ZD30 series engine user manual

ZD30 系列发动机特点
The Characteristics of ZD30 Series
Engine
1.1 主要特点Main Features：

ZD30系列发动机为直列四缸、四气门、电控高压共轨、
增压中冷柴油机，电控EGR、功率80～132KW。
ZD30 series engine has four-cylinders in line, and each
cylinder has four-valves, two for intake, the other two for
exhaust. Its common rail and EGR systems are controlled by
ECU. After enhancing by turbocharger and inter-cooler, the
power of this series diesel engine can cover 80~132kW.
该发动机具有以下优点
The Engine’s Advantages:
☆电子控制：发动机电子控制单元（EECU）从传感器

接收信息，随时调整发动机供油量和喷油正时，以获得最
佳性能和最佳燃油效率：
☆Electric control: The engine electronic control unit
(EECU) receives signals from the sensors. The EECU uses
these signals to adjust the fuel supply and injection timing in
time, in order to obtain the best performance and the best
fuel efficiency.
☆低排放：现有配置排放满足国Ⅲ、国IV法规，具备

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 国V、国Ⅵ升级潜力。
☆Low emission: The existing technical configuration can

meets the China Ⅲ and China Ⅳ emission regulations, if

upgraded, the series engine would also meet China Ⅴ.

☆低噪声设计：包括动态静音链、整体式主轴承盖、

可选配双平衡轴等多项先进减震降噪设计。
☆Low noise design: To reducing vibration and noise,
some special designs are used, such as the dynamic mute
chain, the integral crankshaft bearing cap and the double
balanced shaft (optional), etc.
☆ 良好的低温起动性能：采用缸内预热装置，保证
在－30℃环境条件下顺利起动。
☆ Good cold starting performance: By adopting
preheating device in cylinder, the engine can start at -30℃
very easily.
☆ 高可靠性：一次性通过300000公里高温、高原、
高湿、高寒试验，经久耐用。
☆ High reliability: The engine has pass through 300,000
km road durability test and can stand various rigorous
environment, such as high temperature, high altitude, high
humidity and low temperature.

“可以说，ZD30发动机是从零件级别上保证了发动机的可靠性。
”

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 ZD30 series engine user manual

——日产副总裁今津
“So to speak, the reliability of ZD30 engine is ensured from
component level.”
——Imazu, vice President of Nissan
☆ 低油耗：全负荷最低比油耗208g/Kw·h,连续荣获
多届国际卡车节油大赛“最节油发动机”奖。
☆ Low fuel consumption: The minimum specific fuel
consumption is 208g/kw·h at full load. Since 2011，the engine
had continued to win the international truck fuel economy
contest for three times, and won the award for "the best
fuel-efficient engines".
1.2 Specifications ：

机型Engine type ZD30D14-3N

直列四缸、双顶置凸轮轴、四冲程、四气门、
共轨直喷、增压中冷
型式Typical mechanism four cylinder in-line, double overhead
camshaft, four-strokes, four-valves,
common rail, direct injection in cylinder,
turbocharged inter-cooled
缸径/冲程Bore/Stroke (mm) 96/102
着火顺序Injection order 1-3-4-2
排量Displacement（L) 2.953
压缩比Compression ratio 16.9/1
燃烧室型式
Necking ω Combustion chamber
Type of combustion chamber
额定功率
103（140）
Rated powerkW (ps)
净功率Net power kW(ps) 96（130.6）

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 额定转速
3600
Rated speed（r/min）
最大扭矩
280
Maximum torque（N·m）
最大扭矩转速
Maximum torque speed 1600～3200
（r/min）
额定点燃油消耗率
Specific fuel consumption at 243
rated speed（g/kW.h）
最低燃油消耗率
Minimum specific fuel 208
consumption（g/kW.h）
低怠速
750±25
Idling speed（r/min）
高怠速
Maximum no-load speed 4300
（r/min）
排放标准/投产时间
Emission China Ⅲ/2009.3、China IV/2011.2
standards/Production time
调温器开启温度
Thermostat open 80℃～84℃
temperature
调温器全开温度
Thermostat full open 95℃
temperature
气阀冷态间隙
Intake exhaust valve:
valve clearance at normal
valve:0.35mm 0.35mm
temperature
主油道最小油压
Minimum pressure of the 121kPa /700rpm；337kPa /2000rpm；
main oil passage 465kPa /3600rpm
（kPa/85℃）
机油调压阀开启压力
Opening pressure of the oil 568±32Kp
jet relief valve
机油滤清器旁通阀开启压差
Opening differential pressure 98.1±9.8Kp
of the oil filter bypass valve

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 ZD30 series engine user manual

燃油喷射类型
电控共轨直喷
Fuel injection type Electronic controlled common rail direct
injection
最大油轨压力
1600 bar
Maximum rail pressure
润滑方式
转子式机油泵强制润滑
Lubrication method Forced lubrication driven by the rotor-type
oil pump
冷却方式Cooling method
强制水冷，闭式循环
Forced water-cooling, closed loop
曲轴旋转方向
顺时针（从风扇离合器端看）
Rotation direction of
crankshaft clockwise (see from Fan clutch)
外形尺寸 （length x width x highly ）
Overall dimensions（mm） 773.8×704.8×757.3
281±5 （包含发电机/空调压缩机/飞
轮及动力转向泵/离合器/机油，不含
发动机重量 起动机
Engine weight（kg） (Including generators, air conditioning
compressor, flywheel, power steering
pump and oil, excluding starter)
发电机Generator 90A/12V
起动机Starter 2.8kW/12V

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 1.3 外形尺寸Overall dimensions：

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8
Specific fuel consumption (g/kW.h) Power (kW)

Speed (r/min)
1.4 特性曲线Characteristic curve：

发动机外特性曲线Engine performance curve

Torque (N.m) Fuel consumption (kg/h)

 ZD30 series engine user manual

发动机万有特性试验曲线
Engine universal characteristic curve

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 发动机铭牌
The engine label
发动机铭牌位于发动机气阀室罩盖上。
The engine label placed on the rocker cover.
如下图示例：
As shown in the figure below.

发动机铭牌
Engine label

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 ZD30 series engine user manual

产品型号定义Production model definition:

Code Brand
separator
Engine series

Brand
Engine power code
Diesel

NISSAN brand
DONGFENG brand

Code
Emission standards
Emission standards

China Ⅲ
China Ⅳ
Engine power code=Rated power (kw) / 7.35
China Ⅴ

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 ZD30 系列发动机外部总成识别
Identify the external parts of ZD30 series engine

进气侧Air intake side

1.后吊耳 2.EGR回水管－EGR阀侧 3.EGR管－排气管侧 4.废气混合管 5.
燃油进（回）油管 6.机油压力报警传感器7.机油限压阀 8.飞轮壳 9.
油底壳总成 10.风扇 11. 动力转向助力泵总成 12.正时齿轮室带机油
泵总成 13. 高压油泵总成 14.机油进油管－真空泵 15.高压油轨总成
16.EGR冷却器 17.回水管过渡接管 18.喷油器回油管总成 19.机油标
尺管总成 20.机油标尺总成 21. EGR阀总成 22. 出水管接头

1. Rear engine slinger 2. water pipe 3. EGR tube 4. Intake

manifold 5. Fuel feed (return) tube 6. Oil pressure switch 7.
Oil jet relief valve 8. Oil level gauge tube bracket (Lower) 9.
Oil pan 10. EGR volume control valve 11. Water outlet 12.
Gear case and oil pump assembly 13. Power steering oil
pump assembly 14. Fuel supply pump assembly 15. Oil inlet
pipe 16. Common rail assembly 17. EGR tube 18. water hose
19. spill tube 20. Oil level gauge tube 21. Oil level gauge

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 ZD30 series engine user manual

排气侧Exhaust side
1.气阀室罩盖 2.发电机总成 3.暖风进水管 4.进水管接头
5.空调压缩机支架 6.空调压缩机总成 7.皮带 8.曲轴箱通
风软管 9.排气弯管隔热上罩 10.增压器总成 11.排气弯管
隔热中罩 12.排气弯管隔热下罩13.机油冷却器带滤清器总
成
1. Rocker cover 2. Alternator 3. Water inlet pipe 4. Water inlet
5. A/C compressor bracket 6. A/C compressor assembly
7. Drive belt 8. Crankcase ventilation hose
9. Exhaust manifold cover 10. Turbocharger assembly
11. Exhaust outlet cover 12. Exhaust outlet cover（lower）
13. Oil cooler and oil cleaner assembly

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 前 端Front
1.凸轮轴相位传感器 2.TDC传感器线束 3.风扇离合器总
成 4.真空泵总成 5.扭振减振器总成 6.发电机支架 7.
水温传感器总成 8.风扇皮带轮 9.水泵总成 10.皮带液
压自动涨紧器
1. Camshaft position sensor 2. TDC sensor wiring harness
3. Fan clutch 4. Vacuum pump assembly 5. Crankshaft pulley
6. Alternator bracket 7. Engine coolant temperature sensor
8. Fan pulley 9. Water pump assembly
10. Drive belt auto tensioner

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 ZD30 series engine user manual

后 端Back

1.缸盖总成 2.缸体总成 3.后端板 4.离合器压盘

1. Cylinder head assembly 2. Cylinder block assembly
3. Rear plate 4. Clutch pressure plate

燃油喷射系统
Fuel injection system
ZD30发动机采用BOSCH公司电控共轨式燃油喷射系统。
ZD30 engine adopts BOSCH electronic control common
rail fuel injection system.

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 4.1 系统布置:
4.1 System layout:

1.喷油器总成 2.油轨压力传感器 3.高压油轨 4.喷油器

回油管 5.燃油回油管总成 6. 燃油进油管总成 7.第4缸
高压油管总成 8. 第3缸高压油管总成 9.第2缸高压油管
总成 10.第1缸高压油管总成 11.高压油管总成－高压油
泵 12.琶型接头 13.回油单向阀 14.高压油泵总成 15.
燃油计量器
1. Injector 2. Rail pressure sensor 3. Common rail
4. Spill tube 5. Fuel return tube 6. Fuel feed tube
7. Injector tube No.4 8. Injector tube No.3
9. Injector tube No.2 10. Injector tube No.1
11. fuel supply tube 12. Eye connector 13. Check valve
14. Fuel supply pump assembly 15. Fuel meter

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4.2 电控燃油喷射系统特点：
4.2 Characteristics of electronic control fuel injection

system：

☆ 燃油喷射压力根据发动机的运行工况而改变，独
立于发动机负荷和转速；
☆ Fuel injection pressure varies according to the engine

running condition, independent of the engine load and speed.

☆ 喷油正时根据发动机的运行工况而改变，独立于
发动机负荷和转速；
☆ Injection timing varies according to the engine running

condition, independent of the engine load and speed.

☆ 压力－时间型燃油计量器；
☆ Pressure-time type fuel meter.

☆ 根据需要进行预喷射（降低柴油机噪声、改善冷

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 起动）。
☆ Pre-inject for reducing the noise and improving the

cold start performance.

☆ECU：从传感器接收信息，并根据相应的控制策略，

控制发动机的燃油喷射以及实现某些辅助功能的控制。
☆EECU: Receive information from the sensors, and

control the engine fuel injection and

some auxiliary functions according to the

corresponding control strategy (such as

idle speed, etc).

4.3高压泵总成由下列部件组成：
4.3 High-pressure pump consists of the following

parts:

1.输油泵
2.燃油计量单元
3.高压单元

1. Fuel supply pump

2. Fuel metering unit
3. High pressure unit

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 ZD30 series engine user manual

☆ 输油泵：输油泵是齿轮泵，安装于高压泵泵体后
端。最大输油能力：140L/h。
☆ Fuel supply pump: gear pump, mounted on the

backend of the high-pressure pump. Largest capacity:

140L/h.

☆ 燃油计量单元：集合了燃油流量调节电磁阀。电
磁阀预控制一个梭形阀，从而管理高压泵入口的燃油流
量。
☆ Fuel metering unit: assembled an electromagnetic

valve for fuel flow regulating. The electromagnetic valve

pre-control a spindle valve, thereby managing the fuel flow of

the fuel supply pump entrance.

☆ 燃油流量调节电磁阀：燃油流量调节电磁阀安装
于燃油计量单元上，用于调节燃油流量使油轨压力达到期
望的设定值。不供电时，电磁阀处于常闭位置（油轨压力
达到最大轨压）。
☆Fuel flow regulating electromagnetic valve: Installed

on the fuel metering unit, Used to regulate the fuel rail

pressure to the desired set point. When there is no power

supply, the electromagnetic valve is in the closed position

(fuel rail pressure has reach to the maximum value).

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 ☆ 高压单元：由3个单元组成。
☆ The high pressure unit is composed of three units.
高压泵总成的检修工作必须由原始设备供应方指定
的技术服务中心（站）专业维修人员进行。
The maintenance and repair work of the
high-pressure pump must be designated by
the professional maintenance staff in the
service center (station) that is specified by
the original engine supplier.

☆ 高压油轨：连接在高压泵和喷油器之间。
☆ High pressure fuel rail:

Connected between the high

pressure pump and the fuel injector.

☆ 高压油轨装备有：轨压传感器和卸压阀。
☆ The high pressure fuel rail was equipped with rail

pressure sensor and pressure relief valve.

☆ 喷油器总成：每个喷油器总成上有
一电磁阀，用来控制喷油器的开关。接线柱
不分正负极性。
☆ Fuel injector: There is an

electromagnetic valve on each injector, which is used to

control the action of the injector. The terminal is not divided

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into positive and negative polarity.

喷油器的检修工作必须由原始设备供应方指定的技
术服务中心（站）专业维修人员进行。 每次拆卸该单元，
所有密封件必须要换。
The maintenance and repair work of the
injector must be designated by the
professional maintenance staff in the
service center (station) that is specified
by the original engine supplier.

☆ 凸轮轴相位传感器：为感应型，通过凸轮轴链轮
上的凸台可以产 生类似正弦电压信号。信号频率与发动
机转速成比例。
☆ Camshaft position sensor: It’s an

induction type sensor. The convex platform

on the camshaft sprocket can produce a

signal which is similar to the sine voltage.

The signal frequency is proportional to the engine speed.

☆ 转速传感器：为感应型，通过扭
振减振器齿圈可产生类似正弦电压的信
号。信号频率与发动机转速成比例。
☆ Crankshaft position sensor: It’s a induction type

sensor. The gear teeth of the signal plate installed to the

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 crankshaft pulley can produce a signal which is similar to the

sine voltage. The signal frequency is proportional to the

engine speed.
☆ 冷却液温度传感器：为负温
度系数（NTC）热敏电阻。

☆ The coolant temperature sensor is a negative

temperature coefficient (NTC) thermistor.

☆ 发动机机油压力报警传感
器：

☆ The oil pressure switch: It’s a piezoresistive type

sensor.

电控共轨燃油喷射系统的维修保养
必须由原始设备供应方指定的技术服务
中心（站）专业维修人员进行，必须使用
经过认证的正品备件。
The maintenance and repair work of the common rail system
must be designated by the professional maintenance staff in
the service center (station) that is specified by the original
engine supplier.
Must use the designated spare parts.

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禁止拧松高压管路接头进行排气。
特殊情况下需要更换高压油管时，要待完全停机3分
钟后，慢慢松开远离油轨端的螺母，使高压油路压力完全
释放后再更换油管。在任何情况下都不要向下压或者拉扯
喷油器回油管，以免发生燃油泄漏。
CAUTION:
Never unscrew the high-pressure pipe connectors for
exhaust.
If need to replace the injector tube, wait at least 3
minutes after engine stop, then slowly loose the union nut
which is far away from the rail. After the high pressure is fully
released, replace the tube. Never press or pull spill tube,
avoid fuel leak.

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 冷却系统
Cooling system

Cylinder head
To heater

Backwater from heater

Backwater
from EGR

Cylinder block

To the radiator

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冷却系统示意图如下：
The schematic diagram of the cooling system is as following:
Pressure side of
Radiator the water tank Water tank

Thermostat

EGR volume Water pump

control valve Heater

Oil cooler

Cylinder block Thermostat

Water pump
From the radiator Oil cooler

Cylinder head Thermostat close

Thermostat open

冷却液温度低于 81℃时，冷却液经水泵、机油冷却
器，进入气缸体水套，经上水孔进入气缸盖水套，从前端
盖回水至水泵，进行小循环。
When the coolant temperature is below 81 ℃, the
coolant first flows through the water pump and oil cooler into
the cylinder block water jacket, then through the scripture
hole into the cylinder head water jacket. At last the coolant
returns to the water pump from the front end of the cylinder
head for minor cycle.
当冷却液温度高于 81℃时，调温器逐渐打开，直至

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 关闭小循环泄水孔，从链条盖进入散热器进行冷却，再进
入水泵进行大循环。
When the coolant temperature increases above 81 ℃,
the thermostat opens gradually, till close the minor cycle bays,
the coolant flows into the radiator from the chain cover for
cooling, then returns to the water pump for systemic
circulation.
当打开车上的暖风装置时，在冷却系统压力的作用
下，部分热水从缸盖右侧的出水管引出，进入暖风散热器，
热风经送风管吹到风窗玻璃除霜或从风门吹出供驾驶室
取暖，由暖风机散热器冷却的冷却液，经回水管返回水泵
进水管，重新参加循环。
When the vehicle heater is open, under pressure of the
cooling system, part of the hot coolant flow into the warm
wind radiators from the outlet pipe on the right side of the
cylinder head. The air flowing over the radiators is heated,
and the heated air is send to the window by the wind pipe for
defrosting or to the cab for warming passengers. After cooled
by the heater radiator, the coolant finally returns to the pump
inlet through the return pipe and attends the recycling.
EGR 阀冷却水从缸体流出，冷却 EGR 阀后，经回水管
返 回 水 泵 进 水 管 ， 重 新 参 加 循 环 。 Some coolant is
distributed from the cylinder block to cool the EGR valve.

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 ZD30 series engine user manual

After cooling the valve, it returns to the pump inlet through the
return pipe and attends the recycling.

润滑系统
Lubrication system
润滑系统示意图：
The schematic diagram of the lubrication system:
Camshaft (INT) Camshaft (EXH)

Turbocharger
To chain tensioner

Oil cooler

Oil jet

To oil jet of timing chain Oil cooler

Oil filter
Balanced shaft bearing

Main oil passage

To vacuum pump

Oil pump Oil feed

Oil return
Oil pan
Oil strainer

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 Oil pan

Oil flow
Oil passage
Oil strainer
By-pass
To oil pan
Oil jet Oil pump
Oil regulating valve

Oil jet relief valve

Oil bypass valve Oil bypass valve

Oil cooler Oil filter

Balance shaft Vacuum

Main oil passage
Turbocharger bearing pump

Oil jet
Oil jet Cylinder head oil passage
Main bearing Timing chain
Piston Timing gear
Crankshaft
Camshaft bearing
Chain tensioner

Piston Camshaft
Connecting rod Timing chain
bearing Timing gear

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发动机的使用及注意事项
Precautions
7.1 发动机的起动
7.1 Engine starting

☆ 气温在-15℃以上时，可以不使用起动辅助装置
（如缸内预热装置等）
；气温在-15℃以下时，须使用缸内
预热装置或其它起动辅助装置。
☆ When the ambient temperature is above -15 ℃, no

need to use the starting aids (such as preheating device in

cylinder, etc.).When the temperature is below -15 ℃,

preheating device in cylinder or other starting aids shall be

used.

☆ 每天首次起动前要检查冷却液面、机油液位。
☆ Check the coolant level, oil level before the first

starting everyday.

☆ 起动机起动时间不能超过30秒，连续起动要至少
间隔2分钟。连续起动3次不成功，应检查处理后再起动。
☆The continuous cranking time of starter mustn’t excess

30 seconds, wait at least 2 minutes between each start. If

start failed 3 times consecutively, check and repair the start

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 system.

☆ 起动成功后15秒内，注意机油压力报警灯的变化。
☆ Check the change of the engine oil pressure alarm lamp
within 15 seconds after success engine start.
☆ 气温较低时，首次起动应暖机2分钟才能起步。
☆ In cold weather, after first start, keep the engine idling
at least 2 minutes to warm it up before racing the vehicle.
☆ 装有发动机制动器的发动机低温起动时，要确保
发动机制动器开关处于断开位置。
☆ If engine brake system was equipped, make sure the
system switch is in the off position before the cold start.
☆ 如果燃油系统中有气，可能导致起动困难。可以
用油水分离器上的排气螺钉排气。
☆ If air exists in the fuel system, a difficult start may
happen. Use the screw at the oil-water separator for exhaust.

禁止使用起动机拖动发动机进行燃油
系统排气。
CAUTION:
Never use the starter to crank engine for
exhaust.
禁止拧松高压管路接头进行排气。
Never unscrew the high-pressure pipe connectors for
exhaust.

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 ZD30 series engine user manual

7.2 发动机预热和怠速
7.2 Engine preheating and idle
☆ 冷机时禁止大油门运转发动机，低温起动时应逐
渐提高发动机转速。
☆ Never accelerate rapidly just after cold start, increase
the engine speed gradually as it warms up.
☆ 发动机怠速不要超过10分钟。发动机怠速时间过
长，易形成积炭阻塞喷油器喷孔，并引起活塞环和气阀胶
着。
☆ Don’t idle the engine for more than 10 minutes.
Otherwise carbon deposit may form and the nozzle orifice
would be clogged. The piston ring and the valve would also
be stalemated.
7.3 发动机停机
7.3 Engine stop

经长时间高速或大负荷运转，停机前
应怠速2分钟，否则易引起发动机局部过
热，并损坏增压器轴承。
After operating at high speed or high load
for a long time, the engine should idle at least for 2 minutes
before shutdown. Otherwise engine may overheat, and the
turbocharger bearing may be broken.
7.4 正确加注冷却液的方法

31
 7.4 The right way to fill coolant
☆ 加注冷却液不要过急，否则，发动机水套中的气
体不易排出。
☆ Fill the coolant slowly, otherwise gas may be blocked
in the water jacket.
☆ 加注后，怠速运行1分钟后检查膨胀水箱液位，补
充至上限。
☆ After fill, idle the engine for 1 minute, and then check
coolant level in the expansion tank and refill to the upper limit.
7.5 其它操作注意事项
7.5 Other precautions
☆ 经常观察水温表，若冷却液持续低于60℃或高于
100℃，应尽快查找原因。
☆ Pay attention to the coolant temperature gauge on the
instrument panel regularly, if the coolant temperature was
below 60 ℃ or above 100 ℃ continually, check the engine as
soon as possible.
☆ 经常观察机油压力表，禁止在机油压力过低时运
转发动机。热机时机油压力：怠速时不低于180kPa，额定
转速时不低于380kPa。
☆ Pay attention to the oil pressure gauge on the
instrument panel regularly, never run the engine when oil
pressure is lower than the stipulated limit. The stipulated oil

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 ZD30 series engine user manual

pressure limit of warm engine: not lower than 180 kPa at idle
speed, not lower than 380 kPa at rated speed.
☆ 经常检查机油、冷却液液位。
☆ Check the oil and coolant level regularly.

☆ 避免发动机带故障运行。留心发动机性能、声音
及可见预兆的变化，若不正常应停机检查。
☆ Avoid running the engine with malfunction. Watch for
the change of the engine performance, sound and visible
sign. Shutdown and check the engine if abnormal.
7.6 油液的使用
7.6 The use of fuel and oil
7.6.1 燃油
7.6.1 Fuel
必须使用满足国家相关标准所规定的合格车用柴油，
使用不合格柴油将对发动机造成严重损害。用户可根据本
地区的气温按下表使用不同标号的合格车用柴油:
Always use the qualified automotive diesel which meet the
relevant national standards of fuel, using unqualified diesel
will cause serious damage to the engine. Choose different
diesel listed in the following table according to the local
ambient temperature.
环境温度 The ambient 4℃ -5℃ -5℃～ -14～ -29～
temperature above above -14℃ -29℃ -44℃

33
 柴油牌号 Diesel No. 0# -10# -20# -35# -50#

燃油中水分含量过高将造成高压泵的
严重损坏。
CAUTION:
Water and impurities contained in fuel will
cause serious damage to fuel supply pump.
7.6.2 机油
7.6.2 Engine oil
机油的使用对发动机的可靠性和使用寿命有重要影
响，用户应使用原始设备供应方提供的专用机油。
To ensure proper engine performance and long life,
always choose the specified oil designated by the original
engine supplier.
机油换油里程为：10000公里或1年（以先到者进行更
换）
。
Engine oil change mileage: 10000 km or 1 year (Replace
whichever happens first).
7.6.3 冷却液
7.6.3 Coolant
用户必须使用规定冷却液；更换周期为2年或者
60000km（以先到者进行更换）
。
Always choose the specified coolant designated by the
original engine supplier. The periods of replacement is 2

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 ZD30 series engine user manual

years or 60000 km ((Replace whichever happens first)

不使用规定的冷却液或混用其它冷却液，会造成发动
机的损坏。
The use of improper coolant would cause serious
damage to the engine.

严禁使用自来水！否则会造成发动机的
严重损坏。
CAUTION:
Never use tap water to replace the coolant!
Otherwise destructive damage would be caused to the
engine.
7.7 发动机保养
7.7 Engine maintenance
7.7.1新机检查项目
7.7.1 Check items for new engine:
☆ 检查机油、燃油、冷却液有无泄漏痕迹。
☆ Check whether there is leakage trace of the oil, fuel,
coolant.
☆ 检查高低压油管与其它部件之间有无挤压、摩擦
以及磕碰划伤现象。
☆ Check whether there is extrusion, friction, clash and
scratch between fuel(or oil) pipes and other components.
☆ 检查线束以及传感器的插接有无松动。

35
 ☆ Check whether there is any loosing between the
harness connectors and the sensor plugs.
☆ 检查各机械连接处有无松动。
☆ Check whether there is any loosing on the mechanical
joints.
☆ 检查各处软垫有无撕裂现象。
☆ Check whether there is any tear on all the cushions.

☆ 检查发动机的声音有无异常。
☆ Check whether there is any abnormal sound of the
engine.
7.7.2每日检查项目
7.7.2Daily check items
每日首次起动前，检查下列项目，如有不正常应及时
修理。Before everyday starting, check the following items, if
there is anything abnormal, check and repair the engine as
soon as possible.
☆ 检查各部位是否正常，附件连接是否可靠，各管
路有无破损或磨损。
☆ Check that each part is in good condition, the joints
between peripheral accessories and engine is reliable, and
there is no break or scuff on the pipes.
☆ 检查机油油面高度及泄漏情况：将车停在比较平
坦的路面上，在整车热机停机10分种后检查油面高度，取

36
 ZD30 series engine user manual

出机油标尺，用干净抹布擦干后插入到极限位置，然后再
次拉出，观察其油面位置，油位必须在机油标尺上下刻线
之间，高于上刻线时应放掉部分机油，低于下刻线时要添
加机油，且尽可能使油位接近上刻线。上下刻线间机油量
约2.5L。
☆ Check the oil level:
Park the vehicle on level ground. If the engine has been
running recently, turn off the engine and wait 10 minutes for
the oil to drain back into the oil pan. Checking your oil level
too soon after engine shut off will not provide an accurate oil
level reading. Pull out the dipstick and clean it with a paper
towel or cloth, then push it back in all the way. Remove it
again, keeping the tip down, and check the level.
The oil level must be in the acceptable operating range
(between the upper and lower marks). If the oil is beyond the
upper mark, drain some oil until within the acceptable
operating range. If the oil is lower than the lower mark, add oil
until it’s near the upper mark. The oil amount between the
upper and lower marks is about 2.5 L.
☆ 检查燃油泄漏情况。
☆ 检查冷却液有无泄漏情况。
☆ Check for fuel and coolant leakage

7.7.3 每5000km保养项目（执行日常维护的项目并加

37
 做下列各项）
7.7.3 Every 5000km maintenance items (Include the
following supplemental items besides daily maintenance)
☆ 检查电控系统线束是否有外皮破损，线卡是否松
脱。
☆ Check whether there is any damage of the harness
sheath or loosing between the harness connectors and the
sensor plugs.

☆ 检查皮带磨损情况。
☆ Check wear condition of the belt.

☆ 检查皮带涨紧器以及惰轮的转动是否正常。
☆ Check the rotations of belt tensioner and idler pulley
are normal.
☆ 检查并紧固进排气系统的连接螺栓和螺母，并检
查密封衬垫是否完好。
☆ Check and tighten bolts and nuts of the intake and
exhaust systems and confirm the sealing gasket is intact.
7.7.4 每10000km保养项目（执行5000km保养项目并
加做下列各项）
7.7.4 Every 10000km maintenance items (Include the
following supplemental items besides 5000 km
maintenance).
☆ 更换机油。

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 ZD30 series engine user manual

☆ Replace the engine oil

☆ 更换机油滤清器滤芯及密封圈。
☆ Replace the oil filter element and the seal

☆ 检查燃油滤清器总成。
☆ Replace the fuel filter assembly

☆ 检查空气滤清器总成。
☆ Check the intake air cleaner assembly

7.7.5 每20000km保养项目（执行10000km保养项目并
加做下列各项）
7.7.5 Every 20000 km maintenance items (Include the
following supplemental items besides 10000km
maintenance.)
☆ 检查调整气阀间隙。
☆ Check and adjust the valve clearance

☆ 检查增压器工作情况。
☆ Check the work condition of the turbocharger

☆ 检查减振器外观。
☆ Check the appearance of the shock absorber

☆ 更换空气滤清器滤芯。
☆ Replace the intake air cleaner filter

在检查和更换周期之前出现报警信号，应及时调整或
更换。

39
 CAUTION:

If alarm signals appeared before the next inspection,

check and repair the engine timely.

新车行驶5000km时，必须进行7.7.4
保养项目； 新车首次保养后，按照每日、
每5000km、每10000km、每20000km保养
项目进行保养。
When the mileage is over 5000 km, the maintenance items
listed in 7.7.4 must be executed. After the first maintenance,
execute the routine daily, every 5000km, every 10000km, and
every 20000km maintenance items.
7.7.1、7.7.2、 7.7.3保养项目，用户可按照操作规
程自己进行。
You can perform the maintenance items listed in
7.7.1,7.7.2, 7.7.3 by yourself.
7.7.4、 7.7.5保养项目必须由原始设备供应方指定
的技术服务中心（站）专业维修人员进行。
The maintenance items listed in 7.7.4, 7.7.5 must be
performed by the professional maintenance stuff in the
service center (station) that is specified by the original engine
supplier.
严禁使用用高压水枪直接冲洗发动机顶端，否则可能
会引起电路系统线束故障。

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 ZD30 series engine user manual

Never wash the engine with high pressure water or

immerse the engine in water, otherwise malfunction of the
electric system may be caused.

主要总成的维护和调整
Maintenance and adjustment of the
main assembly
8.1 皮带及皮带张紧轮检查
8.1 Inspection of the drive belt and belt tension

wheel

水泵皮带轮

扭振减震器 发电机

空调压缩机

风扇皮带

液压涨紧轮

拆下驱动皮带，检查多楔带楔形部位是否有裂纹；是

41
 否有异物落在皮带槽内,堵塞皮带；液压涨紧器液压元件
是否有漏油。检查皮带涨紧轮轴承，受力下压时应自由旋
转，没有发卡现象；润滑脂是否有析出现象，若有应及时
更换。
Remove the drive belt and check whether the following
conditions have happen:
1、There are cracks in belt wedges.
2 、 There are foreign materials blocked in the belt
grooves.
3、There is any leakage in the hydraulic tensioner.
Check the bearing of the belt tensioner. Rotate it with
fingers, it should rotate freely.
If there is any grease leakage, replace it with a new one.
8.2 更换机油
8.2 Oil change
新车行驶5000km时，必须进行机油的首次更换，之后，
每正常行驶10000km时，必须更换机油。更换前要预热发
动机。按规定量加注机油：9.5L。加完机油后，怠速运转
发动机，观察机油滤清器和放油螺塞（密封垫必须更换新
的）有无泄漏。停机后等5分钟，待机内机油流回油底壳
中，再用机油标尺检查油位，油位必须在机油标尺上下刻
线之间，高于上刻线应放掉，低于下刻线要添加，且尽可

42
 ZD30 series engine user manual

能使油位达到上刻线。
When the mileage reaches 5000 km, the oil must be
replaced for the first time. After that, every time the car has
been driven for 10000 km, the oil must be replaced. Heat the
engine before the replacement. The specified filling amount
is 9.5 liters. After filling, run the engine in idle, Inspect the oil
filter and oil drain plug (replace new seal) and check if there
is any leakage. Turn off the engine and wait 10 minutes for
the oil to drain back into the oil pan. Pull out the dipstick and
clean it with a paper towel or cloth, then push it back in all the
way. Remove it again, keeping the tip down, and check the
level. The oil level must be in the acceptable operating range
(between the upper and lower marks).If the oil is beyond the
upper mark, drain some oil until within the acceptable
operating range. If the oil is lower than the lower mark, add oil
until it’s near the upper mark.
Oil filling port

加机油口

放油螺塞
Oil drain plug
43
 8.3 更换机油滤清清器滤芯
8.3 Replace the oil filter element.
更换机油的同时必须更换机油滤清器滤芯。
Every time when oil is replaced, replace the oil filter
element.
滤芯的更换要领
Filter element replacement procedures:
①用套筒扳手(S=17mm)松动机油滤清器壳体约4次。
1、Loose oil filter housing about 4 times with a socket
wrench (S = 17 mm).
②将机油滤清器壳体端面的标记(▲印)朝正上方放
出机油。
2、Drain the oil out by keeping the mark(▲) on the
housing upwards.
※参考：机油的放出时间约为３分钟。
Reference: The releasing time of the oil is about 3
minutes
※注意：要把粘在发动机及车辆上的发动机油完全擦
拭干净。
CAUTION:
Clean up the engine oil stuck to the engine and vehicle
completely.

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 ZD30 series engine user manual

③取下机油滤清器壳体，拆下机油滤清器滤芯。
3、Remove the oil filter housing and remove the oil filter
element.
④从机油滤清器壳体上拆下O型圈。
4、Remove the O-ring from the engine oil filter housing.

用手指延凹槽方向按住O型圈，O型圈就会从壳体凸出,
抓住凸出部分取下。
Press the O-ring with your finger along the groove
direction, O-ring will protrude from the housing, seize the
protruding portion and remove it.

1. 机 油 滤 清 器 可 Oil filter
housing
2. “O”型圈O-ring seal
3. 机油滤清器滤芯
Oil filter element

※注意：不能使用铁丝、螺丝刀等。
（会划伤滤清器壳

45
 体）
CAUTION:
Never use wire, screwdriver, etc to remove the O-ring.
(The oil filter housing may be scratched)
⑤O型圈不能重复使用。
5、The O-ring isn’t reusable.

在安装滤清器前，用少量机油涂在“O”型圈表面。
安装时，按规定的扭矩拧紧。
Before installing the filter, coat the surface of the O-ring
with a little oil. Tighten to the specified torque.
8.4 检查燃油滤清器
8.4 The inspection of the fuel filter
新车行驶5000km时，必须检查清理燃油滤清器，之后，
每正常行驶10000km，必须检查清理燃油滤清器，车辆行
驶40000Km时，必须更换燃油滤清器。安装新燃油滤清器
前检查包装有无破损，若有破损则不能使用。安装完成后，
用手油泵进行排气。
When the mileage reaches 5000 km, must check and
clean the fuel filter. After that, every time the car has been
driven for 10000 km, check and clean the fuel filter routinely.
When the mileage reaches 40000 km, replace the fuel filter.
Check the filter carefully before replacement. It can’t be used
if there is any breakage. After replacement, use the hand

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 ZD30 series engine user manual

pump to exhaust.
8.5调温器的检查
8.5 The inspection of the thermostat

将调温器浸泡在水中，逐渐加
热、搅拌，检查调温器的开启温度。
Soak the thermostat in water, then

heat the water gradually, check the

open temperature of thermostat.

开启温度在80℃～84℃，测量温
度在95℃（全开启）的开启尺寸不小于9.5mm；关闭温度
大于77℃。如有问题，更换调温器。
The opening temperature is 80 ℃ ~ 84 ℃, fully open

temperature is 95 ℃, and fully open lifting volume is not less

than 9.5 mm. The closing temperature is higher than 77 ℃. If

the thermostat is not functioning normally,

replace it.
调温器的检查更换必须由原始设备供
应方指定的技术服务中心（站）专业维修人
员进行。
CAUTION:
The check and replacement of thermostat must be
performed by the professional maintenance stuff in the

47
 service center (station) that is specified by the original engine
supplier.
8.6 增压系统的保养
8.6 The maintenance of the turbocharger system
增压器与进、排气管的连接必须严密不能漏气，如果
排气歧管和涡轮之间漏气，增压器效率将大大降低，发动
机排气温度将急剧升高，从而损坏增压器。如果进气管路
泄漏，将造成发动机的严重磨损或故障。凡更换机油、机
油滤清器、增压器或使用长期停放（发动机停用7天以上）
的发动机，首次起动前必须通过增压器进油管对增压器注
满清洁机油，以保证一起动，增压器轴承就能得到润滑。
在停机前，应在怠速下运转2分钟，使增压器转速下降、
温度降低，并监听增压器运转声音。
The inlet and exhaust pipe of turbocharger must be
connected tightly, if there is any leakage between the exhaust
manifold and the turbocharger, the efficiency of turbocharger
will be greatly reduced, and the engine exhaust temperature
will rise sharply, and the valve and the turbocharger would be
burn out. The leakage of intake pipe will cause serious wear
or fault of engine. Before starting an engine whose oil, oil
filter or turbocharger was just replaced, or starting an engine
that has stopped running for more than 7 days, remember to
fill the turbocharger with clean oil through the oil inlet pipe of

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 ZD30 series engine user manual

the turbocharger to ensure good lubrication. Before shutdown

the engine, idle it for 2 minutes, when the speed and
temperature of the turbocharger get low, inspects the sound
of the turbocharger.
如发现异常应停机检查，如增压器转子转动不灵活有
卡滞或磨损声，必须由原始设备供应方指定的技术服务中
心（站）专业维修人员进行维修。
CAUTION:
If anything abnormal has been found, such as the rotor
of turbocharger rotating stiffly or generating wear noise, stop
and check the engine immediately. The maintenances of
turbocharger must be performed by the professional
maintenance stuff in the service center (station) that is
specified by the original engine supplier.

发动机常见故障
Engine Troubleshooting
下表中列出了易于被用户识别并能够处理的常见故
障，如果用户在使用ZD30发动机的过程中遇到任何不能自

49
 行处理的故障，请及时与原始设备供应方指定的技术服务
中心（站）联系。
The malfunctions listed in the table below can be easily
identified and handled by the user. If you can’t handle the
malfunction by yourself, please contact with the service
center (station) that is specified by the original engine
supplier.
可能出现的故障
原因分析 处理方法
Possible
Reason analysis Approach
malfunction
一、发动机起动困难或
不能起动 Impossible
to start, or possible
but hard to start
检查燃油液面高度；
燃油系统中有空气 检查系统有无漏气处，用手油泵排除系
There is air in the fuel supply 统内空气。
system 检查排除
1、供油系统故障 Check the fuel level;
Malfunction in fuel Check whether there is any location
supply system 燃油系统内有水 from where air would enter into the
There is water in the fuel fuel system; exhaust the air from the
supply system system with the hand pump.
燃油滤清器堵塞 更 换 燃 油 滤 清 器。 Replace the fuel
Fuel filter clogged filter
起动机故障 针对具体故障处理 Treat according to
Starter failure the actual situation.
2、电气系统故障 EECU 供电故障 检查保险
malfunction in electric EECU power supply failure Check the insurance
system 充电，使电压达到规定要求
蓄电池电压不足
Charge and make sure the voltage
Low battery voltage
meets the specification.
环境温度过低
启用冷起动辅助装置 Enable the cold
The ambient temperature is
3 、 其 它 原 因 Other start assist device
too low
reasons
变速箱不在空档位置 Gearbox
调整档位 Change gear
is not in the neutral position

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 ZD30 series engine user manual

用手油泵排除系统内空气，检查系统
有无漏气处。
燃油系统中有空气 Check whether there is any
There is air in the fuel supply location from where air would enter
system into the fuel system; exhaust the air
二、发动机能起动， from the system with the hand
但运转不稳，或无法 pump.
控 制 Engine 燃油系统内有水 检查排除
running instability There is water in the fuel supply Check and remove the water
or can’t be system
controlled
燃油滤清器堵塞 检查更换
Fuel filter clogged Check and replace the fuel filter

更换燃油
燃油脏 Fuel is dirty
Replace the fuel
清洗或更换滤芯
空气滤清器堵塞
Clean or replace the air cleaner
Air cleaner clogged
filter
压气机至进气歧管漏气 检查连接段，拧紧连接卡箍
There is air leakage between the Inspect the connector of the air
compressor and the intake manifold duct, and tighten the clamp
三、发动机动力不 燃油系统进入空气或堵塞
检查排除疏通油路 Check and clear
足，功率下降 The fuel system has been mixed
the fuel system.
with air or blocked.
Lack of power or
power down 排气管路堵塞 清除堵塞物
The exhaust pipe was blocked Remove the blockage
涡沦进气口处漏气 检查并更换垫片
The turbo inlet leaks. Check and replace the gasket

发动机过热 检查冷却系
Engine overheats Check the cooling system
四、发动机烟色不正
常 Abnormal
smoke color
机油油位太高，窜机油 检查调整
Too much oil was filled. Check and adjust the oil level
发动机曲轴箱窜气软管堵塞
1、 冒蓝烟 The crankcase ventilation hose
清洗疏通管路
blue smoke Clean up the hose
clogged
怠速运行时间过长 减小怠速运行时间
Idle engine too long Reduce the idle time
2、 冒白烟 环境温度过低 使用进气预热
white smoke The ambient temperature is too low Enable the air intake preheating
空气滤清器堵塞 检查清理
3、 冒黑烟 Air cleaner clogged Check and clean up the air cleaner
black smoke 排 气 制 动 阀 卡 死 Exhaust brake 检查处理
valve jams Check and troubleshoot

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 冷却液面过低 Coolant level is 加 注 冷 却 液 ， 检 查 渗 漏 Refill
too low coolant, check the leakage
调温器打不开 Thermostat can't 检查更换 Check and replace the
open thermostat
检查或更换水泵
水泵损坏 Water pump failure Check and replace the water
pump
检查更换皮带
五 、 发 动 机 过 热 风扇皮带损坏 Fan belt failure
Check and replace the belt
Overheat
检查更换
风扇离合器失效
Check and replace the fan
Fan clutch failure
clutch
检查更换
皮带涨紧器失效
Check and replace the drive
Drive belt tensioner failure
belt tensioner
检查清洁 Check and clean up
散热器太脏 The radiator is dirty
the radiator
检查渗漏，加油至规定油位
机油油位太低 Oil level is too low Leakage check, add to the
specified level
六、机油压力低 Low oil 检查机油牌号、温度及是否被稀
pressure 释 Check the oil grade and
机油等级或粘度不对
temperature, if all is correct,
Improper oil grade or viscosity
check whether the oil was
diluted
检查更换
风扇离合器故障
Check and replace the fan
七、发动机温度升不高 Fan clutch failure
clutch
Low engine coolant
检查更换
temperature
调温器故障 Thermostat failure Check and replace the
thermostat
机油泄漏 Oil leakage 检查排除 Check out
机油液位太高 降低至规定油位
八、机油耗量太高 Oil level is too high Reduce to the specified oil level
Excessive oil 发 动 机 呼 吸 器 堵 塞 Engine 清洗疏通管路
consumption
respirator blocked Clean up the pipe
机油等级或粘度不对 更换规定的机油
Improper oil grade or viscosity Use the specified oil instead

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 ZD30 series engine user manual

储 存
Storage
发动机应贮存在通风、干燥、无腐蚀性物质的仓库内。
The engine should be stored in well-ventilated, dry and

noncorrosive warehouse.

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