到间隙要求。检查调整完第一缸或第六缸后再正盘车360°使对应的另一缸处于压缩行程上止点，检查调整剩余的气门。 Requirement of valve clearance for WD615 diesel engine: Intake valve: 0.3mm, Exhaust valve: 0.4mm，adjust the clearance between valve stem end and valve rocker with feeler, if the clearance is too wide or too narrow, you can adjust the adjusting bolt of the rocker to reach the requirement. After having checked and adjusted the cylinder 1 or cylinder 6, you should turn the flywheel conversely for 360°to make the cylinder 6 or cylinder 1 at TDC of compression stroke, then check and adjust the remainder valves.

high pressure fuel pump 第四节 供油系统：Fuel supply system 高压油管 high pressure fuel pump 喷油器总成 Injector assembly 喷油泵 Injection pump 润滑油回油管oil return pipe 联轴器connector

喷油泵：Injection pump 在增压机型的喷油泵上都装有冒烟限制器，是为了改善低速时废气涡轮的转速低，压气机出口压力低，进气减少使燃烧恶化，而增大烟度，增压补偿器通过空气管感应了进气管中压力情况，相应得限制了供油量。使柴油机在低速时压度不致过大。柴油机出公司试验时，已完成调整，用户请勿调改。 Injection pump: Smoke limiter is fitted to the injection pump of turbocharged engine so as to improve smoke exhaust when gas turbine runs at low speed, thus outlet pressure of air compressor is low and air inlet is decreased to worsen the combustion. Pressure compensator responds to the pressure in inlet pipe through air pipe and sets a limit to fuel delivery as that smoke exhaust is not excessive even in low engine speed.The smoke limiter has been aligned in delivery; users would better not to adjust it.

供油提前角的调整。 How to adjust the advance angle 首先按柴油机旋转方向将机器盘车至一，六缸上止点，飞轮壳上刻线与飞轮上OT线对齐,拆下1、6缸缸盖摇臂罩并确定一缸处于压缩行程，此时一缸进排气门均有间隙。 WD615柴油机配两种型号的高压油泵，一种是P30000高压油泵，另一种是PS7100型高压油泵。 First，turn the flywheel positively to TDC of cylinder 1 and cylinder 6, align the scale on flywheel housing with the OT line on flywheel, dismantle the valve rocker arm covers on cylinder heads of cylinder1and cylinder 6, and ascertain the cylinder 1 at compression stroke, the intake and exhaust valves of cylinder 1 all have clearances at this time. The WD615 diesel engine adopted two models of high-pressure fuel pumps, one is P30000 high-pressure pump; the other is PS7100 high-pressure pump.

⑴配PS7100型高压油泵的WD615柴油机供油提前的调整 How to adjust the advance angle for diesel engine with P7100 injection pump 按动手压输油泵排除燃油系统中空气，使高压油泵回油管柴油流出，拆下一缸的高压油管接头，柴油机倒盘车30-40°CA,将高压油泵油门手柄加到最大油量位置再缓慢正盘车，直至该缸高压油管中每秒流出一滴燃油的速度时停止盘车，此时即为该缸供油开始时刻，检查飞轮壳上刻线相对于飞轮OT线的角度即为柴油机供油提前角。若检查柴油机供油提前角不在规定的范围内应对其进行调整。 方法是：将柴油机先正盘车到规定的一缸供油提前角，再松开联轴节上角度调节板上的螺钉,使高压油泵与柴油机可相对转动，将高压油泵手柄推到最大油门位置同时按动手动输油泵，转动旋转高压油泵传动轴使一缸的高压油管喷出油来，再缓慢顺时针旋转传动轴至高压油管中每秒流出一滴燃油，此时即为高压油泵一缸供油开始时刻。确定一缸供油时刻时紧固连接螺栓，此螺栓要求紧固扭矩140n.m,复查供油提前角是否在要求范围内，若仍不符合要求应重新进行调整。

Press the hand transfer pump to drain off air from fuel system and let the diesel oil outflow from the fuel return pipe of high-pressure pump, dismantle the connection for high-pressure pipe of cylinder 1, turn the flywheel conversely for 30-40°, push the throttle grip to the position for largest fuel quantity, then turn the flywheel positively and slowly, the very moment when fuel from the end of high pressure pipe drops about one drop per second is the fuel delivery beginning, check the angle included between the scale on flywheel housing and the OT line on flywheel, the angle is the very fuel supply advance angle. You should adjust it according to the method below if the advance angle is outside of specified range: The method is： turn the flywheel positively to specified fuel supply advance angle for cylinder 1, then loosen the bolt on angle adjusting plate of the coupling to make the high-pressure pump can be rotated relatively against the engine, push the throttle grip of the high-pressure pump to the position for largest fuel quantity, and press the hand transfer pump simultaneously, turn the transmission shaft of high-pressure pump clockwise slowly, until the fuel from the end of high-pressure pipe of cylinder 1 drops about one drop per second, this moment is the very fuel delivery beginning for cylinder 1. You should tighten the connecting bolt after ascertaining the fuel delivery beginning for cylinder 1, the required tightening torque for the bolt is 140N.m. recheck if the advance angle is within the specified range, you should readjust it if it is still not meet the requirement.

⑵配P30000型高压油泵的WD615柴油机供油提前的调整。 按柴油机旋转方向将机器盘车至一缸压缩冲程上止点，此时飞轮壳上刻线与飞轮上OT线对齐且一缸进排气门均有间隙，按动手压输油泵排除燃油系统中的空气,使高压油泵回油管柴油流出,拆下高压油泵上一缸高压油管，柴油机倒盘车30-40°CA, 将高压油泵手柄打到最大油量位置,带停车手柄的高压油泵要注意此时停车手柄处于供油位置。再缓慢正盘车，直至一缸出油阀内燃油液面刚刚上升时立即停止，此时即为高压油泵一缸供油开始时刻，检查飞轮壳上刻线相对于飞轮OT线的角度,此角度即为柴油机供油提前角。若检查柴油机供油提前角不在规定的范围内应对其进行调整。 方法是：将柴油机先正盘车到规定的一缸供油提前角, 再松开联轴节上角度调节板上的螺钉, 使高压油泵与柴油机可相对转动，按柴油机的运转方向转动高压油泵传动轴直至一缸高压油管接头有油冒出来，将凸起的油面吹去，反转联轴器再缓慢按高压油泵转动方向旋转联轴器至油面刚动为止，此时即为高压油泵一缸供油开始时刻。检查飞轮上的柴油机供油提前角，确定一缸供油时刻后紧固连接螺栓，此螺栓要求紧固扭矩140n.m, 复查供油提前角是否在要求范围内,若仍不符合要求应重新进行调整。

（2）Adjust the advance angle of WD615 diesel engine with P30000 high-pressure pump Turn the flywheel positively to TDC of compression stroke of cylinder 1, align the scale on flywheel housing with the OT line on flywheel, the intake and exhaust valves of cylinder 1 all have clearances at this time. Press the hand transfer pump to drain off air from fuel system and let the diesel oil outflow from the fuel return pipe of high-pressure pump, dismantle the high-pressure pipe of cylinder 1 on high-pressure pump, turn the flywheel conversely for 30-40°, push the throttle grip of high-pressure pump to the position for largest fuel quantity, by the way, for the high-pressure pump with stop handle, please pay attention to that the stop handle should be at position of fuel supply here. Then turn the flywheel positively and slowly till the fuel level swells up in the delivery valve cylinder 1, the very moment when the fuel start to swell is the fuel delivery beginning. Check the angle included between the scale on flywheel housing and the OT line on flywheel, the angle is the very fuel supply advance angle. You should adjust it according to the method below if the advance angle is out of specified range. The method is: rotate clockwise the flywheel to a specified advance angle of fuel supply of the first cylinder and then unscrew the bolt on the angle modulation board of the coupler to make sure that the high pressure fuel pump can rotate relatively with the diesel engine. along running direction of diesel engine to Rotate the transmission shaft of the high-pressure fuel pump until there is fuel puffing out of one of the high-pressure fuel pipe joint. Blow off the bulging fuel surface and reverse rotate the transmission shaft in the rotating direction of the high-pressure fuel pump until the fuel surface starts to move. This very moment is just the starting point of fuel delivery of the high-pressure fuel pump. Check the advance angle of the fuel supply. The connecting bolt must be fastened after the fuel supply of the first cylinder begins. The fastening torque of this bolt should be 140nm. Recheck the advance angle of fuel supply to see whether it is within the required range, if not, do some readjustment.

Check the advance angle 2.提前角的验证： Check the advance angle 用上述调整方法调整到高压油管端柴油以每秒一滴左右滴油时为止，此时观察飞轮端的刻度值是否是要求值，若不是则继续按步骤1进行调整，直到达到要求值为止。然后拧紧第一缸高压油管。 Adjust the engine according to above method until the fuel from end of high pressure pipe drops about one drop per second, inspect the graduation on the flywheel, if the value is not the specified one, regulate the advance angle according to step 1 until the specified value is reached, then tighten the high pressure pipe of 1st cylinder.

The throttle is at the largest fuel quantity 油门在最大位置 The throttle is at the largest fuel quantity 油面波动 The fuel level swells up 紧固角度调节板螺栓 The fastening torque of this bolt should be 140N.m

第五节润滑系统： Lubricating system 机油泵 oil pump 主油道限压阀 Main passage relief valve 集滤器 oil strainer 机油冷却器 Oil cooler 机油滤清器 oil filter 增压器Turbocharger 空压机 Air compressor 高压油泵 fuel pump

润滑油路走向图 Lub-Oil passage flow chart

润滑系统: lubricating system 润滑系统的功能是减速、冲洗、冷却和防锈，机油的应用应根据公司标准的规定选用。多级机油更有利于冷起动性应优先选用。全年使用的多级机油如5W30、10W40、15W40等也仅可以在规定的温度范围内使用。对于偶尔的低温情况可以采取适当措施预热机油，或者更换与环境温度相适应得机油。 每次更换机油时要同时更换机油滤清器。 The functions of lubricating system are reducing wear and corrosion, washing and cooling for parts. Lubricating oil should be adopted in accordance with the factory regulations. Multi-grade oil has top priority for its better cold-start characteristics. Multi-grade oil used in all climate such as 5W30,10W40,15W40 are applied in the specified temperature range.Take proper measures to preheat oil or use oil adapted to the ambient temperature when low ambient temperature occurs occasionally. When exchange oil, replace oil filter at the same time!

压力润滑： Pressure lubrication 机油泵通过集滤器，将机油由油底壳中吸入，压向机油滤清器和机油冷却器，通过油路 系统到达润滑位置。绝大部分油量到达主轴承并由此通过曲轴上的油孔，到达连杆轴承。气缸套表面和活塞销是由喷嘴喷出油来实现润滑。气门操纵系统、增压器、高压油泵、空压机、中间齿轮轴承同样是通过油管 和油槽实现压力润滑。活塞底部是通过喷嘴喷油冷却。机油通过机油冷却器由冷却水来冷却。机油循环系统的机油压力是通过一个限压阀来调整的。 The lubrication oil is drawn from the oil sump through the sump strainer into the oil pump, and is fed to the oil filter and oil cooler and then enters into the lubricating parts through the oil passages. Much part of oil enters into the main bearing and flows to connecting rod bearing through the oil port in crankshaft. The cylinder liner and piston pin are lubricated with oil injected by nozzle. Valve operating system, turbocharger,high-pressure pump, air compressor, intermediate gear bearings are also pressure lubricated through oil pipe and oil groove.The piston bottom is cooled with oil injected by nozzle. The oil is cooled through oil cooler.Oil pressure in oil circulating system is adjusted by relief valve.

1)油底壳：用薄钢板冲压成型，其与曲轴箱的结合面有较深的翻边，刚度大。配以凹形油底壳密封垫，经12只油底壳托块和M8螺栓压紧下结合面密封性好，不会出现渗油现象。 1)The oil sump is forged with steel plate, the joint face between oil sump and crankcase has deep rim and good rigidity. Fitted with concave oil sump gasket, 12 brackets and M8 screws fixed to the lower joint face,it has good sealing without occurring oil leakage. 2)机油冷却器：为了防止机油冷却器堵塞或冬季起动时油温低，黏度大，机油冷却器阻力高等情况从而造成发动机缺油损坏的可能性，发动机油路中设置了机油冷却器安全阀（旁通阀），该阀的开启压力为600±36 kPa。 2)The oil cooler safety valve(bypass valve) is fitted to the oil line in order to prevent oil lack damage to the engine when oil cooler is blocked, or high resistance exists inside the oil cooler because of low oil temperature and high viscosity in winter.The opening pressure of the valve is 600±36 kPa. 3)主油道限压阀：位于曲轴箱右下部，突出在油底壳内腔的主油道限压阀，其开启压力为500±50kPa。装机前已校正好，用户不可自行改变。 3)Main oil passage relief valve:The main oil passage relief valve is fitted on the right side of crankcase and projected from oil sump inner cavity, the opening pressure of the valve is 500±50kPa.The valve has been aligned in delivery;users would better not to change it.

第六节 冷却系统 Cooling System 1.水泵：WD615系列柴油机上水泵安装在柴油机前端，水泵蜗壳在正时齿轮室上方，铸成一体，蜗壳出水直接进入机体右侧水室，冷却水横掠过机油冷却器，从机体右下部通道孔流入缸筒水夹层，冷却气缸筒后再经上水孔进入气缸盖水腔，冷却气缸盖后从缸盖出水口排入出水管，出水管终端有节温器。节温器有两个出口，一路通往水箱，一路通往水泵进口即为小循环。 1.Water pump:For WD615 series diesel engine, water pump is mounted on the front of engine, water pump housing cast in one piece is fitted to the upper side of timing gear. The cooling water from pump housing comes into right water tank of the cylinder block and enters into the oil cooler,then the cooling water flows into the cylinder passage through holes on the lower right side of cylinder block to cool the cylinder liner.The water enters into the cylinder head passage through water ports and comes into the water outlet pipe through outlet port of the cylinder head.The thermostat is fitted to the end of water outlet pipe.There are two openings on the thermostat;one opening is for water to the radiator.Another is for water to inlet port of the water pump,that is the “short circulation”.

2.风扇：塑料风扇以玻璃纤维增强PA6压注成型，直径Φ570及Φ620两种。风扇传动为硅油离合器传动（即粘性传动）。粘性风扇主要原理是一种通过双金属感温元件实现由温度控制风扇工作，所以不仅有节能的效果，更重要的是保证柴油机有良好的热状态，对柴油机的运行和使用寿命都有明显的优点。 使用粘性风扇时必须注意，当风扇拆卸下来时切不可平卧放置，否则硅油要从传感器轴配合间隙中漏出，从而使风扇失效。 2.Fan:The plastic fan is pressed by reinforced plastic PA6,the diameter is Φ570 or Φ620.It is silicone viscous clutch drive type.The viscous fan is controlled by temperature through double metal sensing elements. Not only the energy saving effect is reached, but also the good running status of the engine is assured so as to guarantee the operating and service life. Pay attention to that, when using the viscous fan,it is forbidden to put the dismantled fan in level, otherwise the silicone oil will flow from sensor shaft fit clearance to make fan lose effectiveness.

进气系统：Intake system 增压器 turbocharger 进气管 Intake pipe

排气系统：exhaust system 隔热罩 heat insulation cover 增压器 Turbocharger 排气管 Exhaust pipe

第七节进排气系统：intake and exhaust system 1)进气管：采用铸铝制造，安装在高压油泵一侧，具有较大容积的内腔，增压中冷进气口必朝前。 1)Intake pipe:The intake pipe made of cast aluminium is mounted at the side where the high pressure pump is set, its inner cavity is rather large. The positions of inlet port for turbocharged and inter-cooled diesel engine must be facing at the front. 2)排气管：采用球墨铸铁制造，排气管分两段：前排气支管和后排气支管。两个支管互相套接并装有钢片密封环，能够有效地密封。后排气支管是用带夹层双出口排气管，使前三缸和后三缸分别向增压器供给废气，不会产生干扰。 2）exhaust pipe:The exhaust pipe made of nodular cast iron consists of two parts: front exhaust manifold and rear exhaust manifold. The two manifolds are linked with each other with steel seal ring fitted to so as to provide good sealing. The rear exhaust manifold is of double ports manifold, it makes the front three cylinders and the rear three cylinders supply exhaust gas to the turbocharger separately without occurring disturbance.

3）空滤器：双级空滤器，第一级为旋流除尘器，第二级为空滤纸滤芯及安全滤芯。空滤器最大阻力应小于5kPa，当保养指示灯亮时要及时保养或更换，否则影响柴油机功率和寿命。在选配合安装空滤器及连接管路时，用户还应高度注意其密封性和可靠性。否则由于滤清失效，短路，导致发动机早期磨损，发动机使用没有达到规定的寿命，即出现机油耗量大量增加，曲轴箱窜气，发动机功率下降，冒黑烟等不正常现象，严重时还会产生缸套活塞环严重磨损，活塞环折断，拉缸等故障。 空滤器的滤芯要按规定及时保养，滤芯从空滤器中拆卸后轻拍端面使灰尘落下，也可将主滤芯横卧在干净水泥地上滚动使灰尘震落，切勿用力摔打，如有条件再用压缩空气反吹（由内向外吹）则更好。 注意： a 滤芯有破损时必须调换 b 保养时，不要污染滤芯内部 c 即使保养后若使用周期小于保养周期时也应调换滤芯 3）Air cleaner The air cleaner is of double-stage,the first stage is spiral remover,the second stage is air cleaner paper element and safety element.The max. resistance of the air cleaner should be less than 5Kpa. When the maintenance indicator lights,it means that it’s time to maintain or replace the filter,otherwise the engine power and service life will be affected. In choosing and mounting the air cleaner and connecting pipe,users should pay attention to

its sealing and reliability its sealing and reliability.Otherwise largely increased oil consumption,crankcase blow-by,decreased engine power,black smoke exhaust and so on would occur because that the filter lose its effectiveness and is in short cir-cuit leading early wear of the engine and could not achieve the specified service life. It even causes the serious wear of cylinder liner and piston ring, and breakage of piston ring and cylinder scuffing. The element of the air cleaner should be maintained regularly. Beat the side of the element gently to make dust fall down, or put the main element in clean cement ground horizontally and roll it to make dust shake out after dismounting the element from the air cleaner.It is better to blow the element backward(blowback from inside to outside) by compressed air. The air cleaner is not fitted to the engine. Caution: a. Replace the filter element when it is damaged b. Do not pollute the inner filter element when maintaining c. Replace the filter element even after maintenance if its working life is shorter than maintaining period

空气增压系统流程图 Flow chart of air turbocharged system

增压器： WD615系列柴油机的增压机型和增压中冷机型的增压器是配用废气涡轮增压器。 增压器以极高的转速工作（约70000~100000r/min），因此柴油机起动后应有适当空转（约5min，短暂停机可适当缩短），才能加载，柴油机在 高速，大负荷运转时，不得立即停机，应逐渐降低负荷和转速，并空转3~5min，否则会造成增压器轴承损坏并失效。增压器拆卸后，装配时应在进油口加注清洁机油。 注意：应保持增压管路系统及零件的密封性。 Turbocharger： The exhaust gas turbocharger is used for turbocharged and inter-cooled model of WD615 series diesel engine.The turbocharger works at high speed(about 70000~100000r/min), so after starting the engine, run the engine idly for a short time (about 5 minutes, the period can also be shortened in stopping the engine for a short time) before loading.It is forbidden to stop the engine promptly at high speed and on large load.Decrease the speed and load gradually and run the engine in idling for 3~5 minutes before stopping the engine.Otherwise the turbocharger bearing would be worn and lose its effectiveness.Fill clean oil into the inlet port in turbocharger reassembling. Caution:The sealing of the turbocharger line system and its parts .

第八节 、电气系统 Electrical system 火焰预热装置 起动机 Flame preheating unit starter 发电机 generator

电气系统：electrical system 电气系统包括发电机、起动机、水温表传感器、机油压力感应塞、火焰预热装置等 The electrical system includes generator, starter,water temperature gauge sensor,oil pressure induction plug, flame preheating unit etc. 交流发电机： 额定电压为28V，带有晶体管调节器。 发动机皮带张紧力检测：在带与带轮的两切点中心加一个垂直于带的载荷，挠度为3mm，汽车多楔带载荷为：新带43N，正常使用后36N，三角皮带载荷为：新带6N，正常使用后5N。 Alternating generator : The rated voltage of the generator is 28V, transistor regulator is fitted to it. Inspection of tension of engine belt: Taking a vertical load on the center between the belt and the gear’s tangent point, the pressed height is 3mm, the load of truck’s sphenoid belt: the new belt 43N, after intelligent used belt 36N, the load of triangular belt : the new belt 6N, after intelligent used belt 5N.

第三章 WD615系列柴油机运行及保养 Third Chapter Operation and Maintenance of WD615 series Diesel Engine 1.运行注意事项: Precautions 2.保养规则： Maintenance rules

WD615系列柴油机运行及保养 Operation and Maintenance of WD615 series Diesel Engine 1.运行注意事项 柴油机起动前应先检查冷却液面、燃油、机油油面及柴油油面高度是否符合要求。 柴油机起动时，若15s内还没起动，则应隔2min后再重复起动。 柴油机起动后，应先以怠速运行2~3分钟，机油压力应高于100kPa，当冷却水温未高于60°C时切勿突然迅速高速大负荷运行，这将使发动机的耐磨性和可靠性受到影响。 对采用Bosch喷油泵的柴油机，在起动的同时拉动燃油起动加浓装置，当柴油机起动后应该将该装置的手柄复位，通常在热态下发动时可不必使用过量燃油加浓装置。柴油机载磨合期（3000km）以内，只宜在中等负荷以下工作。 柴油机机油面高度检查：必须在停机5min后检查为准。带负荷工作柴油机在停车前，必须先减荷降速，怠速历时不小于5min。

1.Precautions Check the level heights of the coolant, lub-oil and diesel oil whether they conform to the requirements before starting the diesel engine. During starting the engine, if the starting cannot perform in 15s, restarting after 2 minutes. After starting, run idly for about 2~3minutes, and the oil pressure should be above 100kPa. Diesel engine can not run at high speed and on high load suddenly when the cooling water temperature is not more than 60°C, because this would have influence on the wearability and reliability of the diesel engine. For the diesel engine with Bosch pump, while starting the engine,starting fuel thickening device must be pulled. After starting the engine, the handle of the device should be reset. The starting fuel thickening device need not be used during starting in thermal state.Diesel engine works in medium load in running-in period (in 3000 km). Inspection on lub-oil level should be done after stopping the engine for 5 minutes.Before stopping the engine, the load and speed should be decreased and the engine runs at idling speed for 5 minutes at least.

2.燃油 Fuel 夏季：0#柴油 GB252 In summer：0# diesel fuel GB252 冬季：-10#柴油 GB252 In winter： -10# diesel fuel GB252 当环境温度低于-15ºC时，选用-20#柴油；当环境温度低于-30ºC时，选用-35#柴油。 When the ambient temperature is below -15ºC or -30ºC，-20#diesel fuel and –35# diesel fuel should be used separately。 润滑油 Lubricating oil 选用CD级机油。 CD grade oil should be used。 允许用高级别机油替换低级别机油。 Low-grade oil replaced by high-grade oil is permitted。 当环境温度高于-15ºC时选用CD15W/40机油；当环境温度低于-15ºC时选用5W/20机油 CD15W/40 or 5W/20 oil should be used separately when the ambient temperature is above -15ºC or below-15ºC。 在开车前首先检查机油液面，当油面在上限时，机油的容积为20L，机油液面下限为17L Before engine starting，check the oil level in oil sump firstly。When the oil level is at the upper limit，the oil volume is about 20L，and the lower limit is about 17L。

2.保养规则： Maintenance rules 汽车配套三类使用条件 Three operating conditions of the engine used for vehicle WGⅠ WGⅡ WGⅢ 使用条件恶劣（气候严寒或酷热，含尘量高，短距离运输，在工地使用以及公共汽车，市政工程车，扫雪车，消防车）或汽车年行驶里程不到 2万KM 或年工作不到600h. The operating condition is very bad(e.g. cold or hot weather, high dust content, transportation is close distance, used for construction site and bus, municipal engineering vehicle, snow sweeper, fire brigade vehicle), running mileage of the vehicle with this engine is less than or operated time is less than 600h every year 年行驶里程不到 6万KM 的汽车，短中距离运输. Running mileage of the vehicle with this engine is less than every year, namely close, middle distance transportation 年行驶里程超过 6万KM 的汽车远距离运输 Running mileage of the vehicle with this engine is more than every year, namely long distance transportation 2×

The first inspection, period of periodical inspection and maintenance 第一次检查，例行检查和保养的周期 The first inspection, period of periodical inspection and maintenance WG Ⅰ WGⅡ WGⅢ 第一次检查 The first inspection 1000~1500km或30~50h 1000~1500km or 30~50h 1500~2000km时 Running1500~2000km Running 1500~2000km 例行检查 Periodical inspection 每隔5000km或150h Every 5000km or 150h 每隔10000km Every 10000km 每隔15000km Every 15000km 1级保养 Maintenance 1 每隔10000km或300h Every 10000km or 300h 每隔20000km Every 20000km 每隔30000km Every 30000km 2级保养 Maintenance 2 每隔20000km或600h Every 20000km or 600h 每隔40000km Every 40000km 每隔60000km Every 60000km 3级保养 Maintenance 3 每隔40000km或1200h Every 40000km or 1200h 每隔80000km Every 80000km 每隔120000km Every 120000km 4级保养 Maintenance 4 每隔80000km或2400h Every 80000km or 2400h 每隔160000km Every 160000km 每隔240000km Every 240000km

按用油条件要求的机油换油期（随机油的消耗量而不同） The period of renewing the lub-oil in accordance with work conditions(varies from oil consumption)

第四章 常见故障及排除 Trouble Shooting 1.柴油机不能起动。 Failure to start 2.起动不久就停车. Stop soon after staring 3.功率不足 Insufficient output 4.燃油消耗过大 Fuel consumption is too high 5.排气冒黑烟 Black smoke exhaust 6.排气冒白烟、蓝烟 White 、 blue smoke exhaust 7.增压器进气口，进气管附集机油 Lub-oil gathered in air intake port and air intake pipe of turbocharger 8.转速不稳定 Uneven engine speed 9.机油压力过低 Lub-oil pressure is too low

第四章 常见故障及排除 Trouble Shooting 10.冷却水温过高 Cooling water temperature is too high 11.零件磨损过快 parts wore quickly 12.噪音过大 noise is too high 13.柴油机油水混合。the oil mixed with the water 14.柴油机机油消耗量增加。increasing oil consumption 15.柴油机燃油消耗量增加。increasing fuel consumption 16.柴油机窜机油。the oil carry-over 17.柴油机进排气管有油。there is oil in the air inlet and exhaust pipe 18.柴油机工作无力。the diesel engine operates powerlessly 19.柴油机游车。Rough idling of the diesel engine 20.柴油机异响。abnormal noise

常见故障及排除 Trouble shooting 1.柴油机不能起动 Failure to start 故障原因 cause 排除方法 remedy 1.输油泵进油滤网或软管等油路堵塞 Fuel intake filter screen of supply pump or hose clogged 检查清除污物，检查燃油的清洁度 Clear away the dirt and check if the fuel is clean 2.燃油系统内有空气 air entered into the fuel system 排除空气，检查接头密封，修复之 Drain off the air,check the sealing of the connector and repair it 3.喷油泵有故障 Injection pump damaged 检查柱塞、出油阀修理或更换损坏件 Check plunger,fuel outlet valve and repair or replace the broken parts 4.喷油器有故障 Injector damaged 检查喷油器雾化情况，修复之 Check the atomization of injector,and repair it

5.配气或供油初始角不对 Initial angles of valve gear or fuel delivery is wrong 检查并调整之 Check and adjust if 6.高压油管损坏及漏油 High pressure line damaged or leaked 修复与更换 Repair or replace 7.气缸压缩压力不足 Insufficient pressure in cylinder 检查气门密封性，缸垫的密封性，活塞环的磨损，修理或更换 Check the sealing of the valve and cylinder gasket and the wear of the piston ring. Repair or 8.气温过低 The temperature is too low 增加起动辅助设备措施 With the addition of start-assist device

2.起动不久就停车. Stop soon after staring 故障原因 cause 排除方法 remedy 1.燃油滤清器堵塞 Fuel filter clogged 拆卸滤清器体,清除内部污物及水份,必要时更换 Dismantle and clean away dirt and water,replace the filter element if necessary 2.燃油系统内有空气 air entered into the fuel system 检查油管及接头的密封性,放气螺钉是否拧紧,排除残留的空气. Check fuel pipe and sealing of the connector,tighten air venting bolt,and drain off the air 3.输油泵不不工作 Supply pump doesn’t work 检查输油泵活塞 阀们,清理及修复. Check piston and valve of supply pump,clean and repair 4.燃油质量差,含水过多 Poor quality of fuel 清洗滤清器,更换燃油 Clean fuel filter and renew fuel 5.怠速调速过低 Idling speed is too low 重新调整 Readjust it

3.功率不足 Insufficient output 1.进气管堵塞(空滤器堵塞) Air intake clogged(air cleaner clogged) 检查清除污物,检查燃油的清洁度 Check air cleaner and air intake pipe, clean or replace filter element 2.排气背压过高 Exhaust back pressure is too high 检查气门定时,排气管道是否堵塞,调整及修理之 Check the valve-timing and exhaust pipe,adjust and repair 3.增压系统压力不足 Insufficient pressure in supercharging system 检查,排除管路连接处的泄露 Check and block up the leakage of pipeline 4.增压器工作失常 Faults in turbocharger 更换总成 Replace the turbocharger assembly 5.中冷器损坏,漏气 Intercooler damaged 更换或修补 Replace or repair 6.燃油管路漏油或堵塞 Leakage or choke of fuel line 检查油管及接头的密封性,滤清器的污染度及燃油管道,修复或清除污物,更换滤芯 Check the sealing of fuel pipe and connector,fuel filter and fuel line,repair,clean or replace the filter element

7.喷油泵或调速器磨损过大 Excessive wear for injection pump or governor 修理或更换 Repair or replace 8..喷油泵冒烟限制器膜片破损 Smoke-limiter diaphragm of injection pump damaged 更换修理 9.喷油器雾化不良 Poor atomizing 检查喷油压力,喷油嘴积炭,调整及修理之 Check the injecting pressure,clean away the carbon deposit in nozzle,adjust and repair injector 10.配气或供油定时不对 Incorrect timing of valve gear or fuel delivery 检查并调整之 Check and adjust it 11.油底壳机油油面过高 Oil level in the oil sump is too high 检查油尺,放出多余的机油 Check the oil-dipstick,and drain off unnecessary oil

12气缸垫漏气 Leakage in cylinder gaskets 热车时检查压缩压力,更换损坏的气缸垫 Check the compressed pressure at hot state,replace cylinder gaskets 13.活塞环磨损断裂,轴瓦间隙过大 Piston ring broken,the clearance of main bearing is too large 更换磨损零件,或大修发动机 Replace worn parts or overhaul the engine 14.缸套或活塞磨损或拉缸 Cylinder liner or piston worn,or piston scuffing 检查喷油压力,喷油嘴积炭,调整及修理之 Check the injecting pressure,clean away the carbon deposit in nozzle,adjust and repair injector

4.燃油消耗过大 Fuel consumption is too high 1.进气管堵（空滤器堵塞） Air intake clogged(air cleaner choked) 检查空滤器、进气管路、清理之 Check air cleaner and air intake pipe,then clean them 2.排气背压过高 Exhaust back pressure is too high 检查排气管道及制动阀，清理之 Check exhaust pipe and brake valve,then clean them 3.燃油质量差 Poor quality of fuel 按规定更换燃油 Renew the fuel according to requirements 4.燃油管路堵塞 Fuel line choked 检查并修复之 Check and repair 5.燃油管路漏油 Fuel line leaked 6.喷油器雾化不良 Poor atomizing 检查并调整或修复之 Check, adjust and repair

7.配气或供油定时不对 Incorrect timing of valve gear or fuel delivery 按规定调整气门间隙及供油提前角 Adjust valve clearance and injection advance angle according to requirements 8.缸垫漏气 Leakage in cylinder gasket 检查压缩压力 Check compressed pressure 9.轴瓦间隙过大，发动机需大修 The clearance of main bearing shell is too large.Engine need to overhaul 检查及大修 Check and overhaul 10活塞涨缸 Piston scuffing 更换气缸套、活塞及活塞环 Replace cylinder liner, piston and piston ring 11.增压系统压力不足 Insufficient pressure in supercharging system 检查排除管路和连接处泄露 Check and block up the leakage of pipeline 12.增压器工作失常 Faults in turbocharger 检查更换总成 Check and replace 13.中冷器损坏或漏气 Intercooler damaged or leaked 更换或修补 Replace or repair

柴油机排烟是表征燃油情况的重要指标. 排烟不正常说明燃烧有问题 柴油机排烟是表征燃油情况的重要指标.排烟不正常说明燃烧有问题.不正常排烟一般有黑色,蓝色和白色,柴油机冒黑烟说明柴油燃烧不好, 可从空气和燃油两方面查找原因.蓝烟是烧机油,可从机油方面查找原因,白烟分两种情况,持续的灰白烟是燃油中有水,启动时白烟一般是没有燃烧的雾化的柴油微小油滴,柴油机排烟不正常是其他故障的伴随特征, 所以需要根据柴油机运行情况分析判断和解决. Smoke emission is a very important target representing the fuel condition. The abnormal smoke emission indicates that there is problem with the combustion. The colors of the abnormal smoke are usually black, blue and white. Emitting black smoke indicates that the diesel fuel does not burn very well 。Try to locate the reason on air and fuel. Emitting blue smoke suggests oil burning. Look for the reason on the oil. Emitting white smoke can be divided into two categories: continuous gray smoke indicates there is water in the fuel. The white smoke during startup is generally consisted of the tiny diesel fuel particles. The abnormal smoke emission is the incidental phenomenon of other failures. The diagnosis and the removal of relevant failure run through this material.

5.排气冒黑烟 Black smoke exhaust 1.进气堵塞或排气背压高 Air intake is not free or exhaust back pressure is too high 清理之 Clean 2.燃油质量差 Poor quality of fuel 清理及更换 Clean and renew 3.供油或配气定时不对 Incorrect timing of valve gear or fuel supply 按规定调整 Adjust according to requirements 4.喷油嘴雾化不良 Poor atomizing 检查，修复或更换 Check ,repair or replace injector 5.喷油泵油量过多 Excessive injection quantity 检查并调整（由专业厂进行） Check and adjust (by manufacturer)

6.增压器系统压力不足 Insufficient pressure in supercharging system 检查排除管路和连接处漏 Check and block up the leakage of pipeline and connector 7.增压器工作失常 Faults in turbocharger 检查更换总成 Check and replace 8.中冷器损坏或漏气 Intercooler damaged or leaked 更换或修补 Replace or repair 9.冒烟限制器起作用点不对 Incorrect working point of smoke-limiter 重新调整（由专业厂进行） Readjust (by manufacturer)

6.排气冒白烟、蓝烟 White 、 blue smoke exhaust 1.燃油质量差，含水分多 Poor quality of fuel, contains water 更换燃油 Renew fuel 2.冷却水温过低 Temperature of cooling water is too low 检查节温器工作温度，必要时更换 Check working temperature of thermostat, replace if necessary 3.配气或供油定时不对 Incorrect timing of valve gear or fuel delivery 检查并调整 Check and adjust 4.喷油嘴雾化不良 Poor atomizing 检查并修复 Check and repair 5.压缩压力低，燃烧不完全及活塞涨缸 Incomplete combustion, scuffing and the compressed pressure is too low 检查活塞环、气缸套、缸垫，修复之 Check piston ring, cylinder liner, cylinder gasket,and repair them

6.活塞环，缸套未磨合好 Wear-in between the piston rings and cylinder liners is not good 继续磨合 Go on wearing-in 7.活塞环开口未错开 The gaps of the piston rings are not staggered 调整，重新装配 Adjust ,reassembly 8.活塞油环失效 Piston oil rings cease to be in effect 更换 Replace 9.活塞缸套配合间隙过大 The fit clearance between piston and cylinder liner is too large 修理，更换 Repair or replace 10.增压器密封环磨损 The sealing ring of turbocharger worn 检查，更换 Check and replace 11.增压器止推轴承磨损 The thrust bearing of turbocharger worn 12.增压器回油管路堵塞 The oil return pipe of turbocharger choked,clean or repair 清洗或修理 Washing or repair

7.增压器进气口，进气管附集机油 Lub-oil gathered in air intake port and air intake pipe of turbocharger 1.增压器密封环失效 The sealing of turbocharger cease to be in effort 修理或调换增压器 Repair or replace turbocharger 2.油气分离器失效 The gas-oil separator cease to be in effect 调换 Replace 3.油底壳机油面过高，加入机油过多 Lub-oil level in oil sump is too high 检查放出适量机油符合规定 Drain off unnecessary oil according to requirements

8.转速不稳定 Uneven engine speed 1.燃油质量差，含水或蜡质 Poor quality of fuel, mingled with water or wax 清洗燃油系统，更换燃油 Clean fuel system, and renew fuel 2.燃油吸油管漏入空气 Air entered into fuel suction pipe 检查油管 及接头密封性，排除空气 Check the sealing of fuel pipe and connector, drain off air 3.调速器重锤、调速弹簧工作不正常 Faults in flyweight of governor and speed governing spring 检查并修复（由专业厂进行） Check and repair (by manufacturer) 4.供油不均匀 Uneven fuel delivery 检查并调整（由专业厂进行） Check and adjust(by manufacturer) 5.喷油嘴雾化不稳定 Unstable atomizing 检查并修复 Check and repair 6.增压器发生喘振 Surge in turbocharger 检查，清洗压气机流道，排除污塞，清除废气通道积炭。 Check, wash compressor streets, clean away the carbon deposit from exhaust passage 7.增压器轴承损坏 Bearing of turbocharger damaged 更换 Replace it

9.机油压力过低 Lub-oil pressure is too low 1.油底壳油面过低或缺油 Oil level in oil sump is too low 检查油面及是否有漏油处，添加机油 Check oil leakage，add oil 2.主油道限压阀有故障 Faults in pressure regulating valve of main oil passage 检查限压阀，清洗或修复 Check valve，clean and repair 3.集滤器，机油管路，接头垫片等，是否有堵塞或破裂 Strainer，oil pipes，connector gasket choked or broken 检查集滤器，管路接头，油道中是否有铸造疏松，修复 Check strainer and connector，check if 、there is any sponge in oil passage，repair 4.机油牌号不符合规定 Lub-oil doesn’t conform to specifications 按规定更换机油，选用合适牌号机油 Renew the lub-oil according to requirements 5.机油泵进油管漏 Intake pipe of oil pump leaked 检查油管、接头、修复或更换 Check the oil pipe and connector，repair or replace

6.冷却系统水温过高，机油温度过高 Water temperature in cooling system and oil temperature are too high 检查冷却系统工作，纠正之 Check cooling system，and correct it 7.机油滤清器阻力过大 Excessive resistance of oil filter 更换新滤芯 Renew the filter element 8.机油冷却器阻力过大 Oil cooler choked 检查并清理 Check and clean 9.主油道堵塞 Main oil passage choked 10.轴瓦间隙过大，或轴瓦损坏 The clearance of bearing is too large or bearing damaged 检查并更换 Check and replace 11.部件磨损过大，要大修 Excessive wear of parts，need to overhaul 检查发动机工作时间，大修 Check the working time of the engine，overhaul

10.冷却水温过高 Cooling water temperature is too high 1.水箱水面过低 Water level in water tank is too low 检查有无漏水处，加水 Check water leakage, add water 2.水箱堵塞 Water tank clogged 检查水箱，清理或修复 Check or repair 3.水泵皮带松驰 The belt of water pump loosened 按规定调整张紧力 Adjust tension according to requirements 4.水泵垫片损坏，水泵叶轮磨损 Water pump gasket damaged, water pump impeller worn 检查并修复或更换 Check and repair, or replace 5.节温器故障 Faults in thermostat 更换 Replace it 6.水管损坏，漏入空气 Surge in turbocharger 检查水管、接头、垫片等，更换损坏件 Check,wash compressor streets,clean away the carbon deposit from exhaust passage 7.油底壳油面过低或缺油 The oil level in oil sump is too low 检查油面及漏油处，修复并加油 Check oil leakage, repair and add oil

11.零件磨损过快 parts wore quickly Filter element of air cleaner is unqualified or damaged 检查，更换合格滤芯 Check and replace filter element 2.进气系统短路 Air leakage in air intake system 检查进气管、垫片，连接套管，修复或更换 Check air intake pipe, gasket and connecting sleeve, repair or replace 3.油底壳油面过低或缺油 Oil level in oil sum,p is too low 检查油面及漏油处，修复并加油 Check oil leakage, repair and add oil 4.油道堵塞 Oil passage clogged 清理油道 Clean 5.机油牌号不合规定 Oil does not conform to specifications 更换 replace

6.活塞环断裂或磨损 Piston rings broken or won 更换损坏件 Replace 7.缸套或活塞磨损或拉缸 Cylinder liner and piston worn or piston scuffing 拆检活塞及缸套，修复或更换 Dismantle and check piston and liner, repair or replace 8.机油滤清器滤芯没及时更换 Filter element of oil filter can not be replaced in time 按要求更换 Replace it according to specifications 9.部件磨损过大，要大修 Excessive wear of parts, need to overhaul 检查里程数，确定大修 Check the mounting support, replace it 10曲轴与从动件主轴不同心 Crankshaft is not concentric with the shaft of engine follower 检查安装支架，修复 Check the mounting support, repair it 11.使用机油品质不符合要求 Wrong oil grade 采用符合标准规定牌号机油 Adopt correct oil grade

12.噪音过大 noise is too high 1.燃油质量差 Poor quality of fuel 更换燃油 Renew fuel 2.冷却水温过低 Temperature of cooling water is too low 检查节温器，必要时更换 Check thermostat, replace it if necessary 3.配气或供油定时不对 Incorrect timing of valve gear or fuel delivery 检查并修复调整 Check, repair and adjust 4.喷油嘴雾化不良 Poor atomizing 5.喷油泵油量过大 Excessive injection quantity 检查并调整（由专业厂进行） Check and adjust(by manufacturer) 6.减振器损坏 Vibration damper damaged 检查有否损坏，连接螺栓情况，更换损坏件 Check connecting bolt and replace damaged parts

7.气门漏气或调整不当 Leakage in valve or adjusted unsuitably 拆检气门 Dismantle and check valve, readjust it 8.齿轮间隙过大或齿断裂 Excessive injection quantity 检查并更换损坏件 Check and replace damaged parts 9.缸套或活塞磨损或拉缸 Cylinder liner or piston worn, or piston scuffing 检查并修复或更换 Check and repair, or replace 10推杆弯曲或断裂 Push rod bended or broken 更换 Replace it 11.活塞环断裂或磨损 Piston rings broken or worn 检查或更换损坏件 12.轴瓦磨损过大 Excessive wear in main bearing 检查并更换轴瓦 Check and replace 13.曲轴止推间隙过大 Excessive thrust clearance of crankshaft 更换止推片 Replace the thrust ring

14.主轴瓦不同轴心 All main bearings are not concentric 检查并修复 Check and repair 15.曲轴从动件主轴不同轴心 Crankshaft is not concentric with the shaft of engine follower 检查安装支架螺栓，修复 Check the bolts of support and repair 16.部件磨损大，需大修 Excessive wear in parts，need to overhaul 检查里程数，确定大修 Check the mileage and overhaul 17.增压器踹振 Surge in turbocharger 清除压气机气道污塞，及牌气道的积炭 Clean compressor streets，and clean away the carbon deposit from exhaust passage 18.增压器密封环烧结 Sealing ring of turbocharger sintered 更换总成 Replace turbocharger assembly 19.增压器轴承损坏，传动件和固定件碰擦 Turbocharger bearing damaged，moving parts and fixed parts bumped each other 20.增压器涡轮或压气叶轮进入异物 Foreign body entered turbocharger turbine or compressor impeller

13.柴油机油水混合。the oil mixed with the water 1.机油中有水,首先检查空压机气缸盖,如有裂纹需要换相关零部件,检查气缸垫是否冲掉或损坏使冷却水漏入机油中.更换缸垫. 2.冷却水中有油.如果的确是柴油机机油,可按以下步骤检查处理.首先检查机油冷却器是否损坏,可将柴油机内的水放掉,拆下冷却器盖,让柴油机怠速运行10—20秒,若观察到机油冷却器芯子有渗漏或损坏应更换. 1.There is water in the oil. First check the cylinder head and the air compressor. Change the relevant components if there is any crack. Check whether the cylinder gasket is washed off or damaged letting cooling water mix with the oil. Change the gasket. 2.There is oil in the cooling water. If it is indeed the oil, follow these steps: first, check whether the oil cooler is damaged. Drain off the water in the diesel engine, dismantle the cooler lid and let the engine run idly for 10-20 seconds. If there is leakage or damage on the cooler element, change it.

14.柴油机机油消耗量增加。increasing oil consumption 柴油机机油消耗量增多可从机油的非正常损耗上查找原因,首先检查机油牌号是否符合要求或变质,机油有问题要更换机油.检查机油加注量过多应放出. 检查油气分离器及其连接橡胶管如堵塞或太脏应清洗.检查空压机进气管是否堵塞或打折. The reason for that failure can be found on the abnormal oil consumption. First check whether the nameplate of oil conforms to the requirement and whether the oil becomes deteriorating. Change the oil if there is problem with it. Drain some out if oil is too much. Check whether the oil air separator and the connecting rubber pipes are blocked or too dirty. Check whether the air intake pipe of air compressor is blocked or bended.

15.柴油机燃油消耗量增加。increasing fuel consumption 柴油机燃油消耗量增加原因:一是非正常泄漏,二是燃烧不良,柴油机燃烧不良如冒黑烟,工作无力等, 下面仅就非正常泄漏进行分析:检查加注燃油的牌号是否符合要求,检查燃油低压油路及连接管路是否有松脱,检查火焰预热起动系统的电磁阀是否漏油,电磁阀损坏应更换.此外整车工作情况如路面条件,负荷大小,工作环境,车速及操作熟练程度等对燃油消耗量有很大的影响. There are mainly two reasons for this kind of failure: one is abnormal leakage; the other is bad combustion, e.g. emitting black smoke and powerless operation, etc. The following is only the analysis for the abnormal leakage: check whether the grade of the fuel filled conforms to the requirement; check whether the fuel low-pressure pipe and connecting pipeline area loose; check whether the magnet valve of the flame pre-heating starting system has oil leakage (the valve should be changed if it is broken.) Furthermore, the working condition of the vehicle (e.g. road surface condition, load, working environment, speed and operation efficiency of the driver) will have a great influence on the fuel consumption.

16.柴油机窜机油。the oil carry-over 柴油机窜机油一般是从加油口,油尺口或油气分离器口等处喷出机油,原因:一是机油加注量太多,二是曲轴箱内压力太高.排除故障可从这两个方面着手,若机油连续喷出且高速时严重,需检查机油加注量,过多应放出.若间歇喷机油且油气分离器口有少量废气排出,应检查油气分离器及其连接橡胶管是否堵塞或太脏,可清洗干净. The carry-over oil usually comes from the oil filler, oil dipstick port and the oil gas separator. The reason is: one is that the oil is filled too much; the other is that the pressure inside the crankcase is too high. The removal of the failure can be fulfilled in two aspects: if the oil spurts out continuously at high-speed, check the oil quantity. Drain some out if it is too much; if the oil spurts out intermittently accompanied by small amount of exhaust air coming out of the oil air separator. In this case, check whether the oil air separator and the connecting rubber pipes are blocked or too dirty.

17.柴油机进排气管有油。there is oil in the air inlet and exhaust pipe 柴油机的进排气管有油这是非正常泄漏引起的,首先要区分是柴油还是机油,新车有机油一般是油封油,开车后20分钟即可消失.进气管中有柴油:柴油机怠速运转将火焰预热起动系统电磁阀的出油端松开,若有柴油漏出说明电磁阀损坏,应更换.检查各喷油器的雾化情况,柴油机长期低速运行或怠速时间过长,(警告:注意怠速运行不能超过5分钟),在寒冷的冬季也可能出现排气管窜机油,柴油机热车后即可消失. This kind of failure is caused by the abnormal leakage. First determine whether it is diesel fuel or oil. If it is a new engine, that leakage is usually sealing oil that will disappear in 20 minutes after starting. If it is diesel fuel that appears in the air inlet pipe: loose the oil out end of the magnet valve of the flame pre-heating starting system when the engine is in idle operation, if there is diesel fuel leakage, it indicates that the magnet valve is damaged and should be changed. Check the atomization condition of each injector. Longtime low-speed operation of long idle duration (Notice: the idle operation should not exceed 5 minute)also result in oil carry-over in the exhaust pipe that will disappear after the warm-up.

18.柴油机工作无力。the diesel engine operates powerlessly 柴油机运转平稳，排烟少，无高速这种故障是柴油机燃油系统油路不畅，高速时供油量不足所致，首先要检查主机的加速机构，确认柴油机的油门能否到最大油量位置，再检查冒烟限制器空气管是否打折或破损漏气，如破损及时更换。检查燃油系统低压油路是否有空气或堵塞，采用停缸法判断各缸是否正常工作，松开某个缸的高压油管如柴油机转速显著下降则说明该缸工作正常，如柴油机传速变化不大说明该缸工作不正常，可对喷油器或出油阀进行修理或更换，柴油机运不稳工作无力，这种故障多是由某缸或几缸不工作引起的，检查高压油管是否破裂，检查低压管路及柴油滤清器是否堵塞。 The diesel engine runs smoothly with less smoke, but cannot reaches high speed. This kind of failure is caused by the obstructed oil passage of fuel system and inadequate fuel supple at high speed. First check the acceleration mechanisms of the mainframe, make sure that the throttle of diesel engine is at the position of maximum fuel amount and then check whether air pipe of the smoking limiter is folded or damaged. If it is damaged, change it immediately. Check whether the low-pressure fuel pipe has air in it or is clogged. Determine whether the cylinder works normally by the means of “cylinder cut-out”. Loosen the high-pressure fuel pipe of a certain cylinder; if the speed decreases rapidly, it indicates that this cylinder works normally. If the speed changes very little, then this cylinder must be working abnormally. Fix or change the nozzle holder or delivery valve. The powerless and unstable operation of the engine is usually caused by the operation failure of a certain cylinder (or several cylinders). Check whether the high-pressure fuel pipe is broken and whether the low-pressure pipe and diesel filter are clogged.

柴油机无力且冒黑烟，这种故障是燃油没有充分燃烧所致，要从燃油系统和进气系统查找原因。首先检查燃油质量，请加注规定牌号的燃油，再检查空气滤清器是否滤芯太脏以至堵塞，进气管路上各接口是否漏气，排气管路是否堵塞，中冷器是否堵塞或漏气，检查柴油机供油提前角是否在规定范围内，检查气门间隙若不在规定范围内应重新调整，用停缸法判断某缸喷油器是否有故障，如有问题应进行调整或修理，检查增压器是否太脏。 Powerlessness of engine and black smoke result from the incomplete combustion of the fuel. So try to locate the reason on fuel system and intake system. First check the fuel quality (use the specified fuel with certain grade. Then check whether the air filter element is too dirty to be clogged, whether there is air leakage on each joint, whether the exhaust pipe is clogged, whether the inter-cooler is blocked or has leakage and whether the advance angle of fuel delivery is within the specified range. Check the valve clearance, if it is not within the specified range, to make some readjustments. Use “cylinder cut-out” method to determine which injector has problem. Immediately fix the problem if it does exist. Check whether the supercharger is too dirty.

柴油机起动后冒蓝烟提速后冒灰色烟且无力。一般原因是气缸，活塞和活塞环磨损严重或活塞环对口，需检修柴油机活塞，缸套和活塞环。柴油机冒白烟工作无力，柴油机一直冒水汽白烟应考虑柴油中有水或气缸垫冲裂的可能性，若柴油机起动后冒白烟提速后冒黑烟且工作无力，应考虑气缸压缩压力不足。 The diesel engine emits blue smoke after getting started and then gray smoke after acceleration and works powerlessly. This kind of failure is usually caused by the severe abrasion of the piston and piston ring or the piston rings in alignment. Check and overhaul the piston, cylinder liner and piston ring. If the engine continuously emits white smoke and water vapor, consider the possibility that there is water in the diesel fuel or the head gasket is broken. If the engine emits white smoke after starting then black smoke after acceleration and the engine works powerlessly, the compressing pressure of the cylinder might be inadequate.

19.柴油机游车。Rough idling of the diesel engine 柴油机在运行过程中转速在较大范围内周期性忽快忽慢,这种故障是供油系统不能准确，定时定量供油引起的。检查低压管路部分是否有空气，再检查调速器内部机油是否过多，回油管回油不及时请及时更换。 The speed of diesel engine varies rapidly over large range during operation. This kind of failure is caused by the incapability of the engine to make accurate timing and quantitative fuel delivery. Check whether there is air in the low-pressure pipeline and then check whether the oil inside the governor is too much. The oil return pipe should be changed if the oil return is not timely.

20.柴油机异响。abnormal noise 1、首先检查柴油牌号。 2、再检检查柴油机供油提前角是否在规定范围内。 3、用停缸法判断喷油器故障，可将怀疑的喷油器与其他缸喷油器对调，若预想跟随转移证明喷油器由故障，应修理或更换。用听诊法初步确定异响的部位,根据声音的特征可进一步分析，检查和排除故障。 1、Check the grade of the diesel fuel 2、Recheck whether the advance angle of the fuel delivery is within the specified range. 3、Locate the injector failure with “cylinder cut-out” method. Exchange the suspicious injector with other injector. If the noise diverts following the changing of the interchange of the injector, change or fix the suspicious injector preliminarily locate the position of abnormal noise with aural method then carry on with further analysis, check and removal of the problem.

异响在气缸盖部位，检查气门弹簧，摇臂与摇臂轴之间间隙，气门弹簧断裂一般发出嚓嚓的杂乱声音，观察摇臂是否有粘连现象，必要时应更换，柴油机发出嗒嗒有节奏的声响，低速时明显，应检查调整气门间隙。明显杂音伴随大量黑烟，应怀疑是气门座圈或气门破裂。 If the noise is at the cylinder head, check the clearance among the valve spring, rocker arm and rocker arm shaft. The valve spring will give out a “Cha-Cha” noise if it is fractured. Observe the rocker arm to see whether there is conglutination, change it if necessary. If the engine sends out a rhythmic rattling sound (very distinct at low speed), the valve clearance should be checked and adjusted. If there is obvious noise accompanied with large amount of black smoke, the valve seat ring or the valve might be fracture。

异响在气缸体部位，柴油机发出当当的敲缸声音，冷车时明显，是活塞敲缸。可用停缸法判断发出异响的气缸，然后进性检查分析。冬季柴油机刚起动时有时也会发出敲缸声，待温度升高后会自行消失，一般不必理会。增压器发出异响，柴油机运行较长时间后增压器压气机壳和涡轮壳太脏，流道堵塞，增压器发出尖锐的声音，应注意进行清理和保养。若轴承，压气机叶轮或涡轮有损坏应进行修理更换。 If the abnormal noise comes from the cylinder block and the engine sends out clang sound, that is piston knocking. Determine which cylinder sends out the noise with “cylinder cut-out” method then conduct analysis. In winter, the engine will send out piston knocking noise during starting process, which will disappear after temperature rises. If the noise comes from the supercharger, which is because the compressor housing and turbine housing are so dirty that the flow passage is blocked, so keep on with maintenance and clearance. If it is the bearing that sends out the noise, the compressor blade or the turbine is damaged and should be changed or fixed.

空压机部位有异响，可按以下步骤检查：首先检查空压机缸盖螺栓或空压机固定螺栓，如果松动应拧紧，空压机进排气阀片松脱，发出叭叭声，拆开空压机气缸盖进行维修。 If the abnormal noise comes from the compressor, it should be checked in accordance with the following steps: first, check the cylinder head bolt and the fastening bolt of the compressor (if they are loose, fasten them). If the intake and exhaust valve plate of the compressor falls off and sends out the sound of “ba.ba”, dismantle the cylinder head of the compressor and fix it.

第五章 附录 Addendum 1.柴油机主要零件的配合间隙及磨损极限 Fit clearance and wear limits of main parts 2.柴油机主要螺栓螺母扭紧力矩和扭紧方法。 Tightening torque and Tightening method of Main bolts and nuts

1.柴油机主要零件的配合间隙及磨损极限 Fit clearance and wear limits of main parts Unit: mm No. Item Theoretic value Wear limit 1 曲轴轴向间隙 Crankshaft axial clearance 0.052~0.255 0.35 2 主轴承间隙 Main bearing clearance 0.095~0.163 0.17 3 连杆轴承间隙 Connecting rod bearing clearance 0.059~0.127 0.16 4 连杆大端面与曲轴间隙 Clearance between connecting rod big end and crankshaft 0.15~0.35 5 活塞群部冷态最小间隙 Min. clearance of piston skirt at cold state 0.143~0.182 0.35~0.4 6 连杆小头衬套与活塞销间隙 Clearance between piston pin and connecting rod small end bushing 0.045~0.066 0.1

No. Item Theoretic value Wear limit 7 进气阀杆与导管孔间隙 Clearance between inlet valve stem and valve guide 0.05~0.086 0.15 8 排气阀杆与导管孔间隙 Clearance between exhaust valve stem and valve guide 0.03~0.066 0.10 9 气阀底面凹入缸头平面值 Height between valve bottom face and cylinder head face 1.2~1.4 1.8 10 油嘴高出缸头平面值 Height of nozzle above cylinder block upper face 3.2~4.0 11 缸套高出机体上平面值 Height of cylinder liner above cylinder block upper face 0.05~0.10 12 凸轮轴轴向间隙 Camshaft axial clearance 0.1~0.4 13 凸轮轴轴承间隙 Camshaft bearing clearance 0.04~0.12 14 冷态气门间隙进/排 Clearance between piston crown and the bottom of the cylinder head 0.3/0.4

No. Item Theoretic value Wear limit 15 活塞环冷态开口间隙 Placket clearance piston ring at cold state 第一环 1st ring 0.4~0.6 1~1.2 第二环 2nd ring 0.25~0.4 第三环 3rd ring 0.35~0.55 16 活塞环冷态端面间隙 End clearance of piston ring at cold state 0.07~0.12 0.28 0.05~0.085 0.26 17 摇臂与摇臂轴间隙 Clearance between rocker shaft and rocker 0.04~0.119 18 齿轮侧隙 Gear side clearance 0.15~0.33

Tightening torque （N·m）+further turned angle （°） 2.柴油机主要螺栓螺母扭紧力矩和扭紧方法。Tightening torque and Tightening method of Main bolts and nuts No. Item 扭紧力矩（N·m）+再转角度（°） Tightening torque （N·m）+further turned angle （°） 允许重复使用次数 Allowable times 1 主轴承螺栓 M18 Main bearing bolts M18 2 连杆螺栓 M14x1.5 Connecting rod bolts M14x1.5 120+90 ° 同时达到170~250 （Reached to 170~250Nm simultaneously） 3 气缸盖主螺栓 M16 Main bolts of cylinder head M16 200+90 ° 同时达到260~380 （ Reached to 260~380Nm simultaneously） 4 气缸盖副螺母 M12 Secondary nuts of cylinder head 90 +90 ° 同时达到120~160Nm （ Reached to 120~160Nm simultaneously） 5 飞轮螺栓 M14x1.5 Flywheel bolts M14x1.5 60+2*60 ° 同时达到230~280Nm （ Reached to 230~280Nm simultaneously） 6 飞轮壳螺栓 M12 Flywheel housing bolts M12 40+2*60 ° 同时达到110~140Nm （ Reached to 110~140Nm simultaneously）

Tightening torque （N·m）+further turned angle （°） No. Item 扭紧力矩（N·m）+再转角度（°） Tightening torque （N·m）+further turned angle （°） 允许重复使用次数 Allowable times 7 机油泵惰轮轴螺栓 M10 Bolts for oil pump intermediate gear shaft M10 8 凸轮轴齿轮螺栓 M8 Camshaft gear bolts M8 32 9 正时惰轮轴螺栓 M10 230-280NM+60 ° 同时达到100~125Nm （ Reached to 230~280Nmsimultaneously） 10 喷油器压板螺母 M8 Nuts for injector plate M8 50NM 11 排气管螺栓 M10 Bolts for exhaust manifold M10 12 摇臂座螺栓 M12 Bolts for rocker bracket M12

Tightening torque （N·m）+further turned angle （°） No. Item 扭紧力矩（N·m）+再转角度（°） Tightening torque （N·m）+further turned angle （°） 允许重复使用次数 Allowable times 13 空压机齿轮压紧螺母 M18x1.5 Nuts for compressor gear M18x1.5 200 14 喷油泵齿轮压紧螺母 M18x1.5 Nuts for injection pump gear 300 15 张紧轮紧固螺栓 M16 Bolts for tension pulley M16 195 16 角度调节板拉紧螺栓 Tightening bolts for angle adjusting plate M12 M14x1.5 17 弹性联轴器连接螺栓 Connecting bolts for spring connecting plate of coupler M10 74 110

1、缸体与曲轴箱连接后首先将14根M18×2.5的主轴承螺栓按要求扭紧，然后将22个M8×25的内六角圆柱螺栓、两个M8×110小六角头螺栓紧固。在缸体左侧有3个12m6×2的圆柱销定位。主轴承螺栓的扭紧方法按下图顺序先扭紧50Nm，再按顺序扭紧到250 Nm。 1、After the cylinder block join up with the crankcase,screw up the main bearing bolts(14 piece M18*2.5) and then screw up the internal hexagon bolts(22 piece M8*25) and small hexagon bolts (2 piece M8*110).There are 3 orientation pin (12m6*2) set in the left side of the cylinder block. The tightening sequence for main bearing bolts see fig.1.Pre-tighten up to 50Nm,and then tighten up to 250 +25 图1 主轴承螺栓扭紧次序

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