汽修 4JB VE泵柴油发动机维修手册
柴油发电机维修手册
柴油发电机维修手册一、引言柴油发电机是一种常见的发电设备，广泛应用于各个领域。
然而，由于长时间的使用和各种外部因素的影响，柴油发电机可能会出现各种故障。
本手册旨在提供给维修人员一份详细的柴油发电机维修指南，帮助他们迅速准确地排除故障，保障发电机的正常运行。
二、安全须知维修柴油发电机需要一定的专业知识和技能，为了保证维修人员的安全，以下是几个必须遵守的安全须知：1.在维修过程中，一定要切断电源，并确保开关处于关闭状态；2.在直接触摸柴油发电机之前，要确保发电机已经完全停止运行，并进行了冷却；3.维修过程中，请佩戴符合规定的个人防护装备，如手套、防护眼镜等；4.严禁在高压电路附近进行维修，以防触电事故的发生；5.如果维修遇到无法解决的问题，请及时寻求专业人员的帮助。
三、故障排除1.发动机无法启动故障现象：柴油发电机无法启动，尝试多次启动但没有任何反应。
可能原因及解决方法：1) 燃油供应问题：检查燃油供应管路是否受阻或漏油，确保燃料能够顺畅地输送到发动机；2) 电池电量不足：检查电池电量是否充足，如果不足需要及时更换电池或进行充电；3) 点火系统故障：检查点火线圈和火花塞是否损坏，如有需要更换或修复；4) 发动机发动机故障：检查发动机是否存在其他故障，如气缸压力不足等，需要进行进一步维修。
2.发电机运行不稳定故障现象：柴油发电机在运行过程中出现不稳定的情况，如转速忽高忽低，功率波动等。
可能原因及解决方法：1) 供油问题：检查燃油供应管路是否存在泄漏或阻塞的情况，并及时进行维修；2) 空气滤清器堵塞：检查空气滤清器是否堵塞，如果堵塞需要清洗或更换；3) 燃油滤清器堵塞：检查燃油滤清器是否堵塞，如果堵塞需要清洗或更换；4) 点火系统故障：检查点火线圈和火花塞是否损坏，如有需要更换或修复。
3.发电机输出功率不足故障现象：柴油发电机运行正常，但输出功率不足。
可能原因及解决方法：1) 燃油供应问题：检查燃油供应管路是否受阻或漏油，确保燃料能够顺畅地输送到发动机；2) 运行负载过重：检查发电机负载情况，如果超过发电机的额定功率，需要减少负载以保证正常运行；3) 发动机速度不稳定：检查发动机转速是否稳定，如果不稳定需要进一步调整或修复；4) 空气滤清器堵塞：检查空气滤清器是否堵塞，如果堵塞需要清洗或更换。
柴油发电机的维修手册
柴油发电机的维修手册一、前言柴油发电机作为现代发电设备中常用的一种类型，它逐渐被广泛应用于工厂、商店、医院、学校等各类场所。
但柴油发电机在运行过程中，难免会遇到一些故障，需要进行维修。
因此，本手册旨在为维护及修理柴油发电机的工作人员提供指引和帮助。
二、基础知识1. 柴油机原理柴油机是以柴油为燃料的内燃机，它的燃料是以雾化的形式进入燃烧室内，再在高温高压的条件下发生燃烧，驱动发电机旋转，从而产生电能。
2. 柴油机的零部件柴油机主要由缸体、缸盖、活塞、连杆、曲轴、进气歧管、喷油泵、油箱、散热器等部件组成。
3. 柴油机的分类按照冷却方式分类，柴油机分为自然冷却和强制冷却两种。
按照进气方式分类，柴油机分为自然吸气和机械增压两种。
按照应用场所分类，柴油机分为陆用、船用两种。
按照功率大小分类，柴油机分为小功率柴油机、中功率柴油机和大功率柴油机。
三、维修流程1. 维修前的准备维修前要做好以下准备工作：（1）了解发电机故障原因；（2）查找故障可能涉及的部件；（3）检查需要更换的备件是否齐全；（4）检查工具是否齐全；（5）停机前做好发电机的冷却；（6）停机前做好发电机的清洁工作。
2. 维修过程维修过程包括以下步骤：（1）拆卸：在安全的前提下拆卸故障部位；（2）检查：检查故障部位是否有损坏或磨损；（3）清洗：清洗拆下来的部件，把部件中的杂质清除干净；（4）更换：更换需要更换的备件；（5）安装：在清洁干净的部位进行安装；（6）调试：调试后发现故障没有解决，要重新拆卸检查，直到问题得到解决。
3. 维修后的工作维修后要做好以下工作：（1）进行试验；（2）做好防护；（3）规范维护；（4）记录故障情况。
四、注意事项1. 安全第一在进行柴油发电机维修时，要注意保障自己和周围的人员安全。
一些步骤需要双人配合操作，例如更换活塞环、清洗气缸套等，要特别注意协调好操作步骤，确保安全。
2. 保持清洁在进行柴油发电机维修操作之前，应该清洗发电机，尤其是缸体、缸盖、曲轴箱等重要部件清洁。
柴油发电机组维修说明书
柴油发电机组维修说明书一、引言柴油发电机组是一种常见的发电设备，广泛应用于各个领域，如工业、农业、建筑等。
为了确保柴油发电机组的正常运行，及时维修和保养是非常重要的。
本维修说明书将详细介绍柴油发电机组的维修方法和注意事项。
二、维修前的准备工作1. 确保安全：在进行任何维修操作之前，必须切断柴油发电机组的电源，并将开关设到“离”位，以防止电击事故的发生。
2. 工具准备：准备常用的维修工具，如扳手、螺丝刀、电线钳等，确保工具的完好无损。
3. 资料查询：熟悉柴油发电机组的技术手册，了解其结构、工作原理和维修方法。
4. 维修环境：选择一个安全、整洁的工作环境，确保充足的照明和通风条件。
三、故障诊断与维修方法1. 发动机无法启动可能原因：- 柴油油箱无燃油或燃油不足- 燃油管路堵塞或漏油- 电池电量不足或线路接触不良维修方法：- 检查柴油油箱，确保有足够的燃油供应- 检查燃油管路，清洁或更换堵塞或漏油的管件- 检查电池电量，充电或更换电池2. 发动机运行不稳或停机可能原因：- 空气滤清器堵塞- 燃油喷嘴故障- 燃油滤清器堵塞维修方法：- 清洁或更换空气滤清器- 清洁或更换燃油喷嘴- 清洁或更换燃油滤清器3. 发电机输出功率不稳定可能原因：- 发电机负载过大- 发动机转速波动- 发电机内部故障维修方法：- 调整发电机负载，确保在额定功率范围内运行- 检查发动机转速控制装置，调整转速稳定性- 检查发电机内部，如发电机绕组是否短路或断路，进行修理或更换四、保养注意事项1. 定期更换机油和机油滤清器，以确保发动机润滑良好，延长使用寿命。
2. 清洁发电机组外壳和散热片，防止灰尘积累影响散热效果。
3. 检查电线和连接器的接触是否良好，如有松动或腐蚀应及时处理。
4. 定期检查并调整发电机组的皮带松紧度，确保传动效率和使用安全。
5. 清洁燃油滤清器，并定期更换以防止积存的杂质阻塞导致燃油供应不足。
五、安全注意事项1. 维修时注意个人防护，戴好手套、护目镜等安全装备。
柴油发电机维修手册
柴油发电机维修手册第一章概述柴油发电机是一种常见的发电设备，广泛应用于工业、建筑、农业等领域。
为了保证柴油发电机的正常运转和延长其使用寿命，正确的维修非常重要。
本手册将详细介绍柴油发电机的维修方法和技巧，使读者能够通过本手册来解决常见的故障和问题。
第二章维修准备在进行柴油发电机的维修前，必须做好充分的准备工作，以确保安全和高效维修。
以下是维修准备的主要步骤：1. 清理工作区域：确保工作区域干净整洁，减少维修过程中发生意外的风险。
2. 获取维修工具：根据维修手册提供的要求，准备好所需的维修工具和设备。
3. 关闭柴油发电机：在维修前，必须确保柴油发电机已经完全关闭，并断开电源。
4. 获取维修手册和相关资料：阅读维修手册，并准备好相关的维修资料和图纸，以便参考和查阅。
第三章常见故障和维修方法本章将介绍柴油发电机常见的故障原因以及相应的维修方法。
以下是几个常见的故障情况：1. 发动机启动困难：可能是由于燃油供应不足、点火系统故障或电池电量低等原因造成。
维修方法包括检查燃油供应系统、清洁或更换火花塞以及检查电池状态等。
2. 发电机不输出电流：可能是由于发电机电刷磨损、电路故障或励磁系统故障等原因导致。
维修方法包括更换电刷、修复电路故障或检查励磁系统。
3. 发动机运转不稳定：可能是由于进气系统堵塞、燃油供应不足或点火系统故障等原因引起。
维修方法包括清洁进气系统、检查燃油供应系统和点火系统等。
4. 发电机过载：可能是由于负载过大、配电线路过热或电压调节器故障等原因造成。
维修方法包括减小负载、检查配电线路以及更换电压调节器等。
第四章维护和保养为了确保柴油发电机的长期稳定运行，定期的维护和保养工作非常重要。
以下是一些常见的维护和保养事项：1. 更换机油和机滤：定期更换发动机机油和机滤可以确保发动机内部零件的润滑和清洁。
2. 清洗空气滤清器：定期清洗空气滤清器可以防止灰尘和杂质进入发动机，从而保护发动机的正常工作。
柴油机故障维修手册
柴油机故障维修手册第一章：柴油机故障排查步骤柴油机是一种常见的内燃机，广泛应用于各个领域。
然而，由于长时间使用或不当操作，柴油机故障时有发生。
本手册将为您详细介绍柴油机故障排查的步骤，帮助您准确诊断并解决故障。
1.1 清洁检查首先，确保柴油机处于停止状态并断开电源。
然后，对柴油机外部进行清洁检查，包括故障指示灯、连接线路、传感器和连接器等。
清洁检查是排查故障的基本步骤，可以发现明显的损坏或松动的部件。
1.2 故障码读取柴油机通常配备了故障码读取系统，用于记录和提示故障信息。
连接故障诊断仪器，读取故障码并记录下来。
故障码可以为后续的故障排查提供重要线索。
1.3 系统检查对柴油机的各个系统进行检查，例如燃油供应系统、电气系统和冷却系统等。
检查过程中，应关注是否存在破损、漏油、松动等异常情况，并记录下来。
1.4 传感器检查柴油机的传感器起到监测和控制的作用。
使用专业工具检查传感器的电气连接是否正常，以及传感器状态是否正常。
有时候，传感器可能出现损坏或失效的情况，直接导致柴油机故障。
1.5 测试和测量对柴油机的关键部件进行测试和测量，以确保其性能符合要求。
例如，可以使用柴油机排气分析仪检测燃烧效率，使用示波器测量电路的信号波形等。
通过测试和测量，可以准确判断柴油机存在的问题。
1.6 数据分析根据前面的步骤所获得的数据，进行仔细的分析，找出故障的根本原因。
数据分析是诊断故障的关键步骤，需要具备较强的专业知识和经验。
第二章：常见柴油机故障及解决方法2.1 柴油机启动困难柴油机启动困难可能是由于燃油供应不足、电气系统故障或喷油系统问题引起的。
根据具体情况，可以采取以下解决方法：- 检查燃油供应系统，确保燃油泵和滤清器正常工作。
- 检查电气系统，包括电池、起动机和点火系统等。
- 检查喷油系统，确保喷油器正常工作。
2.2 柴油机功率不足柴油机功率不足可能是由于燃油供给问题、气缸压力不足或喷油系统故障引起的。
解决方法如下：- 检查燃油供给系统，确保燃油滤清器和喷油器通畅。
柴油发动机维修手册说明书
Table 2.5Auxiliary connector - pins and signalsa.For more information on hardware links refer to“Power Sense Options” on page121.b.For more information on high power drive refer to “Special Purpose Outputs” on page67.c.Can be switched or unswitched. For more information refer to “Connector Power Supply Options” on page131.Table 2.6Auxiliary connector - DC characteristicsParameterStandardTest method and conditions Comments min.typ.max.unitsDigital signals Input low level:All inputs AUX_GPI20.7V s–4VVNo hardware links fitted a.LK3 fitted.Includes AUX_GPI3 with LK1/2 fitted.Configured as emergency power senseinput.Input high level:All inputs AUX_GPI2 AUX_GPI31.7V s–1.52.6VVVNo hardware links fitted a.LK3 fitted.LK1 and/or 2 fitted.Configured as emergency power senseinput.Configured as power sense input.Input low current:All other inputs AUX_GPI2 AUX_GPI3 AUX_RXD –100–120–13b–500–1µAmAµAmANo links fitted a. Default pullups c.LK3 fitted. V s=13.8VLK1 and 2 fitted.–8V input.Default pullup resistance is 33kΩ.Configured as emerg. power sense input.Configured as power sense input.Input high current:AUX_RXDAll other inputs 110100mAµAµANo links fitted a. Default pullups c.+8V input.3.3V input.5V input.Default pullup resistance is 33kΩ.Output low level:AUX_GPIO4-7 AUX_TXD 50600200mVmVmV100µA sink current.10mA sink current.100µA sink current.Current limit occurs at 20mA typ.Output high level:AUX_GPIO4-7 AUX_TXD 3.12.4VVNo load. Default pullups c.3kΩ load.Safe DC input limits:AUX_GPI1-3 AUX_GPIO4-7 AUX_RXD AUX_TXD d –0.5–0.5–25V–10V s+0.5V s+0.5V s+0.5V s+0.5VVVVInput current must not exceed ±50mA.This is the rating of the clampingdiodes.Analogue signals DC output range:RSSI13V8_SW 09.7317.2VVSee Table2.9 on page24.Follows V s.Output switches off outside this range.DC bias:AUD_TAP_IN AUD_TAP_OUT AUX_MIC_AUD 1.42.12.91.52.33.01.62.53.1VVVNo load. Zero Rx frequency error.Via 2.2kΩ.Bias for electret microphone.Input impedance:AUD_TAP_IN AUX_MIC_AUD 502.11002.21502.3kΩkΩDC to 10kHzOutput impedance:AUD_TAP_OUT RSSI 59095060010006501050ΩΩDC to 10kHzSafe DC input limits:AUD_TAP_IN AUD_TAP_OUT d AUX_MIC_AUD RSSI d –17–0.5–17–17+17+17+17+17VVVVShort circuit-safe. Input current <±20mAa.For more information on hardware links refer to “Power Sense Options” on page121.b.It is recommended that this input is driven by a mechanical switch or an open collector/drain output.c.For more information on pullups refer to “Digital Input Lines” on page39.d.These outputs are protected against accidental input to the limits specified.22Description of the Radio Interfaces TM8000 3DK Hardware Developer’s Kit Application ManualNotes:1.Optional processing blocks are bypassed in the above specification.2.For AUD_TAP_IN and AUD_TAP_OUT specifications the following signal paths apply:Table 2.7Auxiliary connector - AC characteristicsParameterStandardTest method and conditionsCommentsmin.typ.max.unitsAUD_TAP_IN (refer to note 4)Nominal input level:T ap T3, T4, T5, T8, T12T ap T13T ap R7, R100.620.780.620.690.870.690.760.960.76V p-p V p-p V p-p Level for 60% RSD@1kHz.Level for 3kHz dev.@1kHz.Refer to note 3.Equivalent to –10dBm into 600Ω.Full scale input level 2.0V p-pFrequency response:All tap-pointsRefer to the plots inTable 2.10 and Table 2.11.Group delay - absolute:T ap T13T ap T12T ap T8T ap T5T ap T4T ap T31.81.89.611.611.711.7ms ms ms ms ms msAt 1kHz. Refer to note 2.Refer to note 1.Refer to note 1.Group delay - distortion:T ap T12 and Tap T13Refer to the plots in Table 2.12.AUD_TAP_OUTNominal output level:All Rx tap-points except R1T ap R1T ap T30.620.540.620.690.600.690.760.660.76V p-p V p-p V p-p Rload=600Ω.Level at 60% RSD@1kHz.Level at 3kHz dev.@1kHz Refer to “Microphonesensitivity ”of AUX_MIC_AUD.Equivalent to –10dBm into 600Ω.Full scale output level 2.0V p-pRload=600Ω.Frequency response:All tap-pointsRefer to the plots inTable 2.10 and Table 2.11.Group delay - absolute:T ap R1T ap R2T ap R4T ap R5T ap R7T ap R101.81.86.66.78.58.7ms ms ms ms ms msAt 1kHz. Refer to note 2.Refer to note 1.Group delay - distortion:T ap R1 and Tap R2Refer to the plots in Table 2.12.AUX_MIC_AUD Rated System Deviation NB MB WB–2.5–4.0–5.0+2.5+4.0+5.0kHz kHz kHzEIA-603BUnits are peak frequency deviation from nominal carrier frequency in kHz.Modulation frequency responseRefer to the plot in Table 2.13.EIA-603BMicrophone sensitivity 6.07.59.0mV rmsEIA-603BCaseInput Output Tap into Rx chain AUD_TAP_INRX_AUD Tap out of Rx chain Modulation at antenna AUD_TAP_OUT Tap into Tx chain AUD_TAP_IN Modulation at antenna Tap out of Tx chainAUX_MIC_AUDAUD_TAP_OUT3.For tap into the Rx path, nominal level refers to the level required to give output at RX_AUD that is same as the60% dev level from the receiver. The level specified applies at 1kHz only.4.AUD_TAP_IN uses a DC-coupled analog-to-digital converter and the bias voltage specified in Table2.6 should beused to maximise dynamic range. The DC bias is removed internally by a digital high-pass filter so the Tx carrier frequency will not be affected by any bias error. it is recommended to use external AC-coupling for applications which do not require modulation to very low frequencies.Table 2.8Auxiliary connector - data characteristicsParameterStandardTest method and conditions Comments min.typ.max.unitsSerial portBaud rate:1200, 2400, 4800,9600, 14400, 19200bit/s All UART parameters are fixedand common to all UARTsexcept for the baud ratewhich is configurable anddifferent for different modes/applicationsData bits: 8Start bit:1Stop bit:1 Parity:None Protocol:CCDI2 Flow control:Software XON/XOFF GPIODelays:I/O mirror to IOP UI key delay 50050µsmsTable 2.9RSSI voltage vs. signal strength24Description of the Radio Interfaces TM8000 3DK Hardware Developer’s Kit Application Manual。
潍柴动力 维护手册
潍柴动力维护手册说起潍柴动力的维护手册，我想大家都知道，咱们平时用的这机器，不管是工程车，还是各种重型机械，都离不开它的心脏——潍柴发动机。
不过，你别看它们个头大、声音震天，实际上维护起来可是有些小讲究的。
说到这里，我就忍不住想起我上次跟朋友一起去工地看设备的那次经历，真是又好笑又让人有点无奈。
那天是个风和日丽的下午，正好朋友要检查一台潍柴动力的工程车，他让我一块儿去。
我本想着轻松地帮个忙，顺便学学怎么维护这些“大块头”，结果一到现场，我就傻眼了。
设备一停，我朋友就开始往发动机的盖子上一拍，仿佛这是跟它打招呼一样。
我看着他一脸认真的样子，心里突然冒出了一个念头：“难道发动机也能有脾气？”不过，他并没有管我这心里的小疑问，而是拿出了工具箱，开始了他的“例行检查”。
首先，他拿起了那根长长的检油尺，轻轻一插，拔出来，看了看油尺上的油量。
我正好站在旁边，忍不住问他：“油量合适吗？”朋友瞄了一眼油尺，然后神秘兮兮地笑了笑：“油有多重要你知道吗？如果油不够，发动机就会干涸，咱这车就成了‘废铁’了。
”听他这么一说，我这才意识到，发动机的维护真是细致入微，这油位问题也不能忽视。
接着，他又开始清理空气滤清器。
你可别小看这小小的滤清器，它的作用可不简单。
朋友一边清理一边跟我说：“你知道吗？这个滤清器就像是发动机的‘呼吸器’，如果它脏了，发动机就吸不进足够的空气，性能就大打折扣。
”我点点头，看着他拿着刷子一遍一遍地把滤清器刷得干干净净，突然觉得，潍柴发动机的维护工作，真是比我想象的还要复杂。
这时，我朋友又开始检查冷却液。
他拿起了冷却液的盖子，一看那液面，眉头一皱，说道：“这冷却液低了，得加点。
”我正准备问他为什么冷却液这么重要时，他好像看穿了我的疑问，接着说：“发动机就像咱们人的心脏一样，得保持温度正常，太热了会坏，太冷了也不行。
冷却液就负责帮它降温，保持在最佳状态。
”我点点头，觉得这些维护小细节真的不能马虎。
最搞笑的是，他还特意去拿了一把小锤子，敲了敲发动机的某个部件。
汽修资料-4JB1-VE泵柴油发动机维修手册
2.771
17.5
75/3600
65/3600
230/2000
210/2000
740~840
224~234
230~240
1-3-4-2
10°~14°
8°~12°
0 号轻柴油（北方冬季-10 号轻柴油）
0.40（冷态）
上止点前 24.5°
下止点后 55.5°
下止点前 54.0°
下止点后 26.0°
压力循环飞溅复合式
4JB1TI、4JB1TC 柴油发动机 维修手册
成都成发汽车发动机有限公司
目录
一、发动机技术特性……………………………………………………………………………………1 1、 发 动 机 的 主 要 数 据 及 技 术 参 数 … … … … … … … … … … … … … … … … … … … … 1 2、 发 动 机 的 外 形 尺 寸 图 … … … … … … … … … … … … … … … … … … … … … 2 3、 发动机主要配合间隙 ……………………………………………………………………6 4、 发 动 机 主 要 拧 紧 力 矩 … … … … … … … … … … … … … … … … … … … … … … … … 7
4JB1TC 发动机（前视图） 5
3. 发动机主要配合间隙
发动机主要配合间隙如下表：
表1
序 号
配合零件名称
间隙 （mm）
允许 磨损 间隙
(mm)
1 气缸套与活塞裙部 0.025~0.045
气环
0.2~0.4
活塞环开
2 口间隙
1..5
油环
0.1~0.3
第一环 0.09~0.125
柴油发电机组操作规程及维护说明书
柴油发电机组系列操作及维护说明书苏州富凌达机电工程有限公司2017年4月版本一、安全与健康1.安全警告本设备在设计和制造过程中充分考虑了安全因素和对人身健康的影响，使用者在使用前必须认真的阅读以下内容，并在操作过程中严格地遵守本手册规定的制度，以确保设备与人身的安全,以及人身的健康，凡因违章引起的安全事故和人身健康损伤，本公司概不负责。
1)起动发动机前，所有的保护装置，完好无损坏，特别是冷却风扇防护罩与发电机散热防护网等旋转部位必须予以正确安装防护。
2)在运转前，机组的控制、保护电器与连接线路应安装连接好，并对机组进行全面的检查，以确保发动机处于安全状态。
3)应保证机组所有接地装置良好并可靠连接。
4)所有可以锁定的门和盖板在运转前应该固定。
5)保养维护程序可能涉及到重型零件或危及生命的电气设备。
因此，操作员必须经过专业培训，建议不要独自操作设备，工作时须有人协助，以防万一发生意外时能及时处理各类状况的发生6)设备维修、保养前，应断开发动机起动马达电池电源，以防误操作，造成发动机意外起动引起人身伤害。
2.燃油和润滑油的安全使用燃油和润滑油会刺激皮肤，长时间接触会对皮肤造成伤害，皮肤接触到油，要及时用清洁凝胶或清洁剂进行彻底清洗。
在有接触到油类相关工作的人员应戴上防护手套，做好防护措施。
3.冷却液的使用安全1)冷却系统在机组运转前，(散热水箱或热交换器)必须装满清洁的冷却液。
2)当冷却系统没有冷却液或引擎正在运转时，不可起动加热器,否则会造成损害。
3)高温的冷却水会导致严重的灼伤，发动机未冷却的时候，不要打开封闭的冷却系统中的高热及高压的冷却水箱盖，以及水管的堵头。
4.电池的安全使用如果操作员使用铅酸电池时遵守下面的预防措施就会很安全。
为确保安全，必须按制造商的推荐，正确的操作和保养电池。
与酸性电解液接触的人员必须穿戴防护服，尤其要保护眼睛。
4)电解液铅酸电池含有有毒的和具有腐蚀性的稀硫酸，触到皮肤和眼睛会引起灼伤。
柴油发动机维修指南说明书
We don’t know much about alli-gator wrestling (which looks dangerous) or mud wrestling(which looks like tons o’ fun), but we do know something about diesel wrestling.We say “wrestling” because work-ing on diesel engines is different from working on gasoline engines—you don’t get as many in your bays, so you’re less familiar with them. This article is meant to change that. N exttime you “go to the mat” with a dieselengine, you may be able to demon-strate a few new “holds.”As you know, a diesel engine requires no spark plugs to fire the fuel, although glow plugs are typically used to assist engine starts in cold weather. Often, the fuel accumulates slightly before light-off occurs. This is called the delay stage .Once the delay stage concludes, the fu-el mixes with the hot compressed air in the cylinders and ignites, causing crunching blows to occur inside the en-gine. It ’s because of these crunching blows, plus the fact that the engine pro-duces far greater cylinder pressuresthan its gasoline-fed cousin, that the diesel has long been the burly power champ that produces high torque.Two Cummins EntriesSeveral contenders have climbed into the ring on the diesel light truck card.One is the Dodge Ram truck ’s 24-valve Cummins turbo diesel, an inline Six. Featuring big breathing, this en-gine produces 245 hp with the six-speed manual transmission, or 235 hp for automatics. Peak torque of 505 ft-lb comes in at 1600 to 2300 rpm.Cummins says the 24-valve cylin-WRESTLING WITH MODERN DIESELSB Y T HOMAS M ARCYWinning a bout with a diesel engine means using some heavy-duty skills. And as with any tough match, it pays to know the strengths and weaknesses of your opponent.der head design increases airflow and improves low-speed performance.The head also features vertical, cen-tered injection nozzles, which are claimed to boost combustion efficien-cy, cleanliness and fuel economy.Weigh in some electronic fuel control and you ’ve got a tough opponent.A diesel engine ’s fuel injection sys-tem must possess several characteris-tics to deliver maximum perfor-mance. These include accurate injec-tion control, high-pressure atomiza-tion, fast fuel ignition and fuel tem-perature adjustment capability.Fuel ’s fiery entry into the cylinders in the Cummins comes via a Bosch VP44 electronic injection pump and electronically controlled timing. First,the engine is cranked up for the match with an electric-powered lift (or supply) pump. Fuel flow begins as the lift pump pulls fuel from the tank and delivers it to the injection pump.As the engine spins over, the rotary,high-pressure injection pump is driv-en at half the engine speed by a sim-ple front gear train. This simplicity helps cut operating noise.The Cummins-developed ECM re-ceives information from various sensors and controls on the engine, then trans-lates that info into specific fuel quantity and timing commands that are sent to the injection pump metering control.Note that the injection pump used on earlier (1994-98) Cummins-equipped Dodge turbo diesel pickups is a Bosch P7100 inline design —what we sometimes call the jerk pump .The cam-operated six-plunger pump in the jerk pump sends fuel to the in-jector nozzles. The newer VP44, how-ever, is a rotary job with the ability to vary fuel and injection timing basedP h o t o : P a u l W e i s s l e ron input from the ECM. This pump incorporates a fuel pump control module (FPCM), which contains fu-eling, timing and diagnostic data. The FPCM communicates with the ECM to obtain information on desired fuel-ing and timing. The FPCM responds by consulting the fueling data and timing in its memory, then commands fueling and timing solenoids.The VP44 has a fuel temperature sensor inside it. The pump also con-tains a speed sensor that gives the FPCM information on the position and speed of the pump shaft. A crank-shaft reference pulse that marks TDCof cylinder No. 1 is also sent once every pump revolution. By comparing this reference pulse from the ECM to the position signal from the speed sensor, the FPCM can reference the pump ’s position to that of the engine.This allows the FPCM to adjust pump timing to compensate for small posi-tion differences between the fuel pump shaft and the engine cam. If the difference becomes too great, a fault is logged in the FPCM.The FPCM controls the timing and fueling through two solenoids located in the pump. The timing solenoid controls the position of a cam ring in-side the pump by varying internal transfer pump pressure to a cam ring piston. The cam ring has evenly spaced lobes around its inner diame-ter. The pumping plungers ride on rollers that rotate around inside this ring. The rollers follow the inner di-ameter of the ring and push the pumping plungers inward whenever a cam lobe is encountered. This builds injection pressure on the fuel trapped between the plungers. By rotating the cam ring with the timing solenoid,the FPCM is able to advance and re-tard the injection timing by makingthe rollers contact the cam lobes ei-ther earlier or later in their rotation.As its name implies, the fuel solenoid in the pump meters fuel to the injec-tors. It does this by opening a metering valve to allow fuel from the supply pump to flow into the pumping cham-ber. Once this chamber is charged with fuel, the solenoid valve closes, trapping the fuel in the chamber and allowing injection pressure to build.The fuel is routed to the correct in-jection nozzle via the pump distributor head. A port on the distributor rotor aligns with one of the six pump dis-tributor head outlet ports to distribute fuel to a given nozzle. In the cylinder head, the high pressure opens the in-jector nozzles, allowing fuel to pass in-to the combustion chamber. Once the desired amount of fuel is injected, the solenoid valve opens, causing the pres-sure in the pumping chamber to bleed down, which ends injection. The injec-tion nozzle then snaps shut.When the high-pressure fuel reaches the nozzle, the pressure lifts the needle valve against the spring ’s preset “popping ” tension. At the de-sired pressure, the nozzle pops open to let the fuel spray into the combus-tion chamber. A minor fuel leak past the nozzle needle valve enters the fu-el drain manifold in the cylinder head. The fuel in the manifold then exits at the rear of the cylinder head and is routed to the fuel tank. Fuel return from the injection pump is al-so routed back to the tank.Breathing and BelchingBoth Cummins engines —the older Bosch-equipped P7100 and the newer VP44—feature direct injection, sans precombustion chambers. Cummins claims that direct injection produces more power than precombustion chamber-equipped engines, while lowering internal heat stresses. High compression heat and fuel swirl for good combustion develop in the pis-ton ’s symmetrical combustion bowl.In the late-model Cummins turbo diesel, the valvetrain has wider lobes on the tappet face and cam, with longer push tubes. To reduce camshaft wear, an electric lift pump eliminates the need for a mechanical lift pump lobe. The standard valve springs are compatible with engine braking equipment. Top off the en-gine with an engine-matched Holset turbocharger and wastegate and you have a unit ready to rumble. For Cummins, a no-smoke entry into the fray is gained with an Integrated Air Intake Grid Heater. Using this method, white smoke is eliminated and cold-starting is improved. After warmup, compression and combus-tion efficiencies are improved by pro-viding aftercooled air to the engine.WRESTLING WITH MODERN DIESELSFor Dodge Ram trucks, the 24-valve Cummins diesel provides improved block strength and durability, with reduced noise. Also, the water pump, oil pump, cooler housings and coolant bypass are all integrated to eliminate potential leak points.P h o t o : T h o m a s M a r c yAlso, new electronic devices allow monitoring of critical engine data and diagnostic information from the ECM.For example, with the RoadRelay 4(RR4) system, you can tap into the ECM while driving. Then if a problem develops on the road, the system will display the appropriate fault code. Al-so, RR4 can remind the driver when service is due on specific items and can record up to 12 service events.Also new for the Cummins 24-valve turbo diesel is QuickCheck II, a diag-nostic read-only application that runs on Palm devices and lets you view such items as engine sensor and diagnostic information, including boost pressure,oil pressure, fuel rate, percentage en-gine load, engine hours, output torque and intake manifold pressure. The QuickCheck II kit contains a custom data link adapter, cables, connectors and the diagnostic software applica-tion. Load the software, plug it in and you can view data in real time or download it to your shop PC.Ford’s Power StrokeFord enters the ring with an old hand, but with new tricks. In its Pow-er Stroke Garrett-turbocharged diesel, such as found in an F-250 we recently drove, a mechanical fuel pump nests in the valley behind the fuel filter with its plunger riding on a special engine cam lobe.In older models, the feed pump uses a diaphragm to draw fuel from the tank while a piston-type positive displace-ment pump increases the 4 to 6 pounds of pressure to around 50 psi, regulated by a spring and plunger in the filter housing. The 50 psi is delivered to the lower chamber inside the injector through a common rail passage in the cylinder head. The tiny fuel chamber plunger ’s oil-pressure-driven head is seven times the size of the bottom of the plunger, where the fuel is delivered.The head forms the chamber floor that receives a burst of high oil pressure.This happens as an electrical solenoid valve opens and lets the pressure in.The high oil pressure pulse drives the plunger down, multiplying the pressure by a factor of seven at the injector tip. The trapped fuel blows outthe injector tip and into the cylinder.The PCM operates the injector so-lenoids through an injector driver module. The fuel comes to the sole-noids from an injection control pres-sure sensor, a sensor in the oil rail at the front of the driver ’s side head. An injection pressure regulator (IPR)rides in the high-pressure oil pump.This pump mounts similar to the old-er-design injection pump.The fuel enters both the left and right cylinder head high-pressure feed hoses. During a cold start, the high-pressure oil pump receives unfiltered oil from the low-pressure lubrication pump through the left-side valve lifter oil galley and through the antidrainbackDiesel engines need and consume large quantities of air . Always check the airfilter and examine the manometer gauge to look for restrictions.GM growls in V8 style with the new Duramax 6600. The engine features many aluminum components and an electronic common rail fuel system.P h o t o : T h o m a s M a r c ycheck valve. Once the engine starts, or during warm engine starts, the check valve closes and the high-pressure oil pump receives filtered oil from the pump reservoir. The high-pressure pump then supplies the oil under ex-tremely high pressures through the left and right pressure rails. A relief valve in the high-pressure oil pump regulates the available pressure.The control pressure actually deliv-ered to the oil rails is regulated elec-tronically by an injector control pres-sure (ICP) regulator, controlled by the PCM. Once in the oil rail, the oil is fed to the head ’s fuel injector bores through four galleys drilled and ma-chined in the cylinder head. The high-pressure oil then activates the fuel in-jectors based on PCM commands.The GMC & Chevy T ag T eamGMC and Chevrolet enter the ring with a new 6.6-liter turbocharged diesel V8called the Duramax 6600. Although no lightweight in power, the Duramax weighs only 836 pounds. It uses alu-minum extensively in such key compo-nents as the cylinder heads, crankcase,accessory drive brackets, intake mani-fold and flywheel bellhousing. The en-gine is available in 2500 HD and 3500GMC Sierras, and in Chevrolet Silvera-do pickups and chassis cabs.The Duramax cylinder head is made of gravity-cast aluminum and has four valves per cylinder. Each fuel nozzle islocated in the center of the combustion chamber in a stainless-steel holder. The valve arrangement forms a twisting in-take airflow. The intake ports are de-signed to maximize tangential flow for optimum intake swirl. In this head, ade-quately and evenly cooling the valve seats helps minimize any change in the valve gap.The Duramax fuel system has a sup-ply pump, a function block, common rails and injectors. An eccentric shaft drives the three-plunger supply pump,which is driven at crankshaft speed. The pump ’s inlet has a gear-type feed pump and a rail pressure control valve, which is governed by a sensor attached to the function block, on the high-pressure side. The valve is controlled in response to driving conditions. Each injector has a PCM-controlled solenoid in the injec-tor ’s upper portion.According to GM, one advantage of a common rail system is that injection pressure can be raised regardless of en-gine speed. This means the size of the nozzle hole in the injector can be small,which when used in conjunction with high-pressure injection, makes for a fin-er spray and faster combustion. This, by the way, makes a good case for offering timely filter services.WRESTLING WITH MODERN DIESELSWhen servicing a diesel engine, always check the maker’s specs to see what type of oil and fuel filters the engine uses. Because of the stresses of compression-ig-nition, diesels require oil with a unique lubricationcharacter and additive package.Don’t let your customer get pinned to the mat. Battery condition is a very im-portant part of any diesel’s performance, especially during cold-weather months when glow plugs help supply initial combustion chamber heat.P h o t o s : T h o m a s M a r c yThe Duramax 6600 is a relatively high-speed engine as far as diesels go,with a rated speed of 3100 rpm. Faster combustion makes possible shorter in-jection times, which means optimum fuel economy and exhaust emissions even at those higher speeds.Using short-duration, high-pressure injection improves performance in the final exhaust emissions rounds. Howev-er, because there are higher levels of NO X (oxides of nitrogen) with high-pressure injection at the start of the process, injection timing must be re-tarded. But GM says that if the timing is retarded without pilot injection, NO X reduction is limited while particulate matter increases. GM claims that pilot injection overcomes these limitations.Injecting a very small pilot amount of fuel before TDC makes it easier for the main injection to ignite. This makes it possible to retard injection timing and reduce both NO X and particulate levels.Another benefit GM claims for pilot ignition is reduced noise. Generally,combustion noise becomes louder as in-jection pressure increases. According to GM, pilot injection makes it possible to prevent a rapid increase in injection pressure during main injection, which greatly reduces diesel knock.The engine management system and control module of the Duramax are ba-sically the same as with gasoline en-gines, with vehicle-related control items also being similar. However, the com-mon rail system required developingnew software for diesel injection control items. Other new software was devel-oped for self-diagnostic items, such as injection volume, injection timing, pilot injection control, rail pressure control and injector dwell. The ECM drives the injectors by way of an electronic driver unit (EDU), which also senses and ig-nores abnormal injection requests. The engine management system also per-forms all OBD II functions.In servicing these new diesel engines,you can easily see that a technician first needs to know the basic operation of these “oil-burners.” But he must also know the quirks applicable to each powerplant. Also, training in the DTCs that an ECM/PCM can throw into the ring becomes very important.You ’d be well-advised to get a ring-side seat and do some serious manual studying on the art of diesel wrestling.Who knows? You could be called on forthe next match!Always check for proper turbocharger and wastegate function. Although tucked far beneath the cowl on this Ford pickup truck, a simple vacuum pump test can reveal a wastegate servo knocked out of the match.With a stumbling Cummins-equipped Dodge, some technicians crack open an in-jection nozzle line to check for cylinder power output. Instead, we suggest using a contact pyrometer on the exhaust manifold to isolate the offending cylinder .。
柴油发电机维修技术手册
柴油发电机维修技术手册一、引言柴油发电机在现代社会中扮演着重要的角色，广泛应用于工业、农业、建筑等领域。
然而，由于柴油发电机的复杂性，其维修需要具备一定的专业知识和技术。
本手册旨在提供一份详尽而全面的柴油发电机维修技术指南，以帮助维修人员解决各类故障。
二、基本概念1.柴油发电机的组成：柴油机、发电机、控制系统。
2.柴油发电机工作原理：依靠柴油机燃烧柴油产生动力，通过发电机转化为电能输出。
3.柴油机的分类：单缸、多缸，根据排气方式可分为自然吸气和涡轮增压。
4.柴油机的故障检修流程：故障现象观察、故障分析、故障排除。
三、维修准备工作1.工具准备：包括通用工具、特殊工具和仪器设备。
2.资料准备：获取柴油发电机的技术资料、维护手册和维修案例等。
3.环境准备：确保维修场地安全、通风和照明条件符合要求。
四、常见故障排除1.发动机启动困难：检查燃油系统、供油系统和点火系统，清洁或更换相关元件。
2.机油温度过高：检查冷却系统、润滑系统和喷油嘴，及时维修或更换故障部件。
3.功率输出不稳定：检查燃油供应、排气系统和调速装置，调整或更换相关部件。
4.发动机异响：检查气缸、曲轴和凸轮轴等核心部件，修复或更换故障元件。
5.电力输出异常：检查发电机的绕组和调压装置，修复或更换故障部件。
6.其他故障：如发动机冲程不稳定、冷却液泄漏等，根据具体情况进行维修处理。
五、安全注意事项1.维修人员需熟悉柴油发电机的工作原理和维修流程，提前做好安全培训。
2.在维修过程中，必须切断电源，确保工作场所环境安全。
3.佩戴必要的个人防护装备，如手套、护目镜和防护服等。
4.遵循柴油发电机的维护保养规定，定期检查和更换磨损或老化的部件。
5.学会正确使用维修工具，避免不当使用造成人身伤害或设备损坏。
六、维修案例分享1.柴油发电机冷却液泄漏故障分析和处理。
2.柴油机燃油喷射系统故障原因及排除方法。
3.发电机无输出电压问题的解决方案。
4.柴油发电机震动过大的原因分析及处理方法。
潍杰自动汽车维修指南说明书
IndexAccessoriesInstallation................................. 115ACCESSORY (Ignition KeyPosition)....................................... 50AddingAutomatic TransmissionFluid........................................ 154Brake Fluid................................ 156Clutch Fluid.............................. 158Differential Oil.......................... 155Engine Coolant......................... 149Engine Oil.................................. 145Manual Transmission Fluid... 155Power Steering Fluid.............. 158Windshield Washer fluid......... 153Additional Safety Information.... 17Door Locks.................................. 18Driving with Pets....................... 18Head Restraint Position............ 17Seat-back Position..................... 17Storing Cargo Safely................. 18Additives, Engine Oil.................. 146AdjustmentsHead Restraints (57)Mirrors......................................... 63Seats.............................................. 54Steering Wheel........................... 44Airbag (SRS).................................... 11Air Cleaner.................................... 159Air Conditioning............................. 76Maintenance.............................. 167Usage............................................ 76Air Outlets (Vents)......................... 72Air Pressure, Tires...................... 168Alarm, Anti-theft......................... 106Alcohol and Drugs.......................... 27Alcohol in Gasoline...................... 108Aluminum Wheels, Cleaning..... 187Antifreeze...................................... 149Anti-lock Brakes (ABS)Description................................ 218Indicator Light.................. 35, 128Operation................................... 128Anti-theft Steering ColumnLock .............................................50Anti-theft System........................ 106Appearance Care.......................... 185Ashtrays. (68)Audio System..........................79, 189Automatic Speed Control (46)Automatic Transmission............ 122Capacity, Fluid.......................... 216Checking Fluid Level.............. 154Shifting....................................... 122Shift Lever Positions............... 123Shift Lock Release. (126)Back-up Lamp Replacement (180)BatteryCharging System Light............. 34Jump Starting........................... 201Maintenance.............................. 162Specifications............................ 217Before Driving.............................. 107Belts, Seat.......................................... 5Body Repair.. (192)CONTINUEDIndexBrakesAnti-lock System (ABS).......... 128Break-in, New Linings............ 108Fluid............................................ 156Light, Burned-out.................... 180Parking......................................... 65System Light............................... 34Wear Indicators........................ 127Brakes, ABSDescription................................ 218Operation................................... 128System Indicator............... 35, 128Braking System............................ 127Break-in, New Car....................... 108Brightness Control,Instruments................................. 41Brights, Headlights........................ 40Bulb ReplacementBack-up Lights......................... 180Brake Lights............................. 180Courtesy Lights........................ 182Fog Lights................................. 176Front Parking Lights.............. 179Front Side Marker Lights...... 179Headlights................................. 174High-mount Brake Light.. (181)Interior Lights.......................... 182License Plate Lights................ 181Rear Side Marker Lights........ 180Specifications............................ 217Turn Signal Lights .................. 178Bulbs, Halogen (174)Cables, Jump Starting With....... 202Cancel Button................................. 48Capacities Chart........................... 216Carbon Monoxide Hazard ............ 28Cargo, Loading.............................. 116Cassette PlayerCare............................................. 104Operation.............................. 86, 96CAUTION, Explanation of............ ii CD Player....................................... 101Certification Label....................... 214Chains............................................. 173Change OilHow to........................................ 147When to...................................... 139Changing a Flat Tire................... 195Changing Engine Coolant.. (150)Charging System Light...... 34, 206Check Engine Light............ 35, 207CheckingAutomatic TransmissionFluid........................................ 154Battery Condition..................... 162Brake Fluid................................ 156Clutch Fluid.............................. 158Differential Oil.......................... 155Engine Belts.............................. 168Engine Coolant......................... 149Engine Oil.................................. 145Fuses.......................................... 209Manual Transmission Fluid... 155Power Steering Fluid .............. 158Checklist, Before Driving........... 118Childproof Door Locks.................. 52Child Safety..................................... 19Cigarette Lighter........................... 67Cleaner, Air................................... 159CleaningAluminum Wheels................... 187Exterior...................................... 186Interior....................................... 189Leather....................................... 189Seat Belts...................................190IndexVinyl........................................... 189Windows..................................... 190Wood Trim................................ 189CLEAN Light............................... 104Clock, Setting the........................... 66Clutch Fluid................................... 158Code, Audio System..................... 105CO in the Exhaust........................ 220Cold Weather, Starting in........... 120Compact Spare.............................. 194Console Compartment................... 67Consumer Information................ 225Controls, Instruments and............ 31CoolantAdding........................................ 149Checking.................................... 149Proper Solution......................... 149Temperature Gauge.................. 38Corrosion Protection.................... 191Courtesy Lights.............................. 70Crankcase Emission ControlSystem........................................ 220Cruise Control Operation.............. 46Customer Relations Office (225)DANGER, Explanation of.............. ii Dashboard........................................ 39Daytime Running Lights.............. 40Dead Battery, What to Do.......... 201Defects, Reporting Safety............ 29Defogger, Rear Window............... 44Defrosting the Windows............... 78DEXRON ® II AutomaticTransmission Fluid.................. 154Differential Oil.............................. 155Digital Signal Processor................ 99Dimensions.................................... 216Dimming the Headlights .............. 40DipstickAutomatic Transmission........ 154Engine Oil.................................. 145Directional Signals......................... 41Disabled, Towing Your Car If ... 212Disc Brake Wear Indicators....... 127Disposal of Used Oil..................... 148DoorsLocking and Unlocking............. 51Monitor Light............................. 35Power Door Locks. (51)DOT Tire Quality Grading......... 171Downshifting, 5-speed ManualTransmission............................. 121Driving............................................ 117Economy..................................... 114In Bad Weather......................... 129In Foreign Countries (109)Economy, Fuel.............................. 114Emergencies on the Road........... 193Battery, Jump Starting ........... 201Changing a Flat Tire............... 195Charging System Light.......... 206Check Engine Light................ 207Checking the Fuses................. 209Low Oil Pressure Light.......... 205Malfunction IndicatorLamp....................................... 207Manually Closing Moonroof.. 208Overheated Engine.................. 203Emergency Brake.......................... 65Emergency Flashers. (43)CONTINUEDIndexEmission Controls........................ 220EngineCheck Light....................... 35, 207Coolant Temperature Gauge... 38Malfunction IndicatorLamp............................... 35, 207Oil Pressure Light.............34, 205Oil, What Kind to Use ............. 146Overheating............................... 203Specifications............................ 216Ethanol in Gasoline...................... 109Evaporative EmissionControls...................................... 220Exhaust Fumes............................... 28Exhaust Gas RecirculationSystem........................................ 221Expectant Mothers, Use ofSeat Belts by................................ 10Exterior, Cleaning the.. (186)Fabric, Cleaning........................... 189Fan, Interior.................................... 73Fan, Radiator. (30)Features, Comfort andConvenience................................ 71Filling the Fuel Tank .................. 110FiltersFuel............................................. 160Oil................................................ 147First Gear, Shifting...................... 1225-speed Manual TransmissionChecking Fluid Level.............. 155Shifting the................................ 121Flashers, Hazard Warning ........... 43Flat Tire, Changing a.................. 195FluidsAutomatic Transmission........ 154Brake.......................................... 156Clutch......................................... 158Differential ............................... 155Manual Transmission.............. 155Power Steering......................... 158Windshield Washer.................. 153FM Stereo RadioReception...............................81, 91Foreign Countries, Driving in.... 109Four-way Flashers......................... 43Front End, Towing byEmergency Wrecker (212)Fuel................................................. 108Fill Door and Cap...................... 110Filter........................................... 160Gauge............................................ 38Octane Requirement............... 108Oxygenated............................... 108Reserve Indicator....................... 36Tank, Filling the....................... 110Fuel Mileage, Improving ............ 114Fuel Station Procedures ............. 110Fuses, Checking the .. (209)Gasohol........................................... 108Gasoline.......................................... 108Filter........................................... 160Fuel Reserve Indicator............. 36Gauge............................................ 38Octane Requirement............... 108Tank, Filling the....................... 110GaugesEngine Coolant Temperature.. 38Fuel............................................... 38GAWR (Gross Axle WeightRating)........................................131IndexGearshift Lever PositionsAutomatic Transmission........ 1235-speed ManualTransmission......................... 122Glass Cleaning.............................. 190Glove Box......................................... 53GVWR (Gross Vehicle WeightRating) (131)Halogen Headlight Bulbs............ 174Hazard Warning Flashers............ 43HeadlightsDaytime Running Lights.......... 40High Beam Indicator................. 36High Beams, Turning on.......... 40Low Beams, Turning on........... 40Reminder Chime........................ 40Replacing Halogen Bulbs....... 174Turning on................................... 40Heating and Cooling...................... 72High Altitude, Starting at.......... 120High-Low Beam Switch ............... 40Hood, Opening the........................ 111Horn.. (49)Hot Coolant, Warning about...... 149Hydraulic Clutch.......................... 158Hydroplaning.. (130)Identification Number,Vehicle........................................ 214If Your Car Has to be Towed..... 212IgnitionKeys.............................................. 49Switch........................................... 50Timing Control System........... 221Indicator Lights, InstrumentPanel............................................. 33Infant Restraint.............................. 19Inflation, Proper Tire.................. 168Inside Mirror................................... 63Inspection, Tire............................. 169Instrument Panel............................ 32Instrument Panel Brightness....... 41Interior Cleaning.......................... 189Interior Lights................................ 69Introduction. (i)Jacking up the Car....................... 197Jack, Tire....................................... 196Jump Starting.. (201)Keys (49)Label, Certification...................... 214Lane Change, Signaling................ 41Lap/Shoulder Belts.......................... 6Lap Belt.............................................. 6Leaking of Exhaust into Car........ 28Leather, Cleaning......................... 189Lighter, Cigarette.. (67)CONTINUED。
柴油机维修手册
柴油发动机排故手册页次发动机不可以转动或转动迟缓发动机起动困难（排气中无烟）
发动机起动困难（排气中有烟）
发动机在运行时停机
发动机运行粗暴或缺火
发动机输出功率偏低
排黑烟过多
机油耗费率偏高
机油被污染
燃油耗费率偏高
冷却液被污染
冷却液损失
机油压力偏低
机油油位高升
冷却液温度超出正常温度
发动机噪声过大
发动机振动过大
发动机不可以转动或转动迟缓
发动机起动困难（排气中无烟）
发动机起动困难（排气中有烟）
发动机输出功率偏低
排黑烟过多
机油耗费率偏高
机油被污染
燃油耗费率偏高
冷却液被污染
冷却液损失
机油压力偏低
机油油位高升
冷却液温度超出正常温度
发动机噪声过大
发动机振动过大。
柴油机维修手册
柴油机维修手册柴油机作为一种重要的动力设备，广泛应用于工业、交通运输、农业等领域。
为了确保柴油机的正常运行和延长其使用寿命，维修工作尤为关键。
本手册将为您介绍柴油机的基本原理、常见故障排查与修复方法，以及维修过程中的注意事项。
一、柴油机工作原理柴油机的工作原理基于内燃机的热力循环，主要由进气、压缩、燃烧和排气四个基本过程组成。
在这一过程中，柴油机通过压缩空气使其温度达到柴油的自燃点，然后喷射柴油使其燃烧产生高温高压气体，从而驱动活塞运动，完成工作循环。
二、常见故障排查与修复方法1. 无法启动当柴油机无法启动时，首先需要检查燃料供给是否正常。
可以检查燃油泵的工作情况，燃油滤清器是否堵塞等。
另外，还需要检查喷油泵的工作是否正常，喷嘴是否堵塞。
如果以上检查都正常，还需检查点火系统和机械传动部分是否有异常。
2. 发动机运行不稳定如果柴油机在运行过程中发生抖动、异响或熄火等问题，可以考虑以下排查方法。
首先，检查燃油供应系统是否正常，如油泵的调整、喷嘴的清洗等。
其次，可以检查压缩系统是否有问题，如活塞环的磨损、气缸垫片的老化等。
另外，还需检查进气系统和排气系统是否通畅。
3. 机油消耗过多柴油机机油消耗过多可能是由于机油系统出现泄漏、活塞环磨损或气缸磨损等问题引起的。
需要仔细检查机油系统的管路，密封件是否完好，同时检查活塞环和气缸的磨损情况。
如有必要，需更换损坏的部件，并及时补充机油。
4. 发动机冷却不良柴油机的冷却系统对于维持发动机的正常工作温度至关重要。
如果发动机冷却不良，可能会导致发动机过热。
在排查时，需要检查冷却液的循环是否正常，散热器是否损坏，水泵是否工作正常等。
同时，需定期清洗冷却系统以保持其良好的工作状态。
三、维修注意事项1. 安全第一柴油机的维修过程中，安全是首要考虑的因素。
在进行维修工作之前，需要切断电源，并遵循相关的安全操作规程。
同时，使用合适的工具和设备，佩戴个人防护装备，以减少事故发生的风险。
VE 泵压力测试仪柴油喷射工具维修保养
VE 泵压力测试仪柴油喷射工具维修保养VE 泵压力测试仪柴油喷射工具维修保养，柴油发动机喷油泵如何调试喷油泵附调速器总成装配后应在喷油泵试验台上进行调试，各项性能必须符合规定要求。
缸预行程通过调整喷油泵缸预行程调整螺栓的高度，按各缸供油次序，静态供油夹角为60度，误差为±0.5度，通过调整泵调整螺栓的一致性来达到。
，将调整齿杆推到底并固定，用螺丝刀旋松调节齿圈上的锁紧螺钉，用螺丝刀触在油量控制套筒小孔，轻敲螺丝刀使套筒转动一个角度以增减供油量;逐次调整，直至各缸供油均匀，后将锁紧螺钉拧牢。
风冷柴油机新件的喷油器喷油压力偏高。
对于直喷式喷油器，新件喷油压力要求调至18.0-18.8MPa，工作过的喷油器的喷油压力要求调至17.5-18.3MPa;涡流室式喷油器，新件为12.0-12.8MPa，工作过的为11.5- 12.31MPa，这种情况是因为新件经装机工作运转后，喷油器组成元件要进行初始磨合，其喷油压力会很快地降低到正常工作压力值，因此要调高些。
另外应注意，在校验喷油压力值时，对新的喷油器不应按工作时的喷油压力值，而应按使用状态所要求的喷油压力值来调整。
第二，使用中检修喷油泵调试时，应注意以下要点:定期检查供油提前角及各缸供油间隔角。
在使用时，由于联轴节联接螺栓的松动，凸轮轴及滚轮体部件的磨损，常导致供油提前角及各缸供油间隔角发生变化，使柴油燃烧变坏，柴油机的动力性、经济性变差，同时启动困难，运转不稳，发出异响及过热等。
在实际使用中，多数重视整体供油提前角的检查调整，却忽视了供油间隔角(涉及单泵供油提前角调整)的检查调整，导致整体调整后虽然第1缸供油正时，但其余各缸由于凸轮轴、滚轮传动部件的磨损等原因使供油并不一定正时，同样会导致柴油机启动困难、动力不足、运转不平稳，尤其对于使用时间较长的喷油泵来说，更要重视对供油间隔角的检查调整。
第三，定期检查凸轮轴间隙，对喷油泵凸轮轴的轴向间隙要求很严，一般在0.03- 0.15mm之间，该间隙过大，会加剧滚轮传动部件对凸轮工作表面的冲击，从而加大凸轮表面的早期磨损，改变供油提前角度;凸轮轴轴承轴径间隙过大，易造成凸轮轴运转不平稳、油量调节拉杆抖动、供油量发生周期性变化，使柴油机运转不平稳，因此要定期检查调整;凸轮轴轴向间隙过大时，可在两侧加入垫片调整;径向间隙过大，一般要更换。
柴油电动驱动机维修手册说明书
RAF430-1F430-1, FC430F430-2, FC430-1 (cont’d) KEYNO. 1 2 3 4 5 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 40 41 42 43 44 45 46DESCRIPTIONShroud, RearShroud, FrontBracket (2 used)Tool TrayHex Nut 1/4" - 20 (2 used)Console, CoverRing, Panel MountingGauge, RT HandGauge, LT HandManifoldNipple, 1/4 x 2.5"Check ValveRegulatorSafety ValveAdaptorNut/Sleeve Assy.Pressure SwitchConnector BodyNut/Sleeve Assy. (2 used)Pressure Relief TubeCord AssemblyOutlet TubeNut Brass Compression (3 used)Silicone SleeveScrew, 1/4-20 x .75 (2 used)Cup, Saddle Mount (2 used)Isolator (3 used)Screw 10 x 5/8 (2 used)Shroud PlateDrain ValveStrip, Rubber FootShoulder Bolt (2 used)Wheel - 10" (2 used)Nut, Hex 3/8-16 unc - 2B 2 (used)HandleScrew (4 used)PART NUMBERAC-0046AC-0078CAC-1121CAC-1080SS-655-ZNAC-0011CAC-61AC-0009-1AC-0010-1AC-0027-2SSP-480CAC-4290-3AC-000797503734H-2101SSP-7813AC-0008-2SS-8553SSP-7811AC-0160SUDL-413-2AC-0125SSP-7821-1CAC-112091895680ACG-18ACG-19SSF-953-ZNAC-0047SS-2707SUDL-6-1CAC-60CAC-4313SSF-8080-ZNAC-0564SSF-981F430-1, FC430F430-2, FC430-1 (cont’d) TORQUE7 to 10 Ft. Lbs.7 to 10 Ft. Lbs.100 to 120 In. Lbs.80 to 100 In. Lbs.42 to 48 In. Lbs.uF430-1, FC430F430-2, FC430-1 (cont’d)PART NUMBER ---DAC-143------AC-0037SSF-589SSF-927ACG-45AC-0032SSG-8156------MO-9045AC-0140SSF-990AC-0108SSF-586SSF-3158-1------NOT ILLUSTRATEDH-7040-1SSH-20KK-4315MG2-OFTANK-4A MP2-F430-1MP2-FAC430MP2-F430-2MP2-FC430-1KEY NO.5051525354555657585960616265666769707172DESCRIPTION Air filter fastener (2 used)Air filter Muffler screen Intake muffler Head Stud 1/4"-20 x 1 1/4" Screw 1/4-20 x 1 1/4" O-Ring Valve plate assembly (includes valves, restrictors & screws)O-ring Connecting rod assembly Cylinder sleeve (position locating mark toward motor)Motor Eccentric Flywheel Bearing Assy.Screw (1/4-20 unc-2A)Fan Screw (1/4-20 unc x .75)Screw 10-24 X .75 T25 Torx Compression Ring Connecting Rod Cap Compression RingAir Hose (F430-2)Air ChuckPressure Relief ValveOwners Manual (F430-1, FAC430, F430-2 & FC430-1)Parts ManualParts ManualParts ManualParts Manual+Keys 50, 52 and 53 can only be purchased as part of KK-4981 (also includes Key #51).*Keys 57, 59, 60, 61, 70, 71, and 72 are purchased as part of KK-4835 piston/cylinder kit. Keys 57, 59, 61, 70 and 72 can be purchased as part of K-0058 cylinder sleeve/compression ring kit.+ ++*3*3**3*3**3。
- 1、下载文档前请自行甄别文档内容的完整性，平台不提供额外的编辑、内容补充、找答案等附加服务。
- 2、"仅部分预览"的文档,不可在线预览部分如存在完整性等问题,可反馈申请退款(可完整预览的文档不适用该条件!)。
- 3、如文档侵犯您的权益，请联系客服反馈,我们会尽快为您处理(人工客服工作时间：9:00-18:30)。
2.771
17.5
75/3600
65/3600
230/2000
210/2000
740~840
224~234
230~240
1-3-4-2
10°~14°
8°~12°
0 号轻柴油（北方冬季-10 号轻柴油）
0.40（冷态）
上止点前 24.5°
下止点后 55.5°
下止点前 54.0°
下止点后 26.0°
压力循环飞溅复合式
7
二、发动机主要外部零件的拆卸和安装
18 19
1、 冷却水旁通软管 4、 电热塞和连接器 7、 推杆 10、飞轮 13、机油泵总成 16、曲轴皮带轮 19、喷油泵组件 22、怠速齿轮“A” 25、曲轴轴承盖和曲轴轴承（下侧） 28、曲轴轴承（上侧）
4JB1TI、4JB1TC 柴油发动机 维修手册
成都成发汽车发动机有限公司
目录
一、发动机技术特性……………………………………………………………………………………1 1、 发 动 机 的 主 要 数 据 及 技 术 参 数 … … … … … … … … … … … … … … … … … … … … 1 2、 发 动 机 的 外 形 尺 寸 图 … … … … … … … … … … … … … … … … … … … … … 2 3、 发动机主要配合间隙 ……………………………………………………………………6 4、 发 动 机 主 要 拧 紧 力 矩 … … … … … … … … … … … … … … … … … … … … … … … … 7
API CF-4 级
SAE 15W-40
3.5~4.0（更换机油）
≥98（怠速）
≥441（2000rpm）
压力循环闭式水冷
218g/kw.h VE 型分配泵 P 型多孔式（5 孔或 4 孔）
27
14-70
12-2.8
1
2. 发动机外形图
4JB1TI 发动机（侧视图） 2
4JB1TI 发动机
4JB1TC 发动机（侧视图）
0.~0.1
7 连杆轴颈与连杆瓦 0.029~0.066 0.10
曲轴主轴颈与曲轴
8瓦
0.035~0.080 0.11
9 曲轴轴向间隙
0.05~0.20 0.30
6
4. 发动机主要拧紧力矩
发动机主要拧紧力矩见下表：
表 2：
序号
零部件名称
1 连杆螺母拧紧力矩
2 主轴承盖螺栓拧紧力矩
3 飞轮螺栓拧紧力矩
塞环高度
油环
0.03~0.07
4 连杆衬套孔与活塞 0.008~0.020 0.05
序 号
配合零件名称
间隙 （mm）
允许 磨损 间隙
(mm)
10 凸轮轴轴向间隙 0.05~0.114 0.30
凸轮轴衬套与凸
11 轮轴颈
0.05
0.12
12 挺柱与挺柱孔
0.03
0.10
摇臂轴和摇臂间
13 隙
0.1~0.05
三、发动机主要外部零件的拆卸和安装 ……………………………………………………………23 四、机油泵总成的拆卸和安装……………………………………………………………………26 五、机 油 滤 总 成 的 拆 卸 和 安 装 … … … … … … … … … … … … … … … … … … … … … … 2 7 六、水泵总成的拆卸和安装………………………………………………………………………… 29 七、喷油泵总的拆卸和安装……………………………………………………………………………30 八、发动机预热系统……………………………………………………………………………………33 九、发动机的故障和排除………………………………………………………………………………34
4 气缸盖螺栓拧紧力矩
5 后盖板螺栓拧紧力矩
6 曲轴皮带轮螺栓拧紧力矩
7 油底壳螺母（栓）拧紧力矩
8 喷油器压板螺栓拧紧力矩
9 高压油管螺母拧紧力矩
10 皮带松紧
拧紧力矩（kg.m） 8~9
16~18 11.5~12.5
10~11 7.6~9.2 17~21 1.4~2.4 3.2~4.4
2~4 100N 压力，下沉 8~10mm
4JB1TC 发动机（前视图） 5
3. 发动机主要配合间隙
发动机主要配合间隙如下表：
表1
序 号
配合零件名称
间隙 （mm）
允许 磨损 间隙
(mm)
1 气缸套与活塞裙部 0.025~0.045
气环
0.2~0.4
活塞环开
2 口间隙
1..5
油环
0.1~0.3
第一环 0.09~0.125
活塞环槽 3 宽 度 与 活 第二环 0.05~0.075 0.15
一、发动机技术特性
1. 发动机主要数据及技术参数
机型 项目 柴油机类型 燃烧类型 气缸套 气缸数-气缸×冲程（mm） 活塞环数 活塞排量（L） 压缩比 发动机功率（KW/rpm） 发动机扭矩（Nm/rpm） 怠速转速（rpm） 净质量（Kg） 气缸工作顺序 供油提前角（上止点前） 燃油牌号 进、排气门间隙（mm） 进气门开 进气门关 排气门开
排气门关
润滑方式
机油牌号
机油容量（L） 机油压力（Kpa） 机油冷却方式 最低燃油消耗率 g/kw.h 喷油泵型式 喷油嘴型式 喷油器开启压力（Mpa） 发电机（V-A） 起动机（V-KW）
4JB1TI
4JB1TC
水冷、四冲程、直列、顶置气门
直接喷射式
干式镀铬缸套
4-φ93×102
气环 2 个
油 1 个
二、发 动 机 主 要 部 件 的 拆 卸 和 安 装 … … … … … … … … … … … … … … … … … … … … … 8 1、 气缸体总成的拆卸和安装……………………………………………………………………9 2、摇臂轴总成的拆卸和安装…………………………………………………………………… 13 3、气缸盖总成的拆卸和安装…………………………………………………………………… 14 4、 活塞和连杆总成的拆卸和安装………………………………………………………………16 5、发动机内部零件的测量和安装……………………………………………………………… 18
0.20
进气门与气门导
14 管孔
0.039~0.068 0.20
排气门与气门导
15 管孔
0.064~0.096 0.25
16 进气门下沉量
0.73
1.28
5 活塞孔与活塞销
0.002~0.015 0.04
17 排气门下沉量
0.70
1.20
6 连杆大头侧隙
气缸套对气缸体
0.23
0.35
18 上平面凸出量