Weichai R6160 Series Diesel Engine Shop Manual
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
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.
R6160系列柴油机维修保养手册
– –
Maintenace Manual For R6160 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.
4．柴油机的安装工作
Installation of Diesel Engine
机舱（机房）要求
Engine Room Requirements
管系要求
Piping Requirements
柴油机的起吊要求
Diesel Engine Lifting Requirements
柴油机的对中要求
Diesel Engine Alignment Requirements
机舱（机房）要求
Engine Room Requirements
机舱（机房）必须通风以散发发动机工作时产生的热量，避免机舱内温度过高。安装发动机时，
上方要留有足够的空间用于活塞连杆的拆卸，所需高度从曲轴中心算起，必须大于1.4m，前方需
留出不小于1.6m 的距离以抽出凸轮轴（从机体前端面算起）。
Engine room must be well ventilated so that it can radiate the heat produced while engine running in
order to prevent over-temperature in the room. When installing your engine, sufficient space must be
kept above the engine for removal and assembly of piston and connecting rod. The height required must
be more than 1.4m from the crankshaft centerline. A distance of at least 1.6m (from the front of the
engine block) must be kept in front of the engine to allow the pulling out of the camshaft.
管系要求
Piping Requirements
（1）排气管应通到室外，其内径不得小于140mm，排气出口应有防雨防浪装置。排气管与增压
器不可刚性连接，中间必须装有膨胀管（随机配带）或其它形式的伸缩管。
The exhaust pipe should run out of the room. The inner diameter of the pipe must not be less than
140mm. The exhaust outlet shall be protected with rain-proof and/or wave-proof devices. No rigid
connection is allowed between exhaust pipe and supercharger, expansion pipe (provided with the engine
– –
R6160系列柴油机维修保养手册
Maintenace Manual For R6160 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. The inner diameter of fuel inlet pipe should
be more than 10mm.
（3）陆用开式循环冷却柴油机应使用冷却水池或冷却塔，冷却水池的容量应小于25m3，水泵的
吸水高度应小于25m3；
For land engine cooled with open circulation, water pool or tower with capacity of less than 25m3 should
be used. The suction head of water pump should be less than 2m.
（4）船用柴油机如果不配海淡水热交换器，用户需自配海淡水热交换器，禁止用海水直接冷却
柴油机
For marine engine without seawater/fresh water heat exchanger, the heat exchanger should be provided
by user. It is forbidden to cool the engine with seawater directly.
柴油机的起吊
Diesel Engine Alignment Requirements
柴油机在机体前后端各有一个起吊用的起重把，起吊应平稳，避免出现震荡、摇晃等现象。起
吊时允许有较小角度的倾斜，严禁倾斜角度过大，以免对柴油机内部结构造成相对位移。
柴油机的对中要求
Diesel Engine Alignment Requirements
柴油机作船舶主机安装时，柴油机曲轴和驱动设备必须对中。对中时用百分表来测量发动机
和被驱动装置的同轴度和端面跳动。如果是刚性连接，其同轴度应小于φ0.08mm，如果是弹性连
接，其同轴度和端面跳动均应小于0.2mm，若测得结果超出上述范围，必须进行调整。一般用不同
厚度的钢片进行调整，调整到规定数后，打上定位销以定位。
During installation of marine engine, the crankshaft of diesel engine and driven device must be well
aligned. Measure the coaxiality and face runout of the engine and driven device with a dial gauge
when making alignment. Coaxiality for rigid coupling should be less than 0.08mm, however for elastic
coupling, both coaxiality and face runout should be less than 0.2mm. Otherwise, carry out adjustment
with steel shims of different thickness, and secure with locating pins upon the completion of the
adjustment.
柴油机与发电机或动力输出装置必须采用弹性连接，采用弹性连轴结，其同轴度及端面的平
行度应小于0.15mm。
R6160系列柴油机维修保养手册
– –
Maintenace Manual For R6160 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
Check before Start
旋开柴油滤清器的放污螺塞，放出燃油系统内的油封油料。
Unscrew the screw plug of diesel fuel filter to drain the preservative oil from fuel system.
将柴油机的开车手柄置于停车位置，并旋开气缸盖上的放气螺塞，然后盘动飞轮以驱尽气缸
内油封燃料。
Set starting lever of your engine to STOP position, unscrew the bleeding screw on cylinder head, and turn
flywheel to completely drain the fuel for oil sealing from cylinders.
如在寒冷季节，需取下气缸盖罩壳，用加热至100 ～ 120℃的机油浇入气缸盖上的各运动部件，
使其防锈油料融化。
In cold season, it is necessary to remove cylinder head cover and pour engine oil heated to 100-120℃
onto moving parts on cylinder head to melt the antirust oil.
运行前必须检查所有的管路和螺纹接头、软管接头是否已经拧紧并处于完好状态。检查油门
控制和停车拉杆运动灵活性，监控和停车装置的功能以及线路状态。
Check before operation all pipelines, screwed connections and hose couplings for tightness and they
must be in good condition. Make sure that throttle control and shutdown control lever can move freely,
monitoring and shutdown devices can function properly, and circuits are in good condition.
向柴油机冷却系统内灌入冷却水。
Fill cooling water into cooling system of the engine.
加机油。对静止的发动机，由加油口向油底壳内加机油。直到油面达到油尺的上方标记。然后
用手压泵向管路系统和各润点供油至油压在0.05MPa 以上。（带电动预供油泵的机型在开车前自
行供油）。
Add engine oil. Add engine oil to your engine at stop state through oil filler into oil sump until oil level
reaches the upper mark of dipstick. After that, prime oil with hand pump to pipeline system and various
lubricating points (oil pressure: ≥0.05MPa). For engine with electric primary pump, the oil is supplied
automatically by the pump before starting.
在自备燃油箱内加注规定牌号的清洁柴油，并用手压输油泵向燃油系统内供油，同时，将柴油
滤清器顶部放气螺塞、喷油泵上部两放气螺钉和喷油器上的放气螺杆旋开放气，直至开始溢油并无
– –
R6160系列柴油机维修保养手册
Maintenace Manual For R6160 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. Then
tighten them up.
采用气马达起动时，应先向起动空气瓶内充气，直至瓶内压力在1.5MPa 以上。
When pneumatic motor is used for starting, charge the air bottle to above 1.5MPa firstly.
采用电力起动时，应先向起动蓄电池充电，保证蓄电池电压不低于24V。
For the electric started engine, charge the battery firstly, and the voltage should not be less than 24V.
6．柴油机的起动
Engine Start
采用气马达起动时
Start with pneumatic motor:
将开车把手置于开车位置，首先旋开起动空气瓶上的控制小阀和中央大阀，然后再打开气马
达的开关阀，柴油机将能立即起动。起动后应立即关闭气马达的开关阀，并立即将空气瓶上各阀依
次关闭。
Open the control valve and central gate valve on starting air bottle, then open the switch valve of
pneumatic motor and the engine will be started immediately. Close the switch valve of the motor
immediately after the engine is started, and then close all valves on the air bottle.
如果气马达齿轮未旋出，关闭阀门，检查气马达；如果飞轮转动，但在三秒内未能起动，应立
即关闭阀门，停止喷油，并查找原因。
If the gear of pneumatic motor is not screw out, close the valve and check the motor. If the engine is not
started in 3s with the flywheel rotating, close the valves immediately and stop injecting and find out the
reason.
采用电马达起动时
Start with electric motor:
将开车把手置于开车位置，首先接通蓄电池开关，插入电路钥匙打开，然后按下起动按钮，柴
油机应能立即起动，起动后，应立即释放按钮，使起动电路迅速断开，并关闭电钥匙，断开开关。
起动时间不能大于5 秒，若一次未能起动，再起动时应停2 分钟。
Set up the start handle at the starting position. Turn on battery switch, insert the electric circuit key, press
start button, the engine should be started. After the engine is started, release the button immediately to
open the starting circuit and close the key switch. The starting time should not be more than 5 seconds. If
your engine can’t be started at one time, wait at least 2 minutes before trying again.
R6160系列柴油机维修保养手册
– –
Maintenace Manual For R6160 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.
7．柴油机的运转
Engine Running
柴油机全负荷运转后，应先卸去负荷，逐渐降至怠速，待水温降至60℃以下时再停车。严禁在
水温过高时骤然停车。凡是突然停机，应立即盘车3 ～ 5 圈，避免活塞与缸套之间出现抱缸现象。
If your engine runs with full load, unload it and reduce speed gradually down to idle speed, do not
shutdown your engine until water cools down to below 60℃. Never shutdown your engine abruptly when
water temperature is too high. If the engine is stopped suddenly, rotate the crankshaft of the engine about
3-5 revolutions to avoid piston seizure.
经常注意机油压力和循环水温度，以免因控制系统失灵而造成事故。
Constantly pay attention to oil pressure and circulating water temperature so as not to cause any accident
due to control system failure.
经常注意油耗变化和排气烟色，以鉴别喷油器的工作性能和使用负荷的变化情况。
Constantly pay attention to variation of fuel consumption and exhaust smoke color to verify performance
of fuel injector and applied load.
注意柴油机在正常负荷下工作，避免柴油机超负荷工作。
Make sure that your engine runs with normal load. Never overload operation.
在寒冷季节（气温0℃以下）停车后，应将冷却水放尽，以免冻裂柴油机机体、气缸盖等零部件。
放水应在停车半小时后进行，切不可停车后立即放水，否则，各摩擦表面温度很高，会将其间储存
的少量机油蒸发掉，造成再起动困难及不正常磨损，甚至能使活塞胀死在气缸内。
In cold season (air temperature below 0℃), drain cooling water completely to prevent frost crack of
engine block and cylinder head 30 minutes after shutdown. Never drain cooling water immediately after
shutdown, or the oil on the friction surfaces will be transpired and cause difficult starting and abnormal
wear.
注意：柴油机停车后，不得立即打开热交换器加水盖，以免被水蒸气灼伤。
Caution: Do not open water filler cap of heat exchanger immediately after the engine is
shutdown, so as to prevent being burned by hot vapor.
FILE DETAILS:
LANGUAGE:ENGLISH & CHINESE
PAGES:92
DOWNLOADABLE:YES
FILE TYPE:PDF
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
