G 系列 V 型柴油机 使用保养说明书 Operation and Maintenance Manual G Series V Type Diesel Engine 上海柴油机股份有限公司 Shanghai Diesel Engine Co., Ltd 年 2 月 February of

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2 G 系列 V 型柴油机 使用保养说明书 Operation and Maintenance Manual G Series V Type Diesel Engine 上海柴油机股份有限公司 Shanghai Diesel Engine Co., Ltd 年 2 月 February of 2014

3 告诫 为降低人员受伤和财产损失的可能性, 降低柴油机性能恶化及柴油机早期磨损或损坏的可能性, 请务必认真遵守本手册中所给出的安全须知和操作规范, 尤其是操作警告和注意事项 本手册中给出的警告部分内容必须严格遵循, 否则会引起烧伤 截肢 致残 窒息 其他人身伤害或死亡的可能 ; 注意部分内容是提醒操作者必须按正确的方法操作, 以避免柴油机零部件损坏或柴油机性能恶化 这些 警告 和 注意 并不周全, 上海柴油机股份有限公司不可能, 也不能给出违反这些安全须知和操作规范而产生的所有潜在的危险后果 产品报修 技术咨询 投诉与建议 产品报修 技术咨询 投诉与建议, 请与上柴 易 + 人 呼叫中心联系, 小 时为您提供快捷 专业 真情的服务 全国免费服务热线 产品报修, 请务必提供如下信息 : 柴油机型号柴油机订货号柴油机机号设备采购日期较详细的故障描述联系人地址与电话

4 目录 1 引言 致用户和操作者 用户反映产品质量情况须知 产品售后服务承诺 安全须知 柴油机使用注意事项 柴油机概况 柴油机外形图 柴油机的型号识别 柴油机铭牌 柴油机技术规格 柴油机的安装和连接 柴油机安装 柴油机连接 柴油机使用 燃油 机油 冷却液 柴油机与工作机械功率的匹配 柴油机起动 柴油机运行 柴油机停车 新柴油机或大修后柴油机的磨合 柴油机保养 柴油机保养计划 柴油机保养记录 柴油机保养内容及方法 柴油机故障排除指南 概述 柴油机故障排除 柴油机停运后保存 短期停运保存 长期停运保存... 32

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6 SC27G 型柴油机使用保养说明书 1 引言 1.1 致用户和操作者感谢您选择使用上海柴油机股份有限公司的柴油机产品! G 系列 V 型柴油机有 25 升和 27 升 2 种排量, 是在 12V135A 型机和 12V135B 型机的基础上进行改进的电站用柴油机 ; 在原机基础上提升了功率 增强了柴油机的冷却和润滑能力, 同时解决原机存在的质量问题 G 系列 V 型柴油机动力更强劲 燃油耗和排放更低 可靠性更高 ; 而外形尺寸与 12V135 柴油机基本相同, 有较大的通用性和互换性, 是大功率电站机组的理想配套动力 本手册主要叙述 G 系列 V 型柴油机的技术规格 使用和保养注意事项, 以帮助用户熟悉本产品并正确使用和保养本产品 用户在使用柴油机前应认真阅读本手册中的有关内容和要求 由于产品性能和结构在不断改进, 本手册中所列技术规格和图例说明与您在使用中的实物可能略有不同, 我公司在今后再版时会不断予以补充完善, 不再专门通知用户, 谨请注意 在本产品的使用保养中, 如有任何疑问请随时联系上柴 易 + 人 呼叫中心 ( ), 以获得技术咨询或技术指导 上海柴油机股份有限公司 ( 上柴公司 ) 的产品采用最新技术和高质量零部件 维修保养时, 建议使用上柴公司品牌的服务备件 上柴公司授权的维修站遍布全国各地, 提供维修服务和备件供应, 维修人员经过专业培训 如柴油机转让或出售, 本说明书应跟随柴油机转交给新的用户 1.2 用户反映产品质量情况须知为便于我公司了解和分析产品质量问题及其产生故障的原因, 及时改进产品质量, 更好地为用户服务, 谨请用户在反映产品质量时说明下列事项 : 1) 发生故障的时间和地点 ; 2) 柴油机出厂编号 ( 机号 ) 型号 订货号 发货日期 收货者确切地址; 3) 柴油机使用条件 工作累计时间 ( 小时数 ) 工作状态( 功率 转速 ) 使用的燃油和机油牌号; 4) 被驱动设备的特性 ( 型号 消耗功率 结构特点等 ); 5) 故障现象描述 ; 6) 要求赔偿或检修的零件或部件, 应随同损坏过程记录或说明寄到或带到本公司, 以便进行分析 如用户发现问题较多或问题特别严重时, 应保持现场, 并及时告知, 我公司派员共同分析之 对柴油机质量问题的处理按照质量保修手册有关规定 1.3 产品售后服务承诺为做好产品售后的服务工作, 减小因产品出现质量问题给用户造成损失, 上柴公司建立了 24 小时报修处理制度 用户在全国范围内拨打 电话, 均可得到上柴公司及时 专业的咨询和售后服务 1.4 安全须知 在柴油机或其驱动装置周围工作时不要穿着肥大的衣服并摘掉所有饰物 必要时, 戴上防护眼镜, 穿工作服, 戴安全帽或其他保护用品 为防止人身事故, 所有外露的旋转部件都要有防护装置, 并安装牢固 柴油机工作室应通风良好, 柴油机废气应排到室外 不得将易燃液体存放在柴油机附近 起动前, 从柴油机上拿走所有的工具 电线及其他零星物品 在调整柴油机及其驱动装置之前务必停止柴油机运转 在加注燃油时不准吸烟, 燃油蒸汽容易燃烧 在检查蓄电池电解液液面时不准吸烟, 蓄电池会放出易燃气体 电解液是一种酸 在补充蓄电池电解液时, 必须防止电解液与皮肤或眼睛接触 一旦接触皮肤, 应尽快用肥皂和清水冲洗皮肤, 如进入眼睛, 应立即用大量清水冲洗眼睛 15 分钟, 并且立即到医院就诊 1

7 SC27G 型柴油机使用保养说明书 在加注冷却液时应小心防止蒸汽伤人 应先冷却柴油机, 只有在冷却液温度低于 50 时才可慢慢拧松压力盖, 使冷却系统卸压, 然后进行添加 把溢出的润滑油 燃油 冷却液或其它液体擦干净 将有油的抹布存放在防火容器中, 不得将有油的抹布放在柴油机上 在起动刚修复的柴油机时, 要做好切断空气供给的准备 一旦柴油机起动后发生飞车现象时, 立即断气停止柴油机 不得利用风扇部位盘动柴油机曲轴, 否则会造成严重的人身伤害或风扇叶片损坏 柴油机运转时, 进 排气系统温度较高, 不可用手触摸排气管 增压器 中冷却器进气管 膨胀水箱等高温零部件 在拆卸或松开任何管路 固定接头 接口或有关零部件之前, 要先释放这些零部件所属系统的压力, 如空气系统 冷却系统 润滑系统或燃油系统中的压力 不得用手检查泄漏 高温高压燃油 机油和冷却液会伤害人体 当柴油机长期停车不用时或在维修时, 应拆除柴油机与蓄电池的连接导线, 以防止柴油机意外起动 同时要在操作室或控制部位挂上 停止运转 的标志 使用过的机油可能含有致癌成分, 且能引起再生毒性 要避免吸入机油蒸汽或长时间与其接触 用适当安全可靠的方法处理废油 1.5 柴油机使用注意事项 认真阅读本手册, 严格遵守本手册中规定的操作步骤及保养规程 应严格遵守本手册规定, 进行日常维护和四级保养, 并做好定期保养记录 应按本手册规定, 使用恰当的燃油 机油和冷却液 对新机或大修后的柴油机, 使用前须经 60 小磨合运行 磨合要求见 4.8 章节 不允许在不带空气滤清器的情况下运行柴油机, 以免柴油机发生早期磨损 柴油机的冷却系统在任何气候下都应采用本手册规定的冷却液 在加注机油时, 不同规格的机油不得混用 起动柴油机前, 应做好 起动前的准备 工作, 切记柴油机必须空载起动 起动柴油机前, 必须检查冷却液 机油 燃油是否足够 严禁燃油箱内柴油很少的情况下运行柴油机, 应及时补充燃油箱内柴油, 否则容易造成喷油泵损坏 柴油机运行时, 应经常观察其运行状态和所有仪表的显示值 如遇紧急情况应采取紧急停车措施, 防止因缺冷却液过热或机油压力过低而使柴油机运动件咬合 当冷却液温度低于 60 时, 严禁柴油机高速高负荷运行 检查胶带张力及其它驱动装置时, 柴油机应处于停车状态 如调温器失灵应及时换新, 不得随意拆除不用 柴油机上凡有铅封之处, 用户不得随意拆除自行调节, 如有必要应送专门部门修理或调整 2

8 SC27G 型柴油机使用保养说明书 2 柴油机概况 2.1 柴油机外形图 柴油机左侧 ( 从飞轮端看 ) 1: 飞轮壳 2: 油底壳 3: 起动电机 4: 放油螺塞 5: 油温传感器接头 ( 左 ) 6: 机油滤清器 ( 左 ) 7: 主油道调压阀 ( 左 ) 8: 放水阀 ( 左 ) 9: 机油冷却器 ( 左 ) 10: 油气分离器出气管 11: 油气分离器回油管 12: 前支架 13: 铭牌 14: 水泵 ( 左 ) 15: 风扇 16: 发电机 17: 调温器出水口 ( 左 ) 18: 油气分离器 19: 进气接管 20: 进气总管 21: 排气隔热罩 ( 左 ) 22: 空气滤清器 ( 左 ) 23: 气缸盖罩壳 ( 左 ) 24: 排气管 ( 左 ) 25: 增压器 ( 左 ) 3

9 SC27G 型柴油机使用保养说明书 柴油机右侧 ( 从飞轮端看 ) 26: 水泵 ( 右 ) 27: 燃油粗滤器 28: 前支架 29: 燃油精滤器 30: 放水阀 ( 右 ) 31: 机油冷却器 ( 右 ) 32: 主油道调压阀 ( 右 ) 33: 机油滤清器 ( 右 ) 34: 油温传感器接头 ( 右 )35: 油尺 36: 加油口 37: 增压器 ( 右 ) 38: 排气管 ( 右 ) 39: 气缸盖罩壳 ( 右 ) 40: 空滤器 ( 右 ) 41: 进气总管 42: 排气管隔热罩 ( 右 ) 43: 水温传感器接头 44: 调温器出水口 ( 右 ) 4

10 SC27G 型柴油机使用保养说明书 柴油机后端 45: 高压油管 46: 进气管 47: 输油泵出油管 48: 增压器进油管 ( 右 ) 49 增压器回油管 ( 右 ) 50: 后吊环 51: 转速传感器接头 52: 喷油泵机油进油管 53: 增压器回油管 ( 左 ) 54: 增压器进油管 ( 左 ) 55: 喷油泵总成 5

11 SC27G 型柴油机使用保养说明书 2.2 柴油机的型号识别 柴油机型号表示下列含义 : SC XX G 柴油机排放, 如 2 代表国家 Ⅱ 阶段 ( 非道路 ) 用途 :D 发电用 柴油机功率 ( 马力 ) 发动机系列 柴油机排量 (L) 上柴动力 例 :SC25G690D2 代表上柴 G 系列 25 升 690 马力符合国家 Ⅱ 阶段 ( 非道路 ) 排放标准的电站用柴油机 SC27G830D2 代表上柴 G 系列 27 升 830 马力符合国家 Ⅱ 阶段 ( 非道路 ) 排放标准的电站用柴油机 2.3 柴油机铭牌柴油机铭牌标明了您所购买的柴油机主要技术数据和信息 : 型号 订货号 机号 出厂日期 功率 标定转速, 是用户购买维修零件和我公司进行售后技术服务的主要依据 希望用户将这些信息和数据记录到您的柴油机或所配设备的工作日志中 在日后联系维修和反映质量问题时, 及时提供这些信息, 有助于正确解决您所要反映的问题 请保护好铭牌不受损坏 铭牌位于柴油机前齿轮室侧面 注意 : 未经我公司许可, 用户不得随意更换柴油机铭牌! 6

12 SC27G 型柴油机使用保养说明书 2.4 柴油机技术规格 主要技术规格和性能参数 机型 SC25G690D2 SC27G830D2 型式 吸气方式 12 缸 V 型 水冷 四冲程 直喷 废气涡轮增压 + 空空中冷 缸径 /mm 冲程 /mm 排量 /L 压缩比 16:1 16:1 起动温度 / -5( 不加辅助措施 ) -5( 不加辅助措施 ) 曲轴转向 ( 面向输出端 ) 逆时针 逆时针 发火次序 ( 从前端算起 ) ( 左侧气缸排列 : ;( 右侧气缸排列 : ) 标定工况 超负荷工况 功率 /kw 转速 /r/min 功率 /kw/ 505±2% 610±2% 转速 (r/min) 排放 /(g/kwh) 国家 Ⅱ 阶段 ( 非道路 ) 国家 Ⅱ 阶段 ( 非道路 ) 起动方式 电起动 电起动 允许海拔 /m 净重 /kg 2 200±50( 不包括散热器 ) 2 200±50( 不包括散热器 ) 长 /mm 外形尺寸 宽 /mm 高 /mm 注 :1) 表格中的性能参数系基本型柴油机在标准环境状况下运行的性能参数, 各柴油机的具体性能数值以柴油机铭牌上的数据为准 标准环境状况是指 : 环境温度 25 相对湿度 30%, 大气压力 100 kpa 2) 发动机在超过规定的高原 (2 000 米 ) 上运行, 输出功率将变小, 性能将变差, 必须降低功率运行 不建议在 m 以上使用 7

13 SC27G 型柴油机使用保养说明书 主要技术参数 机型 SC25G690D2 SC27G830D2 排气温度 ( 涡轮前 )/( 700 油底壳机油最高允许 115 温度 / 适宜范围 90~110 主油道机油标定转速 0.25 压力 /MPa 怠速 0.10( 机油温度 75 时 ) 油底壳机油容量 /L 42 润滑系统总容量 /L 65 进水最低温度 / 60 出水最高温度 / 100 适宜工作水温 / 75~95 最低空载稳定转速 /(r/min) 900 电子调速最低空载稳定转速时转速波动 /(r/min) ±30 器调速性 1h 功率工况时突卸负荷 : 能瞬时调速率 /% 稳定调速率 /% 转速重新稳定时间 /s 最小推荐的蓄电池容量 /Ah* 195 蓄电池 -18 C 蓄电池冷起动电流 /CCA 电压 /V 24 起动电机 电压 /V 24 功率 /kw 9 电压 /V 28 发电机 电流 /A 55 额度功率 /kw 1.5 注 : 对起动要求较高的应用, 应适当加大蓄电池的容量 配套技术要求 因环境状况对空空中冷的增压柴油机的运行影响较大, 下表根据环境温度对柴油机运行的最大总功率及其运行参数 进行规定 用户需按此表要求匹配合适的中冷器 散热器 消声器及其连接管路, 及时保养空滤器, 并按表中要求控制 柴油机的负荷, 以防止柴油机超负荷运行导致柴油机故障 环境温度 / 转速 r/min 允许最大总功率 /kw 中冷器出口温度 / 中冷器压降 /kpa 柴油机出水温度 / 油底壳机油温度 进气阻力 /kpa 排气背压 /kpa < < <

14 SC27G 型柴油机使用保养说明书 3 柴油机的安装和连接 3.1 柴油机安装在柴油机齿轮室和飞轮壳两侧有 4 个安装支架 每台柴油机上有用于起吊的吊环和吊板, 能承受柴油机的全部重量 吊装时用链条滑车或其他吊装工具 但必须注意 : 勿使受力链条压向薄壁零件或仪表零件 ( 并尽可能不使吊环承受弯矩 ); 起吊要平稳, 使柴油机基本保持在水平位置, 搬运吊装中, 柴油机应搁置在专用的底座上或稳妥的垫块上, 防止油底壳直接承受柴油机的重量 3.2 柴油机连接 进 排气管的外接 注意 : 当采用加长的进气管路时, 则必须有足够的进气截面 推荐中冷器前 后管路内径为 100 mm, 且不宜过长或急转弯, 否则会增大进气阻力, 从而影响柴油机的工作性能 另外, 必须注意进气管路的密封性, 否则将导致柴油机早期磨损 水管路的外接 G 系列 V 型柴油机冷却系统为闭式循环, 用户不必另设水池或散热水塔等装置 水泵进水管内径推荐 61 mm, 调温器出水管内径推荐 54 mm 燃油管路的外接柴油机燃油箱进油口及燃油回到油箱的接头位置如图所示 燃油进口 Ф10.1 燃油回口 Ф10.1 燃油箱容量要求能存放柴油机工作 8 小时以上的燃油 燃油箱应保证供油的最低油位不低于输油泵中心 1 m, 进油管吸油口必须高于燃油箱底面 50 mm 以上, 最好在吸油口处再接一粗滤网, 防止将沉淀物吸入而堵塞油路 为便于清洗, 燃油箱底部最好设有泄放阀门 燃油箱不应靠近热源 ( 如排气管 ) 和电器设备 柴油机的功率输出柴油机由飞轮端输出功率驱动设备工作 当采用联轴器连接被驱动设备时, 设备中心线和曲轴中心线应在同一直线上 如采用弹性联轴器, 其同轴度应不大于 φ0.30 mm; 如采用刚性联轴器, 其同轴度应不大于 φ0.10 mm 注意 : 柴油机不允许带载起动, 因此在柴油机与本身不能空载运转的负载装置之间应设有离合装置 柴油机曲轴前端可以输出部分功率, 但直接利用前轴胶带盘横向拖动的输出功率不得大于 11 kw 禁止在飞轮上直接安装皮带盘横向拖动被驱动设备, 这样容易损坏曲轴及主轴承 如需用作横向拖动时, 应选用适合横向拖动的变型柴油机或另采用适应横向拖动的动力传动过渡装置, 不要使柴油机曲轴和主轴承直接承受横向力 9

15 SC27G 型柴油机使用保养说明书 4 柴油机使用正确使用柴油机, 不仅能保持柴油机工作正常 性能良好, 而且会延长柴油机的寿命 降低使用成本 按本章节的要求采用正确的燃油 机油和冷却液, 采用正确的操作步骤 4.1 燃油本系列柴油机使用的燃油规格应符合 GB 普通柴油标准规定 根据环境温度选择燃油的牌号 在冬季气温低的环境下, 应使用低凝固点的柴油, 夏季则反之 燃油牌号选择可按 GB 标准推荐, 用户也可按下表的推荐来选用 : 例如, 环境温度为 -27 时, 应选用 -35 号柴油 柴油牌号与适用最低气温的关系柴油牌号 0 号 -10 号 -20 号 -35 号十六烷值 凝点 / 适用最低气温 ( 柴油机工作环境温度 / 4 以上 -5 以上 -14 以上 -29 以上 ) 注意 : 柴油必须保持高度的清洁, 不被灰尘杂质或水所污染 4.2 机油 为确保柴油机的正常运行和长寿命 改善柴油机的排放, 请使用 CF-4 级及以上等级的润滑油 在一般环境温度下 选用 CF-4 l5w-40 机油, 当环境温度保持在 -5 以下时, 应选用较轻质的 CF-4 5W-30 机油有利于起动, 但持续使用低 粘性机油会增加柴油机磨损 本柴油机使用的机油规格符合国家标准 GB 规定 机油规格 (GB ) 规格 运动粘度 (100/ ) 闪点 ( 开口 ) 倾点 机械杂质 % 水分 % 黏度等级 mm 2 /s 不低于 不高于 不大于 不大于 5W ~ < 痕迹 15W ~ < 痕迹 注意 : 机油必须保持清洁, 不被灰尘杂质或水所污染 不同牌号机油不能混合使用 上柴公司用专用的 CF-4 15W-40 润滑油件号 : Y/ (3.5kg) Y/ (16 kg) Y/AG0105(3.5 kg) Y/AG0106(16 kg) 4.3 冷却液 为确保柴油机的正常运行和长寿命, 请在任何气候条件下都使用上柴公司专用的有机型 ( 防冻 ) 冷却液 该冷却液 具有防冻 防腐 导热性好 稳定性好 环保等特点 名称 件号 冰点 / 沸点 / 上柴有机型 ( 防冻 ) 冷却液 F/LQY 柴油机与工作机械功率的匹配用户选用柴油机时不仅应考虑与之配套的工作机械所需功率的大小, 还必须考虑工作机械的负荷率, 比如是间歇使用, 还是连续使用 同时要考虑工作机械的运行经济性, 即负载的工作特性和柴油机的特性必须合理匹配 因此柴油机功率的正确标定和柴油机与工作机械特性的合理匹配乃是保证柴油机运行可靠 经济及使用寿命长的前提, 否则将可能使柴油机超负荷运行和产生不必要的故障, 或负载功率过小, 柴油机功率不能得到充分运用, 这样既不经济并且易产生窜机油等弊病 4.5 柴油机起动在使用柴油机之前, 应根据具体的使用环境和条件, 选用适当规格的机油 燃油和冷却液 起动前应做好如下工 10

16 SC27G 型柴油机使用保养说明书 作 : (1) 对柴油机及起动系统作一次环视检查, 发现问题, 及时解决 (2) 检查机油压力表 机油温度表 冷却液温度表 警示灯 以及其他仪表是否处于正常状态 (3) 检查空滤器保养指示器是否出现红色柱塞 注意 : 绝不允许不带空滤器起动柴油机, 以防柴油机早期磨损 (4) 检查机油油面高度是否在规定的范围内 柴油机刚开始投入使用或大修后, 需要在增压器进油口加入适量清洁机油 (5) 检查冷却液液面高度是否在规定的范围内 (6) 检查电解液液面高度是否在规定的范围内 (7) 柴油机刚开始投入使用或大修后 或停止工作多日, 或者刚更换过燃油滤清器, 燃油系统内会有空气, 需要对燃油系统泵油排气, 具体操作见 5.3 章节 (8) 检查电起动线路是否处于正常状态 (9) 检查电起动系统电路接线是否正确, 蓄电池是否充足 (10) 所有安全防护装置必须安装到位 (11) 检查油门操作杆是否灵活 (12) 对新机或停放 5 天以上未用的柴油机, 起动前应用盘车工具先转动曲轴 3~5 转 常规起动步骤 G 系列 V 型柴油机可以在环境温度不低于 -5 情况下顺利起动, 方法如下 : 使柴油机与传动装置脱离 机械操纵装置等处于运转位置 将喷油泵调速器操纵手柄推到空载, 即转速为 900 r/min 左右的位置 插入电钥匙, 将开关从 OFF 位置转到 START 位置, 起动柴油机 如果在 10 秒内未能起动, 应立即将开关从 START 位置转到 OFF 位置 过 2 分钟后再作第 2 次起动, 如连续 3 次不能起动, 应停止起动 参照第 6 章故障排除指南找出原因并排除故障后再进行起动 每次起动时间一般为 2 至 3 秒 注意 : 柴油机必须空载起动 起动后, 开关自动从 START 位置回到 ON 位置 起动后 15 秒内机油压表必须显示读数 如果 15 秒内没有指示机油压力, 应立即停车, 以防损坏柴油机 按第 6 章故障排除指南查明原因并排除故障 热态柴油机起动后, 应在怠速运转 1~3 分钟后, 方可逐步加速加载运行 冷态柴油机起动后, 应先在怠速运转 3~5 分钟, 然后逐步增加转速到 r/min, 进入部分负荷运行 待柴油机的出水温度高于 75 机油温度高于 50 机油压力高于 0.40 MPa 时, 才允许进入全负荷运行 注意 : 特别是在低温起动后, 转速的增加应尽可能缓慢, 以确保各轴承得到足够的润滑, 并使油压稳定 柴油机在怠速工况下运转时, 检查所有仪表工作是否正常 注意 : 严禁柴油机起动后立即加速加载运转 注意 : 柴油机怠速运转时间不许太长, 否则会损坏柴油机 因为怠速运转时燃烧室温度低, 燃油不能完全燃烧, 造成缸内结碳, 引起喷油器喷孔堵塞 使活塞环和气门卡滞, 导致柴油机性能下降 注意 : 当使用一个跨接电缆起动柴油机时, 一定要将电缆并联 : 正极连正极, 负极连负极 当使用外部电源起动柴油机时, 将断路开关转到 OFF 位置 连接跨接电缆之前, 为了防止意外起动, 将钥匙拔出 低温起动低温起动是指在低于 -5 环境温度下的起动 起动时, 用户应根据实际使用的环境温度采用相应的低温起动辅助措施 然后按常规起动的步骤起动柴油机 一般采取的低温起动辅助措施有如下几种 将柴油机的机油和冷却液预热至 40~50 在进气管内安置预热进气的装置或在进气管口采用简单的点火加热进气的方法 ( 采用此法须注意安全 ) 提高机房的环境温度 选用适应低温需要的柴油 机油和冷却液 对蓄电池采取保温措施或采用加大容量的或高倍放电率蓄电池 ( 特殊的低温蓄电池 ) 11

17 SC27G 型柴油机使用保养说明书 长时间停车或更换机油后的起动每当更换机油后或停车时间小于 30 天起动柴油机时, 必须先使润滑系统充满机油 采用盘车法, 使机油进入各摩擦副, 待柴油机盘车手感顺利轻松后方可起动柴油机 并做好下列起动准备, 然后按常规起动程序或低温起动程序起动柴油机 : (1) 检查机油油面 (2) 检查蓄电池电压是否正常 (3) 给燃油系统泵油排气, 具体操作见 5.3 章节 对于平时停放作为应急用的柴油机, 为便于在急用时能迅速起动运行, 在停放期内, 每隔 3~5 天应起动运行一次至冷却液温度 机油温度达到 60 以上为止 4.6 柴油机运行柴油机运行时注意事项 : 经常关注油压和冷却液温度是否正常, 若见异常, 应该停车检查 机油压力 : 怠速时 ( 允许最低 )150 kpa; 标定转速时 ( 允许最低 )300 kpa; 标定转速时 ( 允许最高 )500 kpa 冷却液温度 : 柴油机正常工作时为 75~95 若柴油机温度过高 ( 水温报警器报警 ), 应降低转速或负荷或二者同时进行, 直到柴油机冷却液温度恢复到正常工作范围 ; 否则应参考第 6 章 故障排除指南 进行检修 在运行过程中, 特别是突减负荷时, 应注意防止因喷油泵调速器失灵使柴油机转速突然升高 ( 俗称飞车 ) 超过规定值 一旦出现此类情况应先迅速采取紧急停车措施, 然后再查明原因 注意 : 柴油机超速运行会导致其严重损坏 大多数柴油机故障出现前有明显的征兆, 通过听柴油机声音变化 看柴油机性能变化和外观变化可以预先知道柴油机需要保养或维修, 应及时进行保养或维修, 否则会酿成严重故障 必要时, 应及时联系上柴 易 + 人 呼叫中心, 以获得技术指导或专业的维修服务 柴油机故障前典型征兆柴油机熄火柴油机异常振动柴油机声音不正常柴油机冷却液温度 机油压力突然发生变化柴油机冒黑烟功率不足机油耗增加燃油耗增加三漏 ( 机油 燃油 冷却液泄漏 ) 4.7 柴油机停车 正常停车柴油机长时间高速高负载运转后, 停机前应逐步卸去负荷 降低转速, 并在怠速运行 5 分钟, 使发动机均匀冷却, 使增压器转速大幅下降, 然后再停机, 以保护柴油机和增压器 停车后关闭燃油箱 柴油机如需停用一段时间, 需要做好保存工作, 具体见第 7 章柴油机停运后保存 紧急停车在紧急或特殊情况下, 为避免柴油机发生严重故障可采取紧急停车 此时用手拨动紧急停车手柄, 即可达到目的 4.8 新柴油机或大修后柴油机的磨合新的或大修后的柴油机, 在正式使用前须经 60 小时磨合并更换机油后方可投入全负荷使用, 以改善柴油机各运动部件的工作状况, 提高柴油机的运行可靠性和使用寿命 磨合应视柴油机用途和拖载方式的不同, 来考虑具体磨合方案, 原则上随着磨合时间的增加分阶段逐步提高柴油机的转速和负载 在整个磨合期内负荷应是标定功率的 50%~80%, 转速应不大于标定转速的 80% 电站恒转速柴油机允许在标定转速磨合, 但在磨合开始阶段的空载运行时间或过小负荷情况下的运转时间不宜太长 柴油机在磨合期及磨合后的正常工作期, 均不宜长时间怠速运行或低负荷运行 柴油机怠速连续运行时间不得超过 10 分钟, 以避免因积碳而引发早期磨损或影响柴油机性能 每当更换缸套 活塞 活塞环 连杆轴瓦 主轴瓦或 / 和曲轴后亦应按上述磨合工况适当进行短期磨合 12

18 SC27G 型柴油机使用保养说明书 5 柴油机保养 5.1 柴油机保养计划下表给出了本柴油机保养周期及保养内容 用户应根据本表规定进行定期保养 若柴油机经常在环境温度低于 -18 或高于 38 情况下运行, 或者在多尘环境下运行, 须适当缩短保养周期 每 250 小时 每 500 小时 小时 每 小时 保养内容 日常维护 或 或 或 或 每 3 个月 每 6 个月 每 12 个月 每 2 年 检查柴油机外围 检查燃油箱 检查空滤器保养指示器 检查机油油面 检查冷却液液面 检查电解液液面 燃油粗滤器积水检查 放水 检查传动胶带 * 检查冷却风扇 检查进气系统 加注润滑脂 检查传动胶带张紧度 更换机油和机油滤清器 更换燃油滤清器 ( 精 粗滤 ) 燃油系统泵油排气 调整气门间隙 检查中冷器及其管路 检查风扇轴承检查增压器检查减振器更换冷却液 清洗冷却系统 * 当胶带表面出现裂痕或其他影响使用的缺陷时, 必须更换 注 : 本表中以小时或年月为单位规定保养间隔的, 以先到为准 13

19 SC27G 型柴油机使用保养说明书 5.2 柴油机保养记录用户应做好定期保养记录 用户可参考下面提供的 保养记录 格式, 编制自己的保养记录本 维护保养记录 柴油机机号 用户名称 柴油机型号 / 订货号 设备名称 / 编号 U 日 期 小时或 时间间隔 保养内容 保养者备注 14

20 SC27G 型柴油机使用保养说明书 5.3 柴油机保养内容及方法 检查柴油机外围每天在柴油机起动前应进行柴油机外围检查, 检查内容如下 : (1) 检查柴油机及散热器上有无揩布 废电线 管夹 螺钉等杂物堆积, 保持柴油机清洁 整齐 (2) 检查燃油系统 冷却系统 润滑系统各接头 接合面有无泄漏 (3) 检查风扇连接和安全护罩是否安全可靠 (4) 检查附件紧固情况 (5) 检查电气线路接头是否松动, 导线是否完好 (6) 检查传动胶带是否完好 检查燃油箱每天检查燃油箱油面 检查空气滤清器保养指示器每天检查空气滤清器上的保养指示器 如果检视窗口显示红色, 表示空气滤清器的进气阻力超过规定值, 需要更换滤芯 滤芯更换要求和步骤见 滤更换芯后, 必须按下保养指示器顶部上的按钮, 使其复位 按钮 注意 : 更换空气滤清器滤芯后, 确保空气滤清器两端面可靠密封, 不得漏气 注意 : 绝不允许不带空气滤清器的情况下运行柴油机 否则极易造成柴油机早期磨损 检查机油油面 每天首次柴油机起动前时检查机油油面, 机油油面应接近刻线 静满 ; 或每天柴油机运转后在怠速或低速时检查机油油面, 机油油面应在刻线 动满 ( 动态高油位 ) 和刻线 险 ( 动态低油位 ) 之间, 需要时应添加机油至近刻线 动满, 低于刻线 险 应立即添加油至近刻线 动满 注意 : 决不能在机油液面低于低油位 ( 刻线 险 ) 情况下运行柴油机 否则会导致柴油机性能变差, 甚至损坏柴油机 但机油液面不得超过高油位 ( 刻线 动满 ) 静满动满险 检查冷却液液面每天在柴油机起动前或停车状态时检查柴油机冷却液液面 警告 : 柴油机工作时, 其冷却液温度较高且有压力, 容易引起烫伤 待柴油机停车并且冷却液温度下降至 50 以下, 才能进行冷却液液面检查或添加 警告 : 冷却液中防锈剂含碱, 应避免皮肤和眼睛与其接触, 以防伤害 (1) 在柴油机起动前或停车后冷却液温度下降至 50 以下后, 慢慢旋开散热器或膨胀水箱上的压力盖 ( 加液盖 ) 以释 15

21 SC27G 型柴油机使用保养说明书 放冷却系统压力 (2) 卸下压力盖, 从加液口或液面检查口检查冷却液液面高度, 应在上下刻线内或满足设备制造商的规定 (3) 必要时, 需添加 添加至接近上刻线或满足设备制造商的规定 注意 : 添加冷却液时应需慢慢注入, 以防产生气阻 检查电解液液面 有些蓄电池是非免维护型, 需要检查电解液液面 (1) 每天卸下加液盖, 查看电解液液面 电解液液面应在加注口底部 如果液面不足, 应按要求补充 (2) 装上加液盖 燃油粗滤器积水检查 放水 燃油粗滤器有油水分离功能 每天需要检查粗滤器下方水杯的中是否有积水 如有积水, 需要排除 旋松水杯下方放水阀, 排除积水杯中的积水和沉淀物, 直到清洁的燃油流出为止, 然后再旋紧放水阀 不要用力拧紧, 手感紧即可 积水杯 燃油粗滤 放水阀 检查传动胶带 每天目视检查传动胶带 检查胶带是否有纵横交叉的裂纹 沿胶带宽度方向的横向裂纹是允许的, 但不允许出现纵向 ( 沿胶带长度方向 ) 和横向贯穿的裂纹 若胶带磨损或出现材料剥落也应予更换 检查冷却风扇 每天目视检查风扇有无裂纹 铆钉松动 叶片松动和弯曲等毛病 应确保风扇安装可靠 必要时应拧紧风扇紧固螺栓, 或更换损坏的风扇 警告 : 风扇叶片损坏会造成伤人的严重事故 绝不允许拖拉和撬动风扇, 更不能借风扇转动柴油机曲轴 16

22 SC27G 型柴油机使用保养说明书 检查进气系统 检查进气胶管是否有裂缝或穿孔, 夹箍是否松动 如有发现进气胶管失效应予以更换, 发现夹箍松动应拧紧夹箍螺钉, 确保进气系统不漏气 加注润滑脂 定期在加油脂的小孔处加上适量的钠基润滑油脂 加油脂处 检查传动胶带张紧力检查在胶带两带轮之中央位置, 以手指用力下压或上拉 ( 施以 98 N 左右力量 ), 观察下压或上拉距离 满足胶带张紧力要求的距离应是 8~12 mm 如超过此范围, 需要进行调整 调整 (1) 拧松张紧轮螺母, 拧动调节螺栓, 调整胶带张力 (2) 拧紧螺母拧紧至 122~152 N m 张紧轮螺母 调节螺栓 张紧轮 更换机油和机油滤清器 警告 : 在更换机油和机油滤清器时要注意安全, 与热机油和柴油机表面接触会引起皮肤烫伤 (1) 待柴油机运转至冷却液温度达到 60 C 时停车, 拆下油底壳上的放油螺塞, 放尽机油 17

23 SC27G 型柴油机使用保养说明书 注意 : 不要在柴油机冷态时放机油 因为在冷态时, 悬浮在机油中的杂质颗粒已沉积到油底壳底部并粘附在油底壳内部表面上, 不能随机油一起排出 机油温热时杂质颗粒悬浮在机油中, 此时放机油, 杂质颗粒易排出 (2) 清洁放油螺塞安装面, 然后装上放油螺塞, 在螺纹上涂可赛新 1567F 密封胶, 拧紧扭矩 60~70 N m (3) 清洁机油滤清器外表面, 用工具拆下机油滤清器并报废 G 系列 V 型柴油机有 2 个机油滤清器 ( 在柴油机两侧, 冷却器上方 ), 必须同时更换 (4) 清洗滤清器座密封面, 不得有旧的 O 形密封圈残留 (5) 只需在密封圈密封表面上涂一薄层凡士林或清洁机油, 用以形成润滑膜 因滤清器是横置的, 在安装前不能将机油注满滤清器内腔 (6) 手旋滤清器直至密封圈接触到滤清器座安装面, 然后用工具再拧紧 45 ± 5 N m 或 3/4 圈至 1 圈 (7) 打开加油口盖 ( 靠机体下端 ), 用清洁的机油注入柴油机至接近油尺上刻线 ( 高油面记号 ) 本柴油机系统机油容量约为 65 L, 油底壳机油容量约为 42 L (8) 起动柴油机并怠速运转, 检查机油滤清器和放油螺塞有否漏油 (9) 在怠速或低速时检查机油机油液面高度, 如需要, 则添加至接近油尺上高油位刻线 ( 刻线 动满 ) (10) 安装加油口盖, 手感拧紧即可 更换燃油滤清器 ( 精滤 ) (1) 清洁燃油滤清器外表面, 用工具拆下燃油滤清器并报废 (2) 清洁燃油滤清器座周围及滤清器座的密封面 不得有旧的 O 形密封圈残留 注 :G 系列 V 型柴油机有 2 个燃油精滤器, 必须同时更换 (3) 安装新的燃油滤清器前, 应从滤清器周边 8 个小孔注入清洁的燃油, 注满滤清器内腔, 油面离螺纹孔下端 3-15 mm 并在 O 形密封圈密封表面上涂一薄层凡士林或清洁机油, 以形成润滑膜 注意 : 不得从滤清器中心孔注入燃油 (4) 手旋滤清器直到密封圈接触到滤清器安装面, 然后用工具再拧紧 45 ± 5 N m 或 3/4 圈至 1 圈 更换燃油滤清器 ( 粗滤 ) 燃油粗滤器也是旋入式的, 其更换步骤与更换燃油精滤器步骤一样 粗滤清器和积水杯拆卸方向滤清器上有说明 18

24 SC27G 型柴油机使用保养说明书 燃油系统泵油排气 柴油机已有多日停止工作或更换燃油滤清器 ( 精滤 粗滤 ) 后, 空气会进入燃油系统, 需要按以下步骤排气 : (1) 松开手揿泵顶面的放气螺钉 ( 一字头 ); (2) 按手揿泵进行泵油排气, 直到从放气螺塞处流出的柴油中没有气泡为止 ; (3) 拧紧放气螺塞至 10 N m 放气螺钉 手揿泵 燃油粗滤 注意 : 没有及时加燃油, 导致空气进入燃油系统, 或者其它因素导致燃油系统有空气, 均需要排除空气 检查 / 调整气门间隙新柴油机和大修后投入使用的柴油机, 在首保时, 进行第一次气门间隙检查, 以便及时调整和纠正气门间隙的初期变化 在其后的正常运转期间, 按保养计划检查和调整 气门间隙检查在柴油机停止运转并冷却液冷温度降至 60 以下后进行 (1) 拆下气缸盖罩壳带帽螺母, 拆下罩壳, 报废罩壳密封圈和垫片 (2) 逆时针盘车使柴油机第 1 缸活塞处于压缩上止点 注 : 通过飞轮壳上监视窗口观察指针位置 如指针对准飞轮上的 0 线刻时即为第 1 缸或第 6 缸活塞上止点 (3) 检查第 1 缸气门摇臂是否能摇动, 如能, 说明第 1 缸的活塞处于压缩上止点 ; 如不能, 说明第 6 缸的活塞处于压缩上止点 (4) 当第 1 缸活塞在压缩上止点时, 用千分尺 ( 厚簿规 ) 检查第 缸进气门间隙, 第 缸排气门间隙 ; 当第 6 缸活塞压缩上止点时, 用千分尺 ( 厚簿规 ) 检查第 缸进气门间隙, 第 缸排气门间隙 注 : 用间隙塞片检查间隙时, 塞片在气门杆顶面与摇臂之间移动时手感有点阻力, 即为正确的气门间隙 (5) 如间隙不符合要求, 拧松该摇臂上的气门间调节螺钉的隙锁紧螺母, 调整气门间隙至规定值, 然后拧紧锁紧螺母至 50~60 N m, 复查该气门间隙, 间隙数值不应有变化 气门间隙 : 进气门 0.30~0.35 mm 排气门 0.35~0.40 mm (6) 在减振器做上标志, 然后旋转曲轴一周 (360 ), 以同样的步骤调整其余的进排气门间隙 19

25 SC27G 型柴油机使用保养说明书 (7) 安装气缸盖罩壳, 采用新的罩壳密封圈和垫片, 安装并拧紧气缸盖罩壳带帽螺母, 拧紧力矩 10~15 N m 检查中冷却器及其管路目视检查中冷器进出气室是否有裂缝 穿孔或其他损坏, 检查进出气管是否有裂缝 脱焊及其他损坏 如有, 应予以更换 检查中冷器进出气管的连接软管有否破裂或穿孔 夹箍有否松动 如有, 应更换软管 拧紧夹箍 检查风扇轴承 拆下传动胶带, 用手转动风扇胶带轮, 检查其有否卡滞或径向 / 轴向窜动, 以此来确定风扇轴承表面是否表面划伤或磨损 如必要, 更换风扇轴承座 检查增压器 目视检查增压器涡轮叶片和压缩机叶片是否损坏或有裂纹, 手指轻压叶片, 叶片是否会与涡轮壳或压气机壳接触, 检查增压器转轴转动是否有卡滞现象 如发现上述问题, 需要更换增压器 检查减振器检查减振器有否减振液 ( 硅油 ) 泄漏 减振器表面有否塌陷 ; 检查减振器厚度以确定减振器有否变形 如发生上述问题, 需要更换减振器 更换冷却液 清洗冷却系统为确保柴油机冷却液的冷却和防蚀效果, 必须每 小时或 2 年 ( 先到为准 ) 更换冷却液 清洗冷却系统 警告 : 在工作温度下, 柴油机冷却液温度较高且有压力 蒸汽能引起人身伤害 只有在柴油机停止工作后, 待冷却液温度降至 50 以下, 才可慢慢拧开散热器上压力盖 ( 加液盖 ) 释放冷却系统压力 警告 : 冷却液内防锈剂含碱, 应避免皮肤和眼睛与其接触, 以防人身伤害 (1) 待柴油机停车且冷却液温度降至 50 后, 慢慢旋松散热器上压力盖以释放冷却系统压力, 然后卸下压力盖 旋开散热器的放水阀, 放尽散热器中的冷却液 (2) 旋松机油冷却器下方的放水阀 ( 柴油机两边各 1 个 ) 拆下水泵下方的放水螺塞( 柴油机两边各 1 个 ), 放尽柴油机冷却系统中的冷却液 (3) 按下列步骤清洗冷却系统 (a) 装上并拧紧所有放水阀和放水螺塞, 从散热器加液口将碳酸钠水溶液 ( 或在市场上能买到的碳酸钠与水的混合物 ) 加入冷却系统 注意 : 每 23 L 水用 0.5 kg 碳酸钠混合 不得用含腐蚀剂的清洗剂, 否则会损坏铝制零件 注意 : 在灌注清洗液过程中必须将冷却水腔中空气排出, 且慢慢注入, 防止产生气阻 清洗液需加至散热器加液口底面, 等待 3~5 分钟, 让空气充分排出 (b) 起动柴油机, 等清洗液温度升至 80 以上后运转 5 分钟, 然后停车放尽冷却系统中的清洗液 注意 : 整个冷却系统清洗过程中, 不安装压力盖, 并在不加盖的情况下运行柴油机 20

26 SC27G 型柴油机使用保养说明书 (c) 将清水注入冷却系统 注意 : 灌注清水时, 须慢慢注入, 防止产生气阻 清水需加至散热器加液口底面, 等待 3~5 分钟, 让空气充分排出 (d) 起动柴油机, 等水温升至 80 以上后运转 5 分钟, 然后停车放尽冷却系统中的清水 注意 : 若排出水仍是脏的, 必须按上述步骤再次清洗冷却系统, 直到流出的水是干净为止 (4) 清洗完毕后, 拧紧散热器上的放水阀和机油冷却器上的放水阀, 拧紧水泵上的放水螺塞, 拧紧扭矩 N m 安装水泵放水螺塞前, 在螺塞螺纹上涂抹可赛新 1567F 密封胶 (5) 加注冷却液, 柴油机本体冷却液总量 : 约 151 L 注意 : 整个冷却系统的添加量应以设备制造商的数据为准 注意 : 加注冷却液时, 须慢慢注入, 防止产生气阻 冷却液需加至散热器加液口底面或符合设备制造商的要求, 等待 3~5 分钟, 让空气充分排出 (6) 安装压力盖, 起动柴油机, 直至冷却液温度达到 80, 然后停车检查冷却系统有否泄漏 (7) 停车后待冷却液温度降至 50 以下, 打开压力盖, 复查冷却液液面, 如有必要, 再补注适量冷却液 更换空气滤清器滤芯 (1) 用压缩空气将吹净附在壳体上的灰尘 (2) 拆下空气滤清器罩盖和滤芯, 报废滤芯 (3) 用清洁覆盖物盖住空滤器壳体内通向压气器 进口, 防止灰尘进入进气系统 (4) 用压缩空气将吹净空滤器壳体内部 (5) 检查新的滤芯是否完好无损, 取下压气机进口处覆盖物 (6) 安装新的滤芯, 并确保空滤器两端密封可靠 ; 安装空滤器罩盖 注意 : 更换空气滤清器滤芯后, 确保空气滤清器两端面可靠密封, 不得漏气 21

27 SC27G 型柴油机使用保养说明书 6 柴油机故障排除指南 6.1 概述如柴油机出现故障时, 操作人员应沉着仔细, 及时分析故障的特征, 判断其产生的原因 一般按下列原则进行 : 1) 当柴油机运转中有不正常的现象时, 可以用 看 听 摸 嗅 综合判断是哪个部位或哪个系统产生故障 看 : 观察各仪表的读数 排气烟色以及冷却液温度和机油压力的变化情况 ; 听 : 用细长的金属棒或木柄起子作为 听诊器 触及柴油机外表相应部位, 听诊 运动发出的声音及其变化情况 ; 摸 : 凭手指感觉检查配气机构等零件的工作情况和柴油机振动情况 ; 嗅 : 凭感官的嗅觉, 嗅出柴油机有否出现异常气味的地方 2) 当柴油机突然发生故障或已判断出故障的原因, 而且故障将影响柴油机正常工作时, 应及时停车检查 对不能立即查明原因的故障, 可以先将柴油机低速空载运转, 再观察分析原因, 以避免发生更大的事故 3) 当判断是较大故障或柴油机突然自行停车时, 即应及时拆检和维修 4) 应将每次出现的故障 特别是大的故障原因和排除方法记录在案, 供下次检修时参考 本章所列的柴油机常见故障和排除方法, 仅供操作人员参考 在实际工作中, 应根据当时当地的具体条件和实践经验灵活掌握, 找出产生故障的内 外原因, 对症下药, 及时排除 6.2 柴油机故障排除下表列出了柴油机使用中一些典型故障模式, 后面故障表列出故障特征 可能的原因和排除方法 用户可自行排除简单的故障, 复杂的故障, 如需要, 可联系上柴 易 + 人 呼叫中心 ( ) 寻求帮助, 以获得技术指导或专业的维修服务 序号 柴油机故障模式 序号 柴油机故障模式 1 柴油机不能起动 6 机油温度过高 机油耗量太大 2 柴油机功率不足 7 机油内有冷却液 3 柴油机运转时有不正常的杂声 振动过大 8 柴油机出水温度过高 4 排气烟色不正常 9 柴油机出水温度过低 5 机油压力不正常 10 冷却液中有机油 序号 系统和零部件常见故障 序号 系统和零部件常见故障 11 电气系统常见故障 14 输油泵常见故障 12 喷油泵常见故障 15 喷油器常见故障 13 调速器常见故障 16 废气涡轮增压器常见故障 22

28 SC27G 型柴油机使用保养说明书 (1) 柴油机不能起动故障特征 可能原因 排除方法 柴油机被起动电机带动后不发火, 回油管无回油 燃油系统故障 : (1) 燃油系统中有空气 (2) 燃油 浊点 高于环境温度, 影响正常流动性 ( 所谓 浊点 就是燃油开始析蜡的温度 ) (3) 燃油管路阻塞 (4) 燃油滤清器阻塞 (5) 输油泵不供油或断续供油 (6) 喷油泵调速器操纵手柄位置不对 (7) 喷油泵静态供油定时不正确 (8) 喷油很少, 喷不出油或喷油不雾化 排除燃油系统中的空气, 方法参见 5.3 节放出油箱和燃油滤清器中所有燃油, 按 4.1 要求选用正确燃油品质和牌号, 然后注入油箱 ; 用手掀泵和放气螺钉将燃油系统内空气排尽检查管路是否畅通清洗滤网 更换燃油滤清器检查进油管是否漏油, 进油管接头上的滤网是否堵塞 如排除后仍不供油, 应检查进油管和输油泵起动时应将手柄位置推到空载, 必要时让专业维修人员调整检查或调整喷油泵静态供油提前角让专业维修人员在试验台上检查喷油器喷雾情况, 调整喷油压力至规定范围, 必要时更换喷油器 起动开关接通时, 柴油机不转动 (1) 电路接线错误或接触不良 (2) 蓄电池电力不足 (3) 起动电机电刷与换向器没有接触或接触不良 (4) 柴油机内部机械故障阻碍了曲轴转动 检查接线是否正确和牢固给蓄电池充电或用电力充足的蓄电池或增加蓄电池并联使用修整或调换碳刷, 用木砂纸清理换向器表面, 并吹净, 或调整刷簧的压力如果将所驱动的设备断开后, 曲轴仍不能转动, 就应人工盘转曲轴, 检查是否因曲轴或连杆轴承咬死 活塞卡住 或凸轮轴定时齿轮安装错误造成 喷油正常但不发火, 排气管内有燃油 气缸内压缩压力不足 : (1) 活塞环或缸套过度磨损 (2) 气门漏气 更换活塞环, 视磨损情况更换缸套检查气门间隙 气门弹簧 气门导管及气门座的密封性, 密封不好应修理和研磨 起动时间长且不发火 环境温度过低 根据实际环境温度, 采取相应的低温起动 辅助措施 23

29 SC27G 型柴油机使用保养说明书 (2) 柴油机功率不足故障特征可能原因排除方法燃油系统故障 : (1) 燃油管路破裂 管接头泄漏 燃油更换破裂的油管 拧紧管接头 清洗滤网 更滤清器阻塞 燃油系统有空气换燃油滤清器 给燃油系统充油排气 (2) 油箱内燃油不足或油箱中有水和确保燃油箱内有充足清洁燃油, 通过泄油阀排除加大油门后功率或转速杂质油箱中的水和沉淀物 如果原有的燃油不清洁, 仍提不高应换注清洁燃油 (3) 喷油泵静态供油定时不正确检查并调整喷油泵静态供油提前角 (4) 喷油泵供油不足检查修理, 必要时更换喷油泵 (5) 喷油器雾化不良或喷油压力低让专业维修人员检查喷油器喷雾情况和调整喷油压力, 必要时更换喷油器进 排气系统故障 : (1) 空气滤清器阻塞清除纸质滤芯上的灰尘, 必要时更换滤芯 (2) 进气系统漏气检查增压器压气机出口至气缸盖进气口之间有正常情况下排温较高 无漏气, 必要时排除泄漏源烟色较差 (3) 排气管阻塞或接管过长 转弯半径清除排气管内积碳, 重装排气接管, 弯头不能太小 弯头太多多于 3 个, 并有足够大的排气截面 (4) 气门间隙不正确检查并调整气门间隙 (5) 喷油泵静态供油定时不正确检查并调整喷油泵静态供油提前角喷油泵供油提前角或进 排气相位变检查并调整喷油泵静态供油提前角, 必要时检各档转速下性能变差动查凸轮轴齿轮定时 (1) 环境温度过高环境温度过高应改善通风, 临时加强冷却措施柴油机过热 (2) 机油和冷却液温度很高, 排温也大检修机油冷却器和散热器, 清除水垢 ; 检查有大增高关管路管径是否过小气缸盖组件故障 : (1) 气缸盖与机体结合面漏气, 变速时按规定扭矩拧紧气缸盖螺母或更换气缸盖衬有一股气流从气缸盖垫片处冲出, 使垫, 必要时修刮接合面柴油机功率不足, 性能气缸盖大螺母松动或垫片损坏下降, 而且有漏气 进 (2) 进 排气门漏气拆检进 排气门, 修磨气门与气门座密封面气管冒黑烟, 有不正常 (3) 气门弹簧损坏更换已损坏的气门弹簧的敲击声等现象 (4) 气门间隙不正确检查和调整气门间隙至规定值 (5) 喷油器孔漏气或其铜垫圈损坏拆下检修, 并更换已损坏的零件 (6) 活塞环卡住 气门杆咬住引起气缸检查活塞环 活塞 缸套 气门, 必要时更换压缩压力不足这些零件连杆轴瓦与曲轴连杆轴颈表面咬合检查连杆大头的侧向间隙, 查看连杆大头是否柴油机声音不正常, 并能前后移动, 如不能移动则表示咬毛, 应修磨有机油压力下降等现象轴颈和更换连杆轴瓦涡轮增压器故障 : 转速下降, 进气压力降 (1) 增压器轴承磨损, 转子有碰擦现象让专业维修人员检修, 如需要, 更换增压器低, 漏气或不正常的声 (2) 压气机进气道沾污 阻塞或漏气让专业维修人员检修清洗压气机壳体 揩净叶音等轮 清洁进气管路 ; 拧紧接合面螺母 夹箍等 24

30 SC27G 型柴油机使用保养说明书 (3) 柴油机运转时有不正常的杂声 振动过大故障特征 可能原因 排除方法 气缸内发出有节奏的清脆金属敲 喷油泵静态供油正时过早 调整喷油泵静态供油提前角 击声 气缸内发出低沉不清晰的敲击声 喷油泵静态供油正时过迟 调整喷油泵静态供油提前角 运转时有轻微而尖锐的响声, 在怠速运转时尤其清晰 活塞销与连杆小头衬套孔配合过大 检查连杆衬套内孔是否磨损, 如有, 更换连杆 运转时在气缸体外壁听到撞击 活塞与气缸套间隙过大 更换活塞或视磨损情况更换气缸套 声, 随柴油机温度升高而减小 运转时, 曲轴箱内发出撞击声, 连杆轴瓦磨损使配合间隙过大 拆检轴瓦, 必要时更换轴瓦 当柴油机从 r/min 突然降低转速时听到沉重而有力的撞击声 柴油机怠转时, 听到曲轴前后窜动的碰撞声 曲轴推力轴承磨损, 轴向间隙过大, 导致曲轴前后窜动 检查轴向间隙和推力轴承的磨损程度, 必要时更换推力轴承 气缸盖处发出有节奏的轻微敲击 气门弹簧折断, 或挺杆弯曲, 或 更换已损坏的零件, 并调整气门间隙 声 推杆套筒磨损或气门损坏 柴油机运转中气缸盖处发出沉重而均匀 有节奏的敲击声, 用手 气门碰活塞 拆下气缸盖罩壳, 检查相碰原因, 调整气门间隙 必要时检查活塞型号是否正确 指轻轻捏住气缸盖罩壳的螺帽有碰撞感觉 在前盖板处发出不正常声音, 突 传动齿轮磨损 齿隙过大 检查齿隙, 视磨损情况更换齿轮 然降速时可听到撞击声 在气缸盖处听到干摩擦发出的 摇臂调节螺钉与推杆的球面座之 拆下气缸盖罩壳, 检查断油的原因 吱吱 响声 间无机油 在气缸盖处听到有节奏的较大响 进 排气门间隙过大 检查和调整气门间隙 声 涡轮运转时有不正常的碰擦声 油路堵塞, 润滑不良, 导致轴承磨损, 从而导致叶轮叶片弯曲 让专业维修人员检查轴承磨损情况, 叶轮叶片弯曲情况, 必要时更换增压器 清洗增压器进出油管路, 确保润滑油道畅通 燃烧噪声太大 (1) 燃油质量差 (2) 喷油泵故障 将油箱里的燃油排掉, 更换燃油滤清器 在油箱内注入质量优良的清洁燃油使柴油机在燃烧噪声最大的工况下运转, 然后逐个拧松喷油泵上每个气缸的油管螺帽 ( 每次一个 ) 如果该油管螺帽拧松后, 燃烧噪声消失, 则检验该气缸喷油泵柱塞副, 必要时换上新零件 (1) 一缸或多缸的喷油器或喷油泵 检修或更换喷油器 喷油泵柱塞或喷油泵 柴油机严重振动 柱塞不工作 (2) 柴油机与机座固定螺栓松动拧紧柴油机与机座的紧固螺母 25

31 SC27G 型柴油机使用保养说明书 (4) 排气烟色不正常 故障特征 可能原因 排除方法 排气冒黑烟 排气冒白烟 排气冒蓝烟 (1) 柴油机负荷超过规定 (2) 各缸供油量不均匀 (3) 气门间隙不正确 气门密封不良, 导致气门漏气, 燃烧恶化 (4) 喷油泵静态供油定时过迟使部分燃油在排气管中燃烧 (5) 喷油器雾化不良 (6) 空气滤清器或进气管阻塞, 涡轮增压器压气机壳过脏等导致进气量不足 (7) 涡轮增压器弹力封气环烧损或磨损, 涡轮各接合面漏气等 (8) 活塞环磨损严重 (1) 喷油器喷油雾化不良, 有滴油现象, 喷油压力过低 (2) 柴油机刚起动时, 个别气缸不燃烧 ( 尤其是冬天 ) (3) 油中含水太多 (4) 气缸盖裂缝, 导致冷却液进入气缸 (1) 空气滤清器阻塞, 进气不畅 (2) 活塞环卡住或磨损过多, 弹性不足 ; 安装时活塞环倒角方向装反, 使机油进入燃烧室 (3) 长期低负荷 ( 标定功率的 40% 以下 ) 运转, 活塞与缸套之间间隙较大, 使机油易窜入燃烧室 (4) 油底壳内机油加入过多 (5) 涡轮增压器油封损坏, 机油进入进气管, 从而进入气缸 降低负荷使之在规定范围内让专业维修人员调整喷油泵调整气门间隙, 检查密封锥面, 并消除缺陷检查和调整喷油泵静态供油提前角 检查喷油器雾化情况清洗和清除尘埃污物, 必要时更换空气滤清器滤芯让专业维修人员检查弹力封气环, 必要时更换 拧紧接合面螺钉更换新环 检查喷油嘴偶件, 进行修磨或更换 调整喷油压力至规定范围适当提高转速及负荷, 多运转一些时间 排除燃油管路中的水分检查排气中是否有水分凝结现象, 必要时更换气缸盖 拆检和清洗空气滤清器滤芯拆检活塞环, 必要时更换活塞环 适当提高负荷 ; 配套时选用功率要适当 按油尺刻线加注机油, 不能超过高油位刻线检查进气管有无机油, 必要时检查或更换涡轮增压器 (5) 机油压力不正常 故障特征 可能原因 排除方法 机油压力下降, 调压阀调整后仍不正常, 同时压力表读数波动 无机油压力, 压力表指针不动 (1) 机油管路漏油 (2) 机油泵进空气, 油底壳中机油不足 (3) 机油冷却器或机油滤清器阻塞, 或冷却器芯子破裂 (4) 曲轴轴承处 曲轴前后油封处 凸轮轴轴承处 连杆轴瓦处 或 / 和摇臂轴和摇臂处泄油严重 (5) 机油内有柴油 (6) 机体内漏装活塞冷却喷嘴 (7) 机油稀释 (1) 机油压力表损坏 (2) 油道阻塞 (3) 机油泵严重损坏或装配不当卡住 (4) 机油压力调压阀失灵, 其弹簧损坏 检修 拧紧螺母加注机油至规定高度清洁机油冷却器, 必要时更换机油滤清器, 机油冷却器芯子检查各轴承磨损情况, 磨损值超过规定范围时更换相应零件 找出柴油进入机油的地方, 根据需要进行修理 更换机油和机油滤清器装上活塞冷却喷嘴检查原因, 更换机油更换检修清理后吹净重新按装机油泵, 必要时更换更换调压阀 26

32 SC27G 型柴油机使用保养说明书 (6) 机油温度过高 机油耗量太大 故障特征 可能原因 排除方法 油温表读数超过规定值, 加强冷却后仍较高, 同时排气冒黑烟 油底壳中机油液面下降较快, 油色较黑, 通气管 加油口冒白烟, 排气管冒蓝烟 (1) 柴油机负荷过大 (2) 温度表指示不准确 (3) 机油油面过低或过高 (4) 冷却液容量或风扇风量不足 (5) 机油冷却器阻塞 (1) 长期处于低负荷运行 (2) 使用的机油牌号不当 (3) 涡轮增压器弹力密封装置失效 (4) 活塞上油环回油孔被积碳阻塞 (5) 活塞环被粘住或磨损过甚, 气缸套磨损过甚使机油窜入燃烧室, 燃气进入曲轴箱 (6) 气门导管磨损 降低负荷校验温度表, 必要时更换调整机油至规定要求注意使冷却液畅通, 调整胶带张紧力, 使水泵和风扇达到规定转速清洗冷却器, 必要时更换 适当提高负荷选择本手册规定的牌号机油让专业维修人员拆检弹力封气环是否烧坏 弹性失效, 必要时更换弹力密封装置清理积碳, 必要时更换油环更换活塞环, 必要时更换气缸套 修理气缸盖 更换导管 (7) 机油内有冷却水 故障特征 可能原因 排除方法 机油中漂浮黄色泡沫, 通气管滤芯表面有水蒸汽凝结 气缸套封水圈损坏导致冷却液泄漏 气缸套与机体接合面泄漏冷却液 气缸套因穴蚀穿孔导致冷却液泄漏气缸盖垫片损坏导致冷却液泄漏机油冷却器芯子损坏, 使冷却液和机油相混水泵中的冷却液漏入油底壳 : (1) 水泵轴与密封圈处泄漏冷却液 (2) 水泵封水圈损坏 机体水腔壁穴蚀导致冷却液泄漏 ( 特别是靠推杆侧气缸壁 ) 更换封水圈 检查气缸套肩胛与机体之间的接合面是否平整, 缸套调整垫片是否损坏, 必要时更换相关零件更换气缸套更换气缸盖垫片 拆检机油冷却器芯子, 必要时更换冷却器芯子 检查并更换封水圈, 必要时更换水泵更换水泵 更换机体 (8) 冷却液温度过高 故障特征 可能原因 排除方法 柴油机起动后出水管不出冷却液或冷却液量很少, 冷却液温度不断上升 在高负荷下, 冷却液温度过高, 机油温度也升高 冷气系统中有空气 (1) 水泵或风扇转速达不到要求 (2) 冷却系统内的冷却液不充足 (3) 散热器压力盖故障 (4) 水管路阻塞 (5) 散热器表面积垢太多, 导致散热水管路阻塞 (6) 水温表不正确 (7) 调温器失灵 (8) 水泵叶轮与壳体的间隙过大 (9) 水泵叶轮损坏 散热器内冷却液有翻泡现象气缸套肩胛处有裂纹更换气缸套 松开出水管上的出气管, 放尽空气, 直至冷却液流出畅通为止, 拧紧水管路中各接头 调整传动胶带张紧力至规定要求补充冷却液至规定要求检查压力盖的工作情况, 必要时更换压力盖清理管路, 清除水道中的积垢清除积垢, 清洗散热器 检查水温表, 必要时更换检查调温器开启与关闭温度 开启升程是否符合要求, 必要时更换调温器更换水泵更换水泵 27

33 SC27G 型柴油机使用保养说明书 (9) 柴油机出水温度过低 故障特征 可能原因 排除方法 环境温度低, 使用负荷低 水温表指示不正确 调温器开闭不灵活或损坏 适当提高负荷 校验水温表, 必要时更换 更换调温器 (10) 冷却水中有机油故障特征 可能原因 排除方法 机油冷却器芯子损坏 更换机油冷却器芯子 气缸盖垫片故障 更换气缸盖垫片 (11) 电气系统常见故障 故障特征 可能原因 排除方法 起动电机不转动 起动电机空转无起动力 起动电机齿轮与飞轮齿圈顶齿或起动电机齿轮退不出 起动按钮脱开, 起动电机继续运转 交流发电机不能充电 充电发电机电压太低或者充电不正常 充电发电机电压太高 发电机有不正常声音 (1) 连接导线接触不良 (2) 电磁开关触点接触不良 (3) 电刷接触不良 (4) 起动电机本身短路 (5) 蓄电池充电不足或容量太小 (1) 电刷 接线头接触不良或脱焊 (2) 轴承套磨损 (3) 磁场绕组或电枢绕组局部短路 (4) 电磁开关触点烧毛, 接触不良 (5) 蓄电池充电不足或容量太小, 以及起动电机的线路压降太大 (1) 起动机与飞轮齿圈中心不平行 (2) 电磁开关触点烧在一起 (1) 起动电钥匙或按钮不复位 (2) 电磁开关触头与连接螺钉烧牢 (3) 起动继电器烧牢 (1) 交流发电机传动胶带松弛 (2) 充电电路, 接地回路或蓄电池接头接触不良 (3) 转子 ( 磁场线圈 ) 发生故障 (1) 传动胶带松弛 (2) 充电电路, 接地回路或蓄电池接头接触不良 (3) 交流发电机电压调节器损坏 (4) 转子 ( 磁场线圈 ) 发生故障 (5) 整流二极管烧坏 (1) 交流发电机或发电机电压调节器上的接头接触不良 (2) 交流发电机电压调节器有故障 (1) 传动胶带磨损或损坏 (2) 传动胶带松动 (3) 传动胶带与胶带轮没有相互对准 (4) 发电机轴承磨损 (5) 电枢或转子轴弯曲 (6) 发电机整流元件短路 清洁和旋紧接线头检查开关触点并用砂皮磨光清洁换向器表面或更换电刷找出短路部位后修理, 必要时更换起动电机给蓄电池充电或增加蓄电池并联使用, 必要时更换蓄电池 清洁表面, 重新焊接或更换换新找出短路部位修理检查开关触点, 并用砂皮磨光给蓄电池充电 必要时更换蓄电池, 增大导线截面或缩短导线长度 重新安装起动机, 消除不平行现象检查开关触点 锉平并砂光烧毛不平处 重新调整检修重新调整 调整传动胶带至合适张紧力检查全部导线和接头, 将全部接头擦拭干净并拧紧 必要时更换导线和接头更换转子 调整传动胶带至合适张紧力检查全部导线和接头, 将全部接头擦拭干净并拧紧 必要时更换导线和接头更换电压调节器更换转子更换整流二极管 拧紧交流发电机或电压调节器上的全部接头 更换电压调节器 更换传动胶带调整传动胶带至合适张紧力调整使传动胶带中心与胶带轮中心对准更换发电机更换发电机更换发电机 28

34 SC27G 型柴油机使用保养说明书 (12) 喷油泵常见故障故障特征 可能原因 排除方法 (1) 燃油箱中无柴油 (2) 燃油系统中进入空气 (3) 燃油滤清器或油管阻塞 及时添加柴油用燃油手揿泵排除空气清洗滤网 更换燃油滤清器, 对管路清洗 喷油泵不供油 (4) 输油泵故障, 不供油 (5) 柱塞偶件咬死 (6) 出油阀座与柱塞套接合面密封不良 后要吹净按输油泵故障排除方法检修让专业维修人员拆出柱塞偶件进行修磨, 必要时更换让专业维修人员拆卸维修, 必要时更换 (1) 燃油管路中有空气, 断续供油 (2) 出油阀弹簧断裂 用燃油手揿泵排除空气更换喷油泵 供油不均匀 (3) 出油阀座面磨损让专业维修人员更换出油阀偶件 (4) 杂质使柱塞阻滞让专业维修人员清洗 (5) 进油压力太小 检查输油泵进油接头滤网和燃油滤清器是 否堵塞, 必要时更换 按期进行清洗保养 (1) 出油阀偶件漏油 让专业维修人员检查出油阀偶件, 必要时 出油量不足 (2) 输油泵进油接头滤网或燃油滤清器阻塞 (3) 柱塞偶件磨损 更换清洗滤网, 换燃油滤清器让专业维修人员更换柱塞偶件 (13) 调速器常见故障故障特征 可能原因 排除方法 转速不稳定 ( 游车 ) (1) 各缸供油不均匀 (2) 喷油嘴孔结碳或和滴油 (3) 齿杆连接销松动 (4) 喷油泵凸轮轴轴向间隙太大 (5) 飞铁销孔磨损松动 (6) 调节齿杆与调节齿轮配合间隙太大或之间有毛刺 (7) 调节齿杆或油门拉杆移动不灵活 (8) 燃油系统中有空气 (9) 飞铁张开或飞铁座张开不灵活 (10) 低转速调整不当 让专业维修人员重新调整各缸供油量让专业维修人员进行清洗 维修, 或更换喷油器让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵用燃油手揿泵排除空气让专业维修人员维修或更换喷油泵让专业维修人员重新调整 达不到标定转速 (1) 调速弹簧永久变形 (2) 喷油泵供油量不足 (3) 操纵手柄不在最高转速位置 让专业维修人员维修或更换喷油泵按喷油泵故障排除方法处理检查并调整操纵手柄机构 达不到最低怠速 (1) 操纵手柄未放到底 (2) 调节齿杆与调节齿圈有轻微卡滞 (3) 低速稳定器调整不当 让专业维修人员调整或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员调整 调速器突然失灵, 使转速超过标定转速 110% 以上 ( 俗称飞车 ) (1) 转速过高 (2) 调节齿杆或油门拉杆卡死 (3) 调节齿杆和油门拉杆连接销脱落 (4) 油门拉杆螺钉脱落 (5) 调速弹簧断裂或弹簧挂耳脱落 应立即紧急停车, 用断开燃油停止进油或切断进气等措施使柴油机停车并让专业维修人员检查维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵让专业维修人员维修或更换喷油泵 29

35 SC27G 型柴油机使用保养说明书 (14) 输油泵常见故障 故障特征 可能原因 排除方法 输油量不足 (1) 止回阀磨损或断裂 (2) 活塞磨损 (3) 进油紧帽泄漏 (4) 输油泵进口滤网堵塞 (5) 活塞卡死断油 (6) 输油泵漏油 修磨或更换输油泵更换输油泵重新拧紧或修理清洗滤网更换输油泵检查输油泵, 必要时更换 (15) 喷油器常见故障 故障特征 可能原因 排除方法 喷油很少或喷不出油 喷油压力低 喷油压力太高 喷油器漏油 喷油雾化不良 喷油成线或油滴 (1) 燃油系统油路有空气 (2) 喷油嘴偶件咬死 (3) 喷油泵供油不正常 (4) 燃油系统漏油严重 (5) 喷油嘴偶件磨损 (1) 喷油器调压螺钉松动 (2) 喷油器调压弹簧变形 断裂 (3) 喷油嘴针阀粘滞 (1) 喷油器调压弹簧弹力过高 (2) 喷油嘴针阀粘滞 (3) 喷孔积碳或堵塞 (1) 喷油器调压弹簧断裂 (2) 喷油嘴针阀体研磨面损坏 (3) 喷油嘴针阀咬死 (4) 喷油器紧帽变形 (5) 喷油嘴与喷油器体密封平面接触不良导致泄漏 (1) 调压弹簧弹力衰减或弹簧断裂 (2) 喷油嘴座面磨损 (3) 喷油嘴偶件配合面有垃圾 (4) 喷油嘴偶件变形或磨损 (5) 喷油嘴针阀咬死 (1) 喷孔结碳 堵塞 (2) 喷油嘴针阀体座面过度磨损 (3) 喷油嘴针阀咬死 排除低压或高压油管中的空气让专业维修人员检查或更换喷油嘴按喷油泵故障排除方法找出原因处理检查 修理或更换相应零件让专业维修人员检查更换喷嘴偶件 让专业维修人员重新调整至规定压力, 并拧紧锁紧螺母让专业维修人员更换喷油器弹簧让专业维修人员更换喷油嘴偶件 让专业维修人员重新调整至规定压力让专业维修人员更换喷油嘴偶件让专业维修人员清理喷孔或更换喷油器 让专业维修人员更换喷油器弹簧让专业维修人员更换喷油嘴偶件让专业维修人员更换喷嘴偶件让专业维修人员更换紧帽让专业维修人员维修或更换喷油嘴偶件必要时更换喷油器 让专业维修人员更换喷油器弹簧让专业维修人员维修或更换喷油嘴偶件让专业维修人员清洗让专业维修人员更换喷油嘴偶件让专业维修人员更换喷油嘴偶件 让专业维修人员清洁喷孔, 必要时更换喷油器让专业维修人员更换喷油嘴偶件让专业维修人员更换喷油嘴偶件 针阀表面烧坏或呈蓝黑色 柴油机过热 检查冷却系统, 柴油机不要长时期超负荷 运行 ; 让专业维修人员检查喷油嘴偶件, 必要时更换 30

36 SC27G 型柴油机使用保养说明书 (16) 废气涡轮增压器的常见故障 故障特征可能原因排除方法 柴油机达不到规定功率柴油机排气烟色不正常, 排气管冒黑烟 ( 空气进气量不足 ) 排气冒蓝烟异常声响及振动涡轮压气机转子转不动或不灵活轴承烧损及转子碰擦转速下降 进气压力降低 漏气或不正常的声音等 (1) 轴承磨损 (2) 压气机叶轮及其涡壳流道沾污 (3) 涡轮 压气机叶轮背部及密封环处积碳过多 (1) 压气机部分流道沾污 (2) 压气机漏气 (1) 弹力密封环失去弹性或过度磨损 (2) 中间壳回油通道阻塞或管道变形 (1) 压气机喘振, 增压器振动时有较大振幅 ( 压气机通道, 进气管及涡轮出口通道有严重的沾污是产生喘振的原因之一 ) (2) 装配不当 ( 涡轮 压气机转子失去动平衡或旋转件与固定件碰擦 ) (3) 涡轮叶轮或压气机叶轮的叶片被进入的异物损坏 (4) 涡轮壳变形产生碰擦 (5) 无叶涡壳通道中存有异物, 在柴油机怠转时就能听到异常声音涡轮 压气机背部及弹力密封环座处严重积碳 (1) 润滑油过脏及油压太低或油路堵塞 (2) 进油温度过高 (3) 涡轮 压气机转子动平衡破坏或组装不当 (4) 排气温度过高及增压器转速过高 (5) 涡轮壳变形 (1) 增压器轴承磨损, 转子有碰擦现象 (2) 压气机进气管路沾污 阻塞或漏气 让专业维修人员更换轴承让专业维修人员清洗让专业维修人员清洗让专业维修人员清洗让专业维修人员检查密封情况, 消除漏气让专业维修人员更换弹力密封环让专业维修人员清洗并修复变形处让专业维修人员清洗, 让专业维修人员拆卸检查和维修让专业维修人员检查和维修, 必要时更换增压器让专业维修人员查明产生变形的原因, 并予以排除, 必要时更换增压器让专业维修人员拆卸检查通道截面, 同时检查柴油机进 排气系统让专业维修人员进行清洗, 同时检查柴油机燃烧不良及漏油现象检查润滑系统并清洗滤清器查明原因使油温降低让专业维修人员拆卸 检查并复校平衡, 必要时更换增压器检查柴油机及排气管有否严重漏气 变形 阻塞等现象, 修复并清洗查明产生变形原因, 并予以排除, 必要时更换增压器让专业维修人员检修, 必要时更换增压器让专业维修人员检修清洗压气机壳体 揩净叶轮 清洁进气管路 ; 拧紧接合面螺母 夹箍等 31

37 SC27G 型柴油机使用保养说明书 7 柴油机停运后保存 7.1 短期停运保存柴油机如需停用一段时间 (1 至 3 个月 ), 需要做好清洁工作和必要的油封措施, 防止生锈 封存前 (1) 清理干净柴油机表面, 检查无可见的脏物 油污 锈迹 水迹等, 然后用压缩空气吹干 ; 用毛刷将防锈油均匀涂在所有柴油机金属表面机加工表面 ( 即未喷漆的机加工表面 ) 上 ; 注意橡胶件 塑料件及纤维织物类零件表面禁止涂防锈油或与防锈油接触 注意 : 附件驱动带轮表面需采取一定防锈措施 发动机外部封存推荐使用 FD615 脱水防锈油或满足下面性能要求的防锈油 项目质量指标外观均匀棕色水分无滴点 55 耐寒性合格油基稳定性 (ml) 2 钢片 14 盐雾试验铸铁片 7 钢片 30 湿热试验铸铁片 14 叠片试验 (7 天 ) 钢片合格钢片合格腐蚀试验 (14 天 ) 铸铁片合格 (2) 断开蓄电池连接线, 清洁端子, 涂上一层薄油脂, 给蓄电池充电 (3) 使传动胶带松弛 (4) 将所有外露气管 水管或油管管口用防潮纸或气相防锈纸或聚乙烯塑料薄膜胶带进行封口或包扎, 整个空气滤清器也应由防潮纸封口或包扎 (5) 用塑料罩或类似的覆盖物覆盖柴油机, 将柴油机置于通风良好的干燥室内 保存期间每月进行蓄电池充电 检查蓄电池液面, 需要时, 添加, 然后进行充电 每月用盘车工具盘动曲轴 3-4 圈 拆封后使用启用时, 拆下燃油喷射泵, 送上柴公司指定的服务站进行调整 ; 卸下覆盖物和包扎物 ; 安装燃油喷射泵, 给燃油系统泵油排气 ; 连接蓄电池连线, 张紧驱动皮带 ; 检查润滑油和冷却液的液位, 在增压器进油口添加适量清洁机油 ; 用盘车工具先转动曲轴 3~5 转 然后参照 4.5 节柴油机起动, 采用正确的方法起动柴油机 7.2 长期停运保存柴油机停用时间超过 3 个月以上, 需要进行封存处理 封存前 (1) 在最后一次柴油机使用后, 在热态下放尽柴油机润滑油, 包括机油滤清器中的机油 因冷却液具有防锈功能, 不需要排放 向曲轴箱内加入合格的规定容量的封存油, 起动柴油机至怠速, 运转 1~1.5 min 即行停车, 然后从油底壳中放出封存油 发动机内部封存油为经脱水的 CF 级 15W/40 润滑油 (2) 柴油机外表面清理防锈及其他封存要求参见 节第 条, 并在柴油机挂上标签, 标签上写明 柴油机没有机油, 不要使用 保存期间参见 拆封后使用拿掉柴油机覆盖物, 拿掉各管口封口包扎材料 ; 启用时, 拆下燃油喷射泵, 送上柴公司指定的服务站进行调整 ; 安装燃油喷射泵, 给燃油系统泵油排气 ; 连接蓄电池连线, 张紧驱动皮带, 然后添加润滑油, 在增压器进油口添加适量清洁机油 然后参照 4.5 节柴油机起动, 采用正确的方法起动柴油机 如果存在期超过 2 年, 必须更换冷却液, 清洗冷却系统, 32

38 Caution Be sure to read this instruction manual carefully and strictly observe the safety and operation instructions herein, especially the warnings and cautions, so as to reduce the possibilities of personnel injury, property loss, engine performance deterioration, premature wear or damage. Warnings in this manual must be observed strictly. Failure to do so can cause burns, amputation, mutilation, asphyxiation, other personal injury or death. Cautions are provided for the user to operate the engine in a proper way, so as to avoid damage to engine parts and engine performance deterioration. Warnings and cautions in this manual are not complete because Shanghai Diesel Engine Co., Ltd. (SDEC) has no possibility and is not able to foresee all potential risks resulted from the failures to follow the safety cautions and operation instructions. Repair, Technical Consultation, Complaint and Suggestion For engine repair, technical consultation, complaints or suggestions, please contact SDEC s after-sale service center: spare@sdecie.com. Please provide the following information for product repair: The model of the diesel engine The order number of the diesel engine The serial number of the diesel engine The date of the equipment procurement The detailed description of the fault The address and phone number of contact person

39 Table of Contents 1 INTRODUCTION TO USER AND OPERATOR NOTICES FOR ENGINE QUALITY FEEDBACK SAFETY INSTRUCTIONS ENGINE OPERATION INSTRUCTIONS ABOUT THE ENGINE ENGINE OUTLINE DIAGRAMS ENGINE MODEL IDENTIFICATION ENGINE NAMEPLATE SPECIFICATIONS AND PARAMETERS ENGINE INSTALLATION AND CONNECTION ENGINE INSTALLATION ENGINE CONNECTION ENGINE OPERATION FUEL LUBRICATING OIL COOLANT POWER MATCHING ENGINE START ENGINE OPERATION ENGINE SHUTDOWN RUNNING-IN OF A NEW OR OVERHAULED ENGINE ENGINE MAINTENANCE MAINTENANCE PLAN MAINTENANCE RECORD TASKS AND METHODS OF ENGINE MAINTENANCE TROUBLESHOOTING GUIDELINES GENERAL TROUBLESHOOTING GUIDELINES ENGINE STORAGE SHORT TIME STORAGE LONG TIME STORAGE...42

40 1 Introduction 1.1 To User and Operator Thank you for purchasing a product of Shanghai Diesel Engine Co., Ltd! The G series V type diesel engine with two displacements of 25 liters and 27 liters is developed from the base diesel engines of 112V135A and 12V135B by increasing the engine power output, improving the engine cooling and lubricating capacity and addressing the quality issue of the base engines. The G series V type diesel engine has produces more power, less fuel consumption and exhaust emissions, and is more reliable than its base diesel engine. It is compatible and exchangeable with the base engines in terms of dimension and installation. The G series V type diesel engine is a perfect power for large generator sets. This manual mainly covers the technical specifications, operation and maintenance instruction, with an aim to familiarize you with the engine, as well as the proper operation and maintenance thereof. Before using the engine, read carefully the relevant contents and requirements in this manual. Due to the continuous improvement of performance and structure of the engine, the technical specifications and illustrations of the engine in this manual may be slightly different from those of the engine you have, please note that we will provide the supplement and perfection in the later editions without notice. In case of any question during your engine operation and maintenance, please never hesitate to contact SDEC s after-sale service center spare@sdecie.com for technical advice or guidance. SDEC has adopted the latest technology and high-quality parts for the engine. The genuine SDEC service parts are recommended to be used for repair and maintenance. Please contact SDEC s after-sale service center spare@sdecie.com for service parts. Since this manual ensures proper engine operation and maintenance, it should be given to the new owner when the engine is traded or sold. 1.2 Notices for Engine Quality Feedback To better our service, please provide following information when you make feedback about quality issue(s), whereby, we can understand and analyze the quality issue(s) and the root cause(s) thereof, and make the improvement in time: 1) When and where fault occurred; 2) Engine serial number, model, order number, delivery date and the detailed address of consignee; 3) Service conditions, cumulative operation time (in hours), operating conditions (power, speed) and the grades of the fuel and the grade of the engine oil that were used; 4) The characteristics of the driven equipment (model, power consumption and structural feature, etc.); 5) The description of fault(s); 6)Part(s) or component(s) claimed for compensation or repair should be mailed or sent in person to SDEC headquarter with the damage process record or description for facilitating analysis. If there are several problems or a very serious problem, please leave the site as it was and inform us promptly, and then SDEC will send staff for a joint analysis. Quality issue(s) should be settled based on the relevant provisions in the quality warranty manual. 1.3 Safety Instructions Do not wear a loose garment or any jewelry when working around the engine or its driven equipment. If necessary, wear safety goggles, work clothes, safety helmet or other protective items. All the exposed rotating parts should be provided with guards with firm installation to prevent personal injury. The workroom of the engine should be well ventilated with waste gas exhausted outside. No flammable liquid is allowed to be around the engine. Take all tools, wires, other odds and ends away from the engine prior to starting. 1

41 Make sure to shutdown the engine before any adjustment is performed to it and its driven equipment. Smoking is not allowed during fuel filling, otherwise, fuel steam can cause fire easily. Smoking is also not allowed when checking the electrolyte level because electrolyte will release flammable gas. Contact between electrolyte and skin or eyes must be prevented when replenishing it for the battery, because electrolyte is an acid. In case of skin contact, please flush the contacted part with soap and clean water; in case of eyes contact, flush your eye(s) for 15 minutes with clean water and seek for medical treatment immediately. Cool the engine first when filling coolant to avoid being hurt by coolant steam. Open the pressure cap only when the coolant temperature is lower than 50, and then slowly loosen the cap to release the pressure of coolant. Wipe up lubricating oil, fuel, coolant or other liquids overflowed. Put oily rags into a fire-protection container, and do not leave it on the engine. Before starting the engine after being repaired, make sure to be ready to cut air supply. In case of any abnormal, cut air supply to stop the engine immediately. Do not rotate the engine with the fan, otherwise severe personal injury or damage to fan blades can be caused. Do not touch by hand the intake and exhaust system components such as the exhaust manifold, turbocharger, intercooler air inlet pipe, expand tank because they are in high temperature when the engine is in operation. Release the pressure in the air system, lubricating system, cooling system or fuel system prior to dismantling or loosening any pipelines, permanent joints, connectors or relevant parts of these system. Do not use your hand to check leakage, otherwise high pressure and high temperature fuel, lubricating oil and coolant can cause personal injury. If the engine will not be used for a long time or is under repair, separate it from the battery to prevent an unexpected start-up. Meanwhile, place a sign STOP in the operation room or on the controller. Used engine oil may contain carcinogenic substance which can result in reproductive toxicity, therefore, inhalation of or longtime exposure to oil steam should be avoided. Waste oil should be disposed in proper, safe and reliable manner. 1.4 Engine Operation Instructions Read this manual carefully, and be in strict accordance with operation instructions and maintenance procedure specified in this manual. Conduct daily and 4-level maintenance as specified in this manual, and keep the records of scheduled maintenance. Use the proper fuel, lubricating oil and coolant specified in this manual. 60 hours running-in must be conducted for a new or overhauled engine. Please refer to Section 4.8 for the running-in requirements. Do not run the engine without air filter, otherwise, early engine wear will happen. The coolant specified in the manual should be adopted for the engine cooling system in any kind of climate. When filling lubricating oil, it is not allowed to use the mixture of oil of different specifications. Preparations should be well done before starting the engine. Be sure to remember that the engine must be started without load. Check if coolant, lubricating oil and fuel are enough before starting the engine. It is not allowed to start the engine with lack of diesel fuel in the fuel tank. The fuel tank should be replenished; or it will cause damage to the high pressure fuel pump. Observe the engine operation and all the instrument readings. In case of critical situation, an emergency stop should be performed to prevent the seizure of moving parts caused by low oil pressure or overheating due to lack of coolant. Do not run the engine at high load and high speed when the coolant temperature is blow 60. The belt tension and the other drive devices can only be inspected when the engine is in stop. Malfunction thermostat should be replaced in time but the use of thermostat cannot be omitted. Do not remove the lead seals on the engine to make adjustment without permission. If necessary, send the relevant components to a professional service location for repair and adjustment. 2

42 2 About the Engine 2.1 Engine Outline Diagrams Left Side (Viewed from the flywheel end) 1 Flywheel housing 2 Oil pan 3 Starting motor 4 Oil drain plug 5 Oil temperature sensor joint (left side) 6 Oil filter (left side) 7 Oil pressure regulating valve (left side) 8 Water drain cock (left side) 9 Oil cooler (left side) 10 Gas outlet pipe of crankcase filtration device 11 Oil return pipe of oil separator 12 Front engine support 13 Engine nameplate 14 Water pump (left side) 15 Fan 16 Alternator 17 Thermostat outlet (left side) 18 crankcase filtration device 19 Air inlet pipe adapter 20 Air inlet pipe 21 Heat shield (left side) 22 Air filter (left side) 23 Valve cover (left side) 24 Exhaust manifold 25 Turbocharger left side) 3

43 Right Side (Viewed from the flywheel end) 26 Water(right side) 27 Fuel filter (first stage) 28 Front engine support 29 Fuel filter (second stage) 30 Water drain cock(right side) 31 Oil cooler(right side) 32 Oil pressure regulating valve(right side) 33 Oil filter(right side) 34 Oil temperature sensor joint(right side) 35 Oil dipstick 36 Oil filler 37 Turbocharger(right side) 38 Exhaust manifold(right side) 39 Valve cover(right side) 40 Air filter(right side) 41 Air inlet pipe 42 Exhaust heat shield(right side) 43 Water temperature sensor joint(right side) 44 Thermostat outlet(right side) 4

44 Rear End (Viewed from the flywheel end) 45 High pressure fuel pipe 46 Air inlet pipe 47 Fuel transfer pump outlet pipe 48 Turbocharger oil inlet pipe(right side) 49 Turbocharger oil return pipe(right side) 50 Rear lifting ring 51 Speed sensor joint 52 Fuel pump oil inlet pipe 53 Turbocharger oil return pipe(left side) 54 Turbocharger oil inlet pipe(left side) 55 Fuel pump 5

45 2.2 Engine Model Identification The engine model represents the meanings as follows: SC 27 G Emission standard: e.g. 2 stands for China Stage II (off-road) Application: D Power generation Power /PS Engine series Displacement /L Shang Chai Power For example: SC25G690D2 stands for Shang Chai Power G series V-type diesel engine of 25 liters with power of 690 PS and compliant with China Stage II for generator sets SC27G830D2 stands for Shang Chai Power G series V-type diesel engine of 27 liters with power of 830 PS and compliant with China Stage II for generator sets 2.3 Engine Nameplate The engine nameplate indicates the main technical data and information: engine model, order number, serial number, date of production, rated power and rated speed, which are the major basis for you to purchase service parts and for SDEC to conduct after-sale technical service. We hope you to put the information and data into the daily work record of your engine or equipment for later repair and reflection of quality problems. That is helpful to the correct settlement of your problems. The nameplate locates at the side of the gear housing. Protect it from being damaged. Notice: Do not change the nameplate without our permission! 6

46 2.4 Specifications and Parameters Specifications Engine model SC25G690D2 SC27G830D2 Type Aspiration type Twelve cylinders, V type, water cooled, four stroke, direct injection Turbocharged and intercooled (air - to- air) Bore/mm Stroke/mm Displacement/L Compression ratio 16:1 16:1 Starting temperature/ -5 (Without starting aid) -5 (Without starting aid) Crankshaft rotation (facing flywheel) Firing order (viewed from the front end) Counterclockwise Counterclockwise (Left side cylinders: 1,2,3,4,5,6; right side cylinders: 7,8,9,10,11,12) Power/kW Rated point Speed/(r/min) 1,500 1,500 Over load Power/kW 505±2% 610±2% Speed/(r/min) 1,500 1,500 Oil consumption/(g/kwh) 0.4 (after running in) 0.4 (after running in) Emissions China Stage II China Stage II Starting mode Electric Electric Altitude/m 2,000 2,000 Net weight/kg 2,200 ± 50 (excluding radiator) 2,200 ± 50 (excluding radiator) Length/mm 1,912 1,930 Dimensions Width/mm 1,220 1,220 Height/mm 1,872 1,872 Note: 1) The listed engine performance data are those of the base engines, which are obtained at the standard test conditions: ambient temperature is 25, relative humidity is 30% and barometric pressure is 100 kpa. The data of a specific engine refer to the nameplate of the engine. 2) When the engine operates on over 2,000 meters above the seal level, its power output will decrease and its performance become bad. So it is required to reduce the engine power output when it runs at altitude higher than 2,000 meter. It is not recommended to run the engine over 4,000 meters above the sea level. 7

47 2.4.2 Parameters Engine model SC25G690D2 SC27G830D2 Exhaust temperature (before turbine)/ 700 Oil temperature in oil Max. allowable 115 pan/ Operational range Pressure of oil rated speed 0.25 main idle 0.10(when oil temperature 75 ) Oil pan capacity About 42 Lubricating system capacity/l About 65 Minimum coolant temperature (inlet) / 60 Maximum coolant temperature (outlet) / 100 Proper operational water temperature rang/ Min. stable idle speed/(r/min) 900 Fluctuation at Min. stable idle speed /(r/min) ±30 Electronic Sudden unloading at one-hour power condition: governor Transit governing rate/% performance Stable governing rate/% Stable speed recovering time/s Min. recommended battery capacity/ah * 195 Battery Battery current of at -18 for cold starting /CCA 1,250 Voltage/V 24 Starting Voltage/V 24 motor Power/kW 9 Voltage/V 28 Alternator Current/A 55 Rated power/kw 1.5 * The capacity of a battery should be properly increased for a starting with higher requirement Application requirement The table below gives requirements on engine operational data and maximum power output because ambient condition has a great effect on the operation of a turbocharged engine with air-to air intercooler. It is required to choose proper intercooler, radiator, muffler and connecting pipeline according to the requirements listed in the table, maintain the air filter timely, and control engine load to avoid overloaded operation that will lead to damage to the engine. Ambient temperature / Speed r/min Max. Power allowance /kw Intercooler outlet Temperature / Intercooler pressure drop /kpa Engine outlet coolant temperature / Oil temp. (in oil pan) / Intake resistance /kpa Exhaust back pressure /kpa 30 1, < , < , <

48 3 Engine Installation and Connection 3.1 Engine Installation There are four engine installation supports on the both sides of the gear housing and flywheel housing. There are lifting rings and plates on the engine, strong enough to bear the engine weight. Chain pulley or other facilities can be used when lifting the engine. However, attention should be paid to avoid thin parts or instrument parts of the engine being pressed by stressed chains, causing damage to them. Keep the lifting rings and plates from bearing bent moment and keep smooth handling when lifting to remain the engine in horizontal position. The engine should be placed on a special base or stable block to prevent the oil sump from directly bearing the engine weight. 3.2 Engine Connection Intake pipe extended Caution:The cross section of an air inlet pipe taken as extended part must be large enough. To avoid big air inlet resistance, a pipe with inner diameter of 100 mm and without sharp angles or over length is recommended for the pipes before and after the intercooler. Air intake pipes must be well sealed or else early engine wear will happen Coolant pipe extended The G series V type diesel engine has a close loop cooling system, so there is no need to have water pool or water tank. The recommended inner diameter of water pump inlet is 61 mm and that of thermostat outlet pipe 54 mm Fuel line extended The fuel inlet from and the fuel return to the fuel tank are showed in the figure below. Fuel inlet Ф10.1 Fuel return Ф10.1 The capacity of the fuel tank should be large enough to hold the fuel that can be used for more than 8 hours. The fuel tank should be such positioned that the lowest fuel level of fuel supply is 1 meter higher than the center of the fuel transfer pump. The inlet port of the fuel suction pipe should be more than 50 mm above the bottom of fuel tank. It is better to add a strainer at the inlet port to avoid sucking in sediments that can block of the pipeline, and to have a drain valve at the bottom of the fuel tank for an easy cleaning. The fuel tank should be away from the heat source (such as exhaust manifold or exhaust pipes) and electrical equipments Engine power output Engine power output for driving the equipment is taken from flywheel. When using coupling to connect the equipment, the centerline of the equipment should be in alignment with the centerline of the crankshaft. If using an elastic coupling, the misalignment shall not be greater than φ0.30mm. If using a rigid coupling, the misalignment shall not be greater than φ0.10mm. Caution: The engine should not be started with load. So there should be a kind of clutch device between the engine and driven equipment. A certain power can be taken from the front crankshaft of the engine. But the output power for transverse driving with a belt directly on the front crankshaft pulley should not exceed 11 kw. It is forbidden to directly install a pulley on the flywheel to drive equipment transversely by belt because such operation can easily damage the crankshaft and main bearings. If it is required to have a transverse driving, use an engine or an additional device that is suitable for transverse driving. Do not let the crankshaft and main bearings sustain transverse forces directly. 9

49 4 Engine Operation Proper use of your engine can not only keep it in normal working order and good performance, but also can extent its service life and reduce its operational cost. Adopt proper fuel, oil and coolant, as well as the correct operation steps stipulated in this section. 4.1 Fuel The specifications of the fuel used for the engine should be in accordance with the standards GB General Diesel Fuels. Proper fuel designation should be chosen for the engine according to ambient temperature. In cold winter, fuel with low-freezing-point should be adopted, while contrary in summer. You may choose the right fuel according to the standards GB or refer to the table below, e.g. fuel with the designation of -35# should be used at the ambient temperature of -27. Relationship between diesel fuel designations and applicable minimum temperatures Fuel designation Cetane value Solid point/ Minimum applicable temperature (engine working temperature)/ Above 4 Above -5 Above -14 Above -29 Caution: Fuel must be kept at the highest level of cleanness and not polluted by dust, impurities or water. 4.2 Lubricating oil Lubricating oil of grade CF-4 and above is required for the engine in order to ensure its normal operation and long service life and to improve its emissions. Lubricating oil of CF-4 l5w-40 is required for common environment temperature, and lubricating oil of CF-4 5W-30 may be used for environment temperature lower than -5 to favor cold starting, but continuous use of the low viscosity lube oil will increase the wear of engine. The specifications of the oil used for the engine should meet the requirements of the national standards GB Specifications of lubricating oil (GB ) Specifications Kinematical Flash Solidifying Mechanical viscosity Water/% Viscosity point(open)/ point/ impurities/% (100 )/ mm 2 /s class 5W/ < Trace 15W/ < Trace Caution: Lubricating oil must be kept clean and free from dust, impurities or water. Caution: Do not use the mixture of oil of different specifications. Part numbers of SDEC-designated special lubricating oil of grade CF-4 15W-40 are as follows: Y/ (3.5 kg) Y/ (16 kg) Y/AG0105 (3.5 kg) Y/AG0106 (16 kg) 4.3 Coolant In order to ensure the normal operation and long service life of the engines, use SDEC- designated special organic coolant (anti-freezing type) under any kind of climate. The coolant proves antifreeze, anticorrosion, good thermal conductivity, performance stability, and environmental friendliness. Name Part No. Freezing point/ Boiling point/ SDEC-designated special organic coolant F/LQY

50 4.4 Power Matching When choosing a diesel engine, users should not only consider the power required by equipment to be driven, but also engine operation type, such as intermittent use or continuous use. Meanwhile, operational economy is an important item to be considered that is, the characteristics of equipment load and engine power output must be reasonably matched. Correct power rating and reasonable match between engine power output and equipment load are essential to guarantee a reliable, long-life and economic operation of an engine. Otherwise, it would lead to overloaded operation and unnecessary failure of an engine. Or load is too small and the capacity of an engine cannot be fully used, which is not an economic way to use an engine and also easy to lead to oil carry-over. 4.5 Engine Start Before using the engine, choose proper lubricating oil, fuel and coolant according to ambient conditions. Besides, the following work should be done before starting: Make a surround inspection of the engine and its starting system, and solve problems in time if any. Check oil pressure and temperature gauges, coolant temperature gauge, warning lamps and other instruments for normality. Check the service indicator of the air filter for appearance in red. Caution: Do not to start the engine without an air filter to avoid early engine wear. Check the oil level for being within the specified range. Add proper amount of clean oil into the turbocharger oil inlet port when the engine is first put into use or overhauled. Check the coolant level for being within the specified range. Check the electrolyte level for being within the specified range. When the engine is first put into use or overhauled, or out of service for some days, or its fuel filter has just been replaced, there can be air in the fuel system. Prime the fuel system with the priming pump. Refer to section 5.3 for specific priming operation. Check the electric starting wires for normality. Check the starting motor for right wire connection, and battery for sufficient electricity. All the safety devices must be installed in place. Check the accelerator lever for free movement. When the engine is new or is not in use for over 5 days, rotate the crankshaft 3 to 5 circles before starting Normal starting procedure The G series V type diesel engine can be started smoothly at temperature of -5 and above. Starting procedure is as follows: Disengage the diesel engine from the drive system. Put the mechanical operating devices into the running position. Push the governor controlling handle to unloaded position with speed at about 900 r/min. Insert electric key and turn the switch from the OFF position to the START position to start the engine. If it cannot be started up in 10 seconds, turn the switch from the START position to the OFF position. Make another starting after 2 minutes. If the engine cannot be started up for three times, stop starting and refer to Section 6 for troubleshooting guideline to find cause. Each starting lasts 2 to 3 seconds. Caution: The engine should be started without load. After the engine has started up, the switch key goes back to the ON operation from the START position automatically. The oil pressure gauge should show reading within 15 seconds after the engine has started up; otherwise, stop the engine immediately to prevent damage to the engine and find the causes and remove the fault(s) 11

51 according to Section 6 Troubleshooting Guidelines. Having started up from a hot state, the engine should run at idle for 1-3 minutes before being accelerated and loaded gradually. Having started up from a cold state, the engine should run at idle for 3-5 minutes. Increase engine speed slowly to 1,500 r/min and run the engine with partial load. Do not run the engine with full load until the outlet coolant temperature is higher than 75, oil temperature 50 and oil pressure 0.40 MPa. Caution: Especially starting the engine from a cold stat, increase the engine speed slowly as far as possible to have every bearing adequately lubricated and oil pressure stable. Check the instruments during the engine running at idle to see whether they work normally. Caution: Do not accelerate and load the engine immediately after it has been started up. Caution: Do not idle the engine for a long period of time or it can cause problems to the engine. When an engine idles, the temperature in combustion chamber is low and combustion is not complete. It can cause carbon deposit in cylinder resulting in block of the orifices of fuel injector, as well as seizures of piston rings and valves, thus leading to engine performance deterioration. Caution: If the engine is start by a jumper cable, parallel connection of the cable should be adopted by connecting the positive pole to the positive terminal and the negative pole to the negative terminal. If the engine is start by external power supply, the circuit breaker should be set to the OFF position. Take out the key to prevent accidental activation before connecting a jumper cable Cold Start Cold start refers to starting the engine at temperature -5. Choose proper cold starting aid to warm the engine according to ambient temperature and then follow the normal starting procedures to start the engine. There are, in general, several ways to warm the engine: Warming the engine oil and coolant to 40~50 ; Installing a heating device in the air inlet pipe or heating air by fire at the entrance of the air inlet pipe, with which special precaution must be paid for safety; Increasing the surrounding temperature of the engine room; Using diesel fuel, engine oil and coolant that are suitable for cold areas; Warming battery or using battery of larger capacity or having higher discharge rate (special battery for low temperature) Starting after a longtime stop or replacement of lubricating oil If the engine hasn t been used for less than 30 days or its engine oil has just been replaced, it is necessary to fill the lubricating system with oil. Crank the engine and make oil enter moving parts. Start the engine only after you feel light when cranking the engine. Finish the following preparation before starting the engine according to the procedures of normal starting or cold starting: Check the oil level for being within the dipstick marks range. Check the voltage of the battery for abnormality. Prime the fuel system. Refer to Section 5.3 for operation. In order to have a quick starting of a standby engine for emergency need, start the engine every three to five days and operate it until its engine oil and coolant temperatures reach 60 and above. 4.6 Engine Operation Cautions for operation of the engine: 12

52 Pay frequent attention to oil pressure and coolant temperature. In case of any abnormality, stop the engine immediately for inspection. Lubricating oil pressure: 150 idle speed (minimum allowable) 300 rated speed (minimum allowable) 500 rated speed (maximum allowable) Coolant temperature: (normal working range) When engine overheating starts to happen that is indicated by the coolant temperature alarming, reduce engine speed or load or take the both actions until the coolant temperature falls down into the normal range; otherwise, find the cause and remove the fault as per Section 6 Troubleshooting Guidelines. During the operation, especially sudden decrease of load, attention should be paid to avoid the failure of the governor, which can cause sudden increase of engine speed exceeding the defined value (usually called flying away). Once such case happens, make an emergency stop first and then check for the cause. Caution: Over-speed running will cause serious damage to the engine. There are significant signs before most engine faults occur, such as changes in performance, sound, or engine appearance. Listening and observing will help detect in advance or predict some problems of the engine that will occur later, with which the proper measures can be taken in time to eliminate such problems as can lead to a serious engine failure. Typical engine fault signs: Engine misfires Engine vibrates abnormally Engine sounds abnormal Engine coolant temperature and oil pressure change abruptly Engine produces black smoke Engine power output is insufficient Engine oil consumption is too much Fuel consumption is too much There is leakage of oil, fuel or/and coolant 4.7 Engine Shutdown Normal shutdown If the engine has just worked at a high speed and heavy load for a long time, reduce its load and speed gradually and run it at idle for 5 minutes before stopping it to let the engine cool down evenly and turbocharger speed fall considerably so as to protect the engine and turbocharger. Turn off the fuel tank cock after the engine has stopped. If the engine will not be used for a period of time (6 months at most), keep it properly. Refer to Section 7 for engine storage Emergency shutdown Under emergency or special condition, make an emergency stop to avoid serious engine failure. Manually pulling of the emergency stop handle can achieve an emergency shutdown. 13

53 4.8 Running-In of a New or Overhauled Engine When the engine is new or has been overhauled, run the engine for 60 hours in running-in condition and change its oil thereafter before running it in full load condition so as to improve its moving parts working condition and its reliability and service life. The way of running-in varies from one engine application and loading manner to another. In principle, engine speed and load in running-in process will be increased gradually with the running-in going on. Load should be 50%-80% of its full one, and speed should not exceed 80% of its rated speed. If the engine is for generator sets with constant speed, it is allowed to run-in at rated speed. However, long time running at idle or with too small load at the beginning of running in is not recommended. Do not run the engine at idle or with low load for a long-time either in running-in period or normal working period thereafter. Continuous running at idle should not be longer than 10 minutes to avoid early wear due to carbon deposit or engine performance being affected. The above running-in process with less time should also be required every time the cylinder liner, piston, piston ring, connecting rod bearing, main bearings or/and crankshaft are replaced. 14

54 5 Engine Maintenance 5.1 Maintenance Plan The following table gives maintenance period and tasks. Make regular maintenance based on this table. If the engine frequently operates at the ambient temperature below -18 C or above 38 C, or in dusty environment, the maintenance period should be shortened properly. Maintenance tasks Daily Every 250 h or 3 months Every 500 h or 6 months Every 1,000 h or 12 months Checking engine periphery Checking fuel tank Checking air filter service indicator Checking oil level Checking coolant level Checking electrolyte level Checking first stage fuel filter and draining water Every 2,000 h or 2 years Checking drive belt * Checking cooling fan Checking intake system Adding grease Checking belt tension Changing lubricating oil and oil filter Changing fuel filter (first and secondary filters) Priming fuel system Checking and adjusting valve clearance Checking intercooler and its lines Checking fan bearing Checking turbocharger Checking vibration damper Changing coolant and cleaning cooling system * The Belt must be replaced when it has crack or defect(s) that affects its use. Note: The maintenance interval in this table is in hours, months or years, whichever comes first. 15

55 5.2 Maintenance Record Make a regular maintenance record. You may make your own maintenance log by referring to the format of Maintenance Record below. Maintenance Record Engine serial number Engine model & order No. User Equipment description & serial No. U Date Hour or Interval Maintenance Operator Remark 16

56 5.3 Tasks and Methods of Engine Maintenance Checking engine periphery Check the periphery of the engine each time before starting: Check if the engine is in clean state and free from useless things on it. Check the joints and connections of the fuel system, cooling system and lubricating system for leakage. Check if the fan and its safety guard are fastened in place. Check the fastening condition of the accessories. Check the electrical circuits and the wire for intact. Check the drive belt for intact Checking fuel tank Check the fuel level in the fuel tank daily Checking air filter service indicator If the viewing window shows the red piston, it represents that the intake resistance of the air filter exceeds the specified value, and the filter element requires to be replaced. Refer to Section for the requirement and procedure of the replacement. Press the button on the top of the service indicator for reset after the replacement. Button Caution: Be sure that both end faces of the air filter are reliably sealed without leakage after the air filter element has been changed. Caution: Do not start the engine without an air filter, and failure to do so would easily cause early engine wear Checking oil level Check the oil level daily before starting the engine for the first time, and the oil level should be near the mark 3 (static high oil level). Or check the oil level daily at idle or low speed when the engine is in operation, and the oil level should be between the mark 2 (dynamic high oil level) and the mark 1 (dynamic low oil level). If oil is not enough, supplement it to near the mark 2 and if the oil level is below the mark 1, add oil immediately to near the mark 2. Caution: Do not run the engine when the oil level is below the mark 1, otherwise it can result in poor engine performance, or even damage to the engine. But the oil level should not exceed the mark

57 5.3.5 Checking coolant level Check the coolant level daily before starting the engine or after the engine has stopped. Warning: At operating temperature, engine coolant is hot and under pressure, and the coolant steam can cause personal injury. Do not remover the pressure cap on the radiator until the engine stops and the coolant temperature drops to below 50. Slowly loosen the cap to release the cooling system pressure before checking the coolant level or making supplement. Warning: Avoid skin or eye contact with coolant to prevent personal injury because the coolant contains alkali. (1) Slowly loosen the pressure cap on the radiator to release pressure before starting the engine or until the coolant temperature goes below 50 after stopping the engine. (2) Remove the pressure cap and check coolant level from the filler or inspection port. The coolant level should remain between the marks in the radiator or expansion tank, or meet the requirement of the equipment manufacturer. (3) Add if necessary. Coolant should be added near the upper mark or meet the requirement of the equipment manufacturer. Caution: Coolant should be added slowly to avoid air block Checking electrolyte level Batteries that are not maintenance-free need electrolyte level checking. (1) Check the electrolyte level before starting the engine. Remove the filler cap and check the electrolyte level. It should be at the bottom of the filler port. If necessary, make supplement as per requirement. (2) Install the cap Checking first stage fuel filter and draining water The first stage fuel filter has a function of fuel and water separation. Check daily if there is water in the water container and discharge water if any. Loosen the water drain cock to drain the water and sediment until clean fuel outflows. Then tighten the valve until you feel suitable. Don t over-tighten it. Water Container Filter Drain cock 18

58 5.3.8 Checking drive belt Perform visual check on the drive belt everyday for any intersecting cracks. Transverse cracks along the width direction of the belt are acceptable, while longitudinal cracks (along the length direction) that intersect with transverse cracks are not allowed. If any wear or abrasion occurs, replace it Checking cooling fan Perform visual check on the cooling fan for crack, loose rivet or blade bent or any other defect. The fan should be installed reliably. Tighten the fastening bolts or replace the damaged fan if necessary. Warning: Damaged fan blade can cause serious personal injury. Do not pull or pry the fan, and do not rotate the engine with the fan Checking intake system Check the intake hoses for any crack, as well as perforation, and clamps for looseness. Replace the hose(s) if any fault is found, and tighten clamp screw(s) if looseness is found to ensure the intake system free from leakage Adding grease Add proper amount of sodium based lubricating grease in the small hole. For grease Checking belt tension Check Apply a force of about 98 N on the middle point of the belt span between the two pulleys with finger by pressing and pulling, and check the position change of that point. The change should be within 8-12 mm. If it is out of the range, make adjustment. 19

59 Adjustment (1) Unscrew the tensioner nut and screw or unscrew the adjusting bolt to adjust belt tension. (2) Tighten the tensioner nut to N m. Tensioner nut Adjusting bolt Tensioner Changing engine oil and oil filter Warning: Be careful when changing lubricating oil and oil filter because skin contact with the hot oil or hot engine surface can cause scald. (1) Don t stop the engine until the temperature of the coolant reaches 60 C, then remove the oil drain plug on the oil pan, scrap the washer and drain the lubricating oil. Caution: Do not drain lube oil when the engine is in cold state at which foreign particles has deposited and attached to the bottom of the oil pan, and will not drain with the oil. When the lube oil is warm, foreign particles suspend in it and can easily drain with it. (2) Clean the installation surface of the oil drain plug on the oil pan. Install the drain plug with sealant Tonsan 1567F and tighten it to N m. (3) Clean the outside surface of the oil filter. Remove the oil filter with tool and scrap it. There are two oil filters (over the oil cooler on each engine side) and both two should be replaced at the same time. (4) Clean the seal surface of the filter head, and there should be no old O-ring left. 5) Do not fill the new filters with clean oil. Only apply a light film of Vaseline or clean lubricating oil to the O-rings on the new filters to form a lubricating film before installation. (6) Turn the filter by hand until the O-ring contacts the sealed surface of the filter head, and further tighten it to 45 ± 5 N m or 3/4 to one of a turn with tool. (7) Open the filler cap (near the lower part of the cylinder block), and fill the engine with clean lubricating oil until the oil level is near the high level mark in the oil dipstick. The lubricating system capacity is about 65 L and oil pan capacity about 42 L. (8) Start the engine and keep it running at idle, and then check the oil filter and drain plug for oil leak. 20

60 (9) Check the oil level at idle or low speed. If required, add engine oil until it is near the dynamic high level mark (the mark 2) in the oil dipstick. (10) Install the filler cap and tighten it until you feel suitable Changing fuel filter (second stage) (1) Clean the outside surfaces of the fuel filters (two filters). Remove the filters with tool and scrap them. (2) Clean the filter heads and its seal surfaces. There should be no old O-ring left. Note: There is two fuel filter, change them at the same time. (3) Before installing a new fuel filter, fill it with clean fuel from the 8 peripheral holes. The fuel level should be 3-15 mm below the threaded hole. Apply a light film of Vaseline or clean lubricating oil on the O-ring on the new filter to form a lubricating film. Caution: Do not add fuel from the central hole of the filter. (4) Screw the filter by hand until the O-ring contacts the seal surface of the filter head, and further tighten it to 45 ± 5 N m or 3/4 to one of a turn with tool Replacing fuel filter (first stage) The first stage fuel filter is also spin-on type. Refer to Changing fuel filter (second stage) for replacement procedure. Refer to the instruction on the filter for the removal directions of the filter and water container Priming fuel system If the engine has not been used for a long time or first and second stage fuel filters are changed, air will enter the fuel system. It is required to prime the fuel system as per following steps: Breeze (1) Loosen the air breezing screw (straight line head) on screw the top of the priming pump. Priming pump (2)Press the priming pump to prime until there is no bubble visible in the fuel that outflows from the plug. Filter (3 Tighten the plug to10 N m. Caution: Priming the fuel system is required if air enters the fuel pipeline due to untimely fuel supplement or there is air in the fuel system due to other reasons. 21