潍柴发动机专用维修工具说明书1
潍柴天然气发动机维修手册
汽车维修工具说明书
AUTOMOTIVE TOOLSGrease, Engine, Pick up tool, Refrigeration Tool, Tyre Repare, Bodywork Maintain Tool汽保机修专用工具润滑工具、引擎维修、底盘／传动维修、制冷维修工具、轮胎维护、车身维修、通用工具工具包， 箱， 车 TOOLS BAG & STORAGE工具包套装、工具包、塑料工具箱、铁工具箱、工具车、铝合金工具箱Tool bag Set, Tool Bag, Tool Box, Tool Trolley, Aluminium Tool BoxHOIST TOOLS立式千斤顶、卧式千斤顶Hydraulic Bottle Jacks, Garage Jack起重类工具液压类工具 HYDRAULIC TOOLS液压压线钳、液压断线钳、液压拉马Hydraulic Crimping Tool, Hydraulic Cutting Tool, Hydraulic PullerTool Set, Flashlight, Tweezer, Voltage Tester, Pliers, Crimping Tool, Screwdriver, Electric IronELECTRICAL TOOLS电子电工类工具套装类、手电筒、万用表、测电类、镊子、电工电子钳、电缆剪、电工剪刀、精密螺丝批、电烙铁及附件DRILLING TOOLS 丝锥板牙及组套、绞手、直柄麻花钻及套装HSS Ground Thread Tap, Stocks, Cobalt Stub Drills刃具类工具PIPE TOOLS切管类、弯管器、管钳Tubing Cutter, Pipe Bender, Pipe Wrench管道类工具AIR TOOLS气动扳手、气动套筒及配件Impact Wrench, Impact Socket and Accessories气动工具FINISHING TOOLS金刚石锉、 修边器、 钳工锉Diamond Needle File, Deburring Tool, File表面修整类工具油嘴特殊设计，增加钢珠自锁，确保油不回流。
玉柴6K系列维修专用工具使用说明(一)
6K系列柴油机采用干式薄壁缸套。当缸套过度磨损或拉缸时，则需对缸套进行更换。 将两个支杆旋入缸体上两个对称的缸盖主螺栓孔中。将拉盘倾斜穿过缸孔，再将拉 盘摆正，其台阶刚好卡在缸套下沿。将薄拉板与平面轴承安装在长螺杆上，并拧紧 螺母及安装螺母总成。旋转螺母总成即可顺利地将缸套拨出。 6K series diesel engine with dry thin wall cylinder. When the cylinder liner wear or scratch, it is needed to replace the cylinder liner. The two supporting rod is screwed into the cylinder head main bolt holes two symmetry. Pull the disc obliquely through the cylinder hole, and then pull the disc to straighten out, the bench just caught in the cylinder along. The thin plate and the plane bearing is installed in the long screw, and tighten the nuts and nut assembly. Swivel nut assembly can smoothly move the cylinder dial out.
4、活塞安装工具Piston Installation Device(TZ100808) （6K10发动机）
工具组成:tool:
TZ100802-2 气缸套拉拔拉盘 Cylinder drawing plate Cylinder rod and nut assembly drawing TZ100802-1 / TZ100102-2 气缸套拉拔支杆及螺母合件 MC11-01-1/TZ80060901/TZ 80062801/TZ100102-4 气缸套拉拔长螺杆及轴承 卡簧合件 Cylinder drawing long screw and the bearing circlip member TZ800311 气缸套压装薄拉板及顶 丝 Cylinder sleeve pressing thin plate and screw
潍柴发动机维修专用工具手册1：潍柴发动机主要结构介绍
潍柴发动机维修专用工具手册1：潍柴发动机主要结构介绍
潍柴发动机维修专用工具手册1——潍柴发动机主要结构介绍：气缸体、曲轴箱、气缸盖。
气缸体、曲轴箱
机体从主轴承孔中心分为两部分，上部分为气缸体，下部为曲轴箱。
曲轴箱与7件主轴承一起构成一个刚性很好的整体式框架。
在框架与气缸体之间没有垫片，装配时在气缸体底平面涂以乐泰510号密封胶。
气缸体与曲轴箱之间除用14个主轴承螺栓（M18）紧固外，两侧还有24个（M8）螺栓将其形成一个良好的刚性结构。
采用了相当紧凑的等气缸中心距和薄壁干式气缸套。
机体前视左侧有前后贯穿的主油道。
右侧有副油道，有6个冷却喷嘴与之联通，用于喷油冷却活塞。
主轴瓦为薄壁、表面有减磨镀层的合金瓦。
气缸盖
气缸盖采用四气门结构，低涡流比。
是一缸一盖结构的六面加工体，进排气道分布于两侧。
每个气缸盖上有4根M14的气缸盖主螺栓及4根M12×1.5的与临缸共用的双头螺柱，副螺母通过具有V型压紧面的压紧块压紧，在两端头处采用悬挂式压紧块。
气缸盖主螺栓及副螺母均用转角扭紧法拧紧。
气缸盖上喷油器竖直安装在进排气门之间位置。
气缸垫是钢板式结构，允许重复使用，但要认真检查，如有损坏，应予以更新。
气缸盖、气缸垫与机体都分别有定位，安装时予以注意！
配套潍柴发动机维修专用工具：
潍柴发动机维修专用工具——TZ100102缸套拔出器
潍柴发动机维修专用工具——TZ100122缸套压入工具。
柴油机维修手册
柴油发动机排故手册页次发动机不能转动或转动缓慢.......................................................................................................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 .................................................................................................................发动机运转粗暴或缺火..............................................................................................................发动机输出功率偏低 .................................................................................................................排黑烟过多................................................................................................................................机油消耗率偏高.........................................................................................................................机油被污染................................................................................................................................燃油消耗率偏高.........................................................................................................................冷却液被污染 ............................................................................................................................冷却液损失..................................................................................................................................机油压力偏低 ............................................................................................................................机油油位升高 ............................................................................................................................冷却液温度超过正常温度 ..........................................................................................................发动机噪声过大.........................................................................................................................发动机振动过大.........................................................................................................................发动机不能转动或转动缓慢发动机起动困难（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转粗暴或缺火发动机输出功率偏低排黑烟过多机油消耗率偏高机油被污染燃油消耗率偏高冷却液被污染冷却液损失机油压力偏低机油油位升高。
潍柴WD12系列柴油机零件图册说明书
前言
为使WD12系列柴油机在使用、维护等工作上的方便特汇编本图册，以供用户在使用中查阅参考，由于时间仓促，篇幅所限，本图册只汇编 了我公司现生产批量较大的机型，其它机型亦可参考本图册。
该图册基本上按组绘出各个零件的图形，相互关系。图号、件数，适用于柴油机的型号，规格标准，中文名称、英文名称等列于明细表栏内。 随着技术和生产的不断发展，柴油机的变形将增多，故本图册的内容将有所更新及变化，不再另行通知，特请用户注意，用户为获取最新产 品信息，应访问潍柴动力股份有限公司网站，网址为： 本公司欢迎用户对产品提出进一步改进的建议与意见。
WD12系列柴油机产品型号的组成及其代表的意义
l、本图册包括的4种机型为： WD12.336、375、390、420
2、DIN 德国标准 3、N05 斯太尔企业标准
SYMBOL AND INDICATION
1、4 Models are included in this illustrated parts manual as follows: WD12.336/375/390/420
WD12系列柴油机零件图册 WD12 SERIES DIESEL ENGINE PARTS CATALOGUE
气缸体 CRANKCASE
序号
图号
Pos． Teile.Number
45 61800011005 46 90003888453 47 90003813628S 48 90003900085 49 90003871305 50 90003932025 51 90003810125 52 90003802419 53 61800060153 54 61800060152 55 6180006015l 56 61500010062 57 90003962020 58 90003098014 59 90003120602 60 612600010709
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。
潍柴汽车维修手册说明书
6. 维修过程中避免制动块和制动盘沾染油污，若沾染油污则使用纱布打磨干净。 7. 切勿重复使用排出的制动液，排出的制动液应储存在专用的回收容器内。 8. 排气过程中要观察制动液壶的制动液液位，低于最低刻度线时，应及时补充。 9. 加注制动液且排气结束后，检查制动系统是否有泄漏；若有应及时给予排除，确保行
前蒸发器 ...........................................71B-39
更换..................................................... 71B-39
空调风道 ...........................................71B-40
更换..................................................... 71B-35
暖风机芯体........................................71B-38
更换..................................................... 71B-38
鼓风机 ...............................................71B-30
更换..................................................... 71B-30
调速模块 ...........................................71B-31
更换..................................................... 71B-31
发动机维修说明书1
发动机维修说明书11. 引言本文档为发动机维修的详细说明书。
它旨在提供给维修人员必要的操作指南和注意事项，以确保发动机能够正常维修和维护。
请在使用本说明书前仔细阅读并严格按照要求进行操作。
2. 安全注意事项在维修任何发动机之前，请务必遵守以下安全注意事项：•在维修过程中，务必断开发动机的电源。
•使用适当的个人防护装备，如手套、安全眼镜和耳塞，以防止受伤。
•在维修发动机之前，确保发动机已经冷却至安全温度。
•遵守相关安全规定和操作程序，如锁定传动装置、使用稳固的工作平台等。
3. 检查列表在维修发动机之前，请先进行以下检查：•检查发动机是否处于正常状态，如有异常请及时记录并分析。
•检查发动机周围是否有任何杂物和液体泄漏，如有请清除和修复。
•检查发动机的连接部件和管道是否紧固，如有松动请进行重新紧固。
4. 维修步骤4.1 拆卸发动机罩1.断开发动机罩上的连接螺丝和夹子。
2.轻轻推开发动机罩，确保没有任何连接部件被固定。
4.2 拆卸发动机部件1.先拆卸发动机的外部表面部件，如进气管、排气管和油箱。
2.接下来，拆卸发动机的内部部件，如汽缸盖和活塞。
4.3 更换损坏的部件1.对于损坏的部件，请先购买相应的替换件，并确保其与原件完全匹配。
2.拆卸损坏的部件，并安装新的替换件。
4.4 组装发动机部件1.在组装发动机部件之前，请确保所有部件已经清洁干净，无杂质和污垢。
2.按照逆序进行组装，将发动机的内部和外部部件依次安装。
3.请务必使用正确的扭矩和工具进行紧固，以避免损坏零件。
4.5 测试和调试1.在发动机维修完成后，请进行调试和测试，以确保发动机正常工作。
2.进行常规的启动和运行测试，并检查发动机的工作参数和噪声水平。
5. 维修注意事项•在维修过程中，请注意保持工作区域的整洁和安全。
•使用合适的工具和设备，以避免对发动机和周围部件造成损坏。
•定期检查和更换发动机的润滑油和滤清器，以保持发动机的良好工作状态。
•如遇到维修难题，请及时寻求专业技术支持和指导。
潍柴发动机维修专用工具手册—WP10柴油机装配工艺要点
潍柴发动机维修专用工具手册—WP10柴油机装配工艺要点潍柴发动机维修专用工具手册—WP10柴油机装配工艺要点：喷油器的安装、喷油器的拆卸、喷油器回油管的安装。
喷油器的安装喷油器通过法兰紧固在气缸盖上。
下图所示为两种喷油器压紧样式。
高压油管可以直接连接到喷油器上（通过外部接头），或间接的通过气缸盖内的内部高压接头连接。
喷油器压紧力必须作用在轴向上，否则喷油器体的变形，将会加剧内部针阀体的磨损，影响寿命。
喷油器紧固螺栓力矩M8（2根）：10~12N.m两个法兰拧紧力必须相等。
法兰与喷油器成90°角，法兰两边必须同时夹紧。
过高的压紧力会使得喷油率变化。
在安装条件下，喷油器油嘴小外圆上不可以有侧向作用力。
在轴向力的作用下，密封圈应可以在径向上发生变形而不接触到气缸盖内孔壁。
每当安装一个喷油器，必须使用一个新的密封圈。
使用过的密封圈会变硬。
使用旧的密封圈很有可能造成泄漏并且导致喷油器压紧力异常。
喷油器和喷嘴也会受到附带影响。
喷油器的拆卸拆卸喷油器的时候，必须采用与安装顺序相反的步骤。
然后手工将喷油器从气缸盖上拿掉。
如果手工拿不下来，可以采用必要的工具将喷油器拿下来。
这个特殊要求的工具必须保证接触到整个喷油器，并且不能有滑落可能。
这个特殊工具不准碰到电磁阀以及电磁阀紧帽。
不允许对喷油器体有任何的伤害。
如果部件有损伤必须更换。
否则会造成以后有漏油的可能性。
在将喷油器再次插入气缸盖之前，应该清除气缸盖孔里的燃烧残渣。
油嘴小外圆不要接触缸盖。
油嘴小外圆上的任何残渣都有可能产生一个侧向力。
喷油器回油管的安装安装回油管时应避免与汽车的高温部件接触（如排气管，涡轮增压器、废气回流管等）。
回油管内不允许存在节流区域。
回油管不可接触锋利的边缘，不可折成尖角，更不可被扭曲。
回油管安装不当会引起燃油泄漏到发动机上，过高的回油压力影响喷油器的喷有规律。
喷油器线束的安装紧固扭矩为1.5N.m。
过高的扭矩会导致电气连接的断裂或松动，从而使喷油器失效。
潍柴发动机专用维修工具说明书1
目录一. 说明 (3)二．发动机专用维修工具 (4)1. 连接板定位器（WPT001） (4)2. 喷油器拆卸器（WPT002） (4)3. 转换手柄（WPT003） (8)4. 活塞安装锥套（WPT004） (5)5. 液压挺柱安装器（WPT005） (5)6. 前油封安装器（WPT006） (6)7. 后油封安装器（WPT007） (7)8. 气缸套拆卸器（WPT008） (7)9. 气缸套安装器（WPT009） (9)10. 气门油封安装器（WPT010） (8)11. 气门弹簧压缩器（WPT011） (9)12. 涡轮增压机油接口拆装器（WPT012） (10)13. 铜锤（WPT013） (10)14. 卡簧钳（WPT014） (11)一、说明适当的维修方法和正确的修理程序对所有发动机和操作人员都是安全和可靠的。
维修的程序、技术和所使用的专用工具及零部件是多种多样的，维修人员的技能也是不尽相同的，所以本专用工具说明未能对所有工具提供详细的说明或冲突之处，请参照维修手册进行。
在维修柴油机零配件时须知：本公司柴油机产品，是高性能的柴油机，用户在维修时请按照柴油机零件图册和维修手册的诸项要求进行工作。
用户在维修时购买有关零配件，必须采用主机厂鉴定认可的产品，以确保其性能及可靠性。
警告：●维修时禁止吸烟。
●为避免严重灼伤，不要触碰任何高温金属表面。
●关闭点火开关，操作规程规定的除外。
●发动机须在通风良好的区域工作。
●避免在发动机工作时拆卸零部件。
●操作时必须戴安全防护眼镜。
二. 发动机专用维修工具1. 连接板定位器（WPT001），如图1配套使用工具：无用途：给连接板做定位。
操作方法：如图2把连接板定位器（WPT001）插入图中箭头所指处，进行连接板的定位。
图1 连接板定位器图22. 喷油器拆卸器（WPT002），如图3配套使用工具：转换手柄（WPT003）用途：拆卸喷油器。
操作方法：如图4把转换手柄（WPT003）的螺纹接头旋入喷油器拆卸器（WPT002）的螺纹孔中，然后把喷油器拆卸器（WPT002）套在喷油器上，手握转换手柄（WPT003）向上提出喷油器。
汽车发动机常用拆装工具使用
套筒扳手
• 使用时，选好合适尺寸的套筒，旋转快速 摇柄拆装。
• 不准拆装过紧的螺栓螺母，以防损坏工具。 • 禁止用锤子敲击。 • 过度磨损后不允许使用。
扭力扳手
• 用于有规定力矩的螺栓螺母的拆装。 • 指针式
• 预调式：扭力达到预设值时，能自动发出 声响，提示达到规定扭矩。
滑动手柄
• 可以通过滑动套筒的套头部分，使套筒 工作更方便或改变扳手力矩。
棘轮扳手
• 扳动棘轮扳手上的手柄可以改变扳手的用
力方向，往左转可以拧紧螺母，往右转可 以松开螺母。
快速摇柄
内六角扳手
4．锤子
（二）专用装配工具 1．活塞环拆装钳
2．气门拆装钳
3．顶拔器
4．其他专用工具
三、测量工具 1．游标卡尺
活动扳手
火花塞套筒
• 一般有16mm，21mm两种。 • 拆装火花塞专用工具。 • 套正后再扳转，以免损坏火花塞。 • 严禁拆装常规螺栓。
2．各类钳子的使用 在汽车维修中，常用的类型有钢丝 钳、鲤鱼钳、
尖嘴钳、斜嘴钳、鲤鱼钳、水泵钳、 大力钳、卡簧
钳、管钳等。
钳子
• 鲤鱼钳：一般用于切断金属丝。
• 尖嘴钳：在狭小的地方夹持零件。
• 挡圈钳
• 平头钳子
活塞环拆装钳
• 不得过快收缩手柄，以免折断活塞环。
3．螺丝刀
套筒扳手
万向节
• 套筒的方形套头部分可以前后或左右移动，
手柄和套筒扳手之间的角度可以自由变化， 使其在有限空间内工作。
加长杆
• 可用于拆下和更换装得太深不易接触的螺 母。
扭力扳手
• 不能用力过猛 • 不能超载 • 干燥存放 • 与套筒配合使用
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 .。
潍柴自动汽车用品维修指南说明书
Accessories and Modifications.... 189Accessories................................. 189Additional Safety Precaution.... 190Modifications............................. 190ACCESSORY (Ignition KeyPosition)........................................ 79Accessory Power Sockets............. 124AddingAutomatic TransmissionFluid........................................ 243Brake Fluid................................. 244Engine Coolant........................... 237Engine Oil................................... 233Power Steering Fluid................. 245Windshield Washer Fluid......... 242Additional Information AboutYour Seat Belts........................ 45Lap/Shoulder Belt....................... 45Seat Belt Maintenance................ 47Seat Belt System Components... 45Additional Information AboutYour SRS................................... 48Additional Safety Precautions. (52)How the Automatic Seat BeltTensioners Work..................... 50How the SRS IndicatorWorks...................................... 50How Your Airbags Work............ 48SRS Components......................... 48Additives, Engine Oil..................... 235AdjustmentsHead Restraints......................... 104Mirrors........................................ 115Seats............................................ 100Steering Wheel............................ 72Airbag (SRS)............................... 9, 49Air Cleaner Element...................... 246Air Conditioning Filter.................. 256Air Conditioning System.......130, 138Maintenance............................... 255Rear A/C Control...................... 146Usage..................................130, 138Air Outlets (Vents)................132, 138Air Pressure, Tires........................ 257Alcohol in Gasoline........................ 321Aluminum Wheels, Cleaning........ 279Antifreeze....................................... 237Anti-lock Brakes (ABS)Indicator Light..................... 59, 206Operation.................................... 205Anti-theft, Audio System............... 180Anti-theft Steering Column Lock .. 78Appearance Care........................... 277Armrests......................................... 103Audio Controls, Remote................ 179Audio System......................... 149, 161Automatic Seat Belt Tensioners.... 50Automatic Lighting Off Feature.... 67Automatic Speed Control................ 73Automatic Transmission............... 198Capacity, Fluid........................... 316Checking Fluid Level................ 243Shifting........................................199Shift Lever Position Indicator.. 198Shift Lever Positions................. 199Shift Lock Release (201)CONTINUEDBatteryCharging SystemIndicator............................ 58, 302Jump Starting............................. 297Maintenance............................... 251Specifications............................. 317Before Driving............................... 181Belts, Seat..................................... 8, 45Beverage Holder............................ 118Body Repair.................................... 283BrakesAnti-lock System (ABS)............ 205Break-in, New Linings .............. 182Fluid............................................ 244Light, Burned-out...................... 268Parking........................................ 116System Indicator.................. 58, 304Wear Indicators......................... 204Brakes, ABSOperation.................................... 205System Indicator.................. 59, 206Braking System.............................. 204Break-in, New Vehicle .................. 182Brightness Control, Instruments (67)Brights, Headlights......................... 66Bulb ReplacementBack-up Lights........................... 269Brake Lights............................... 268Cargo Area Light....................... 272Front Parking Lights................. 267Front Side Marker Lights......... 267Headlights.................................. 266High-mount Brake Light.......... 270Individual Map Lights............... 272License Plate Light.................... 271Rear Bulbs.......................... 268, 269Specifications............................. 317Turn Signal Lights..................... 267Bulbs, Halogen. (266)Cables, Jump Starting With.......... 298Cancel Button................................... 75Capacities Chart............................. 316Carbon Monoxide Hazard.............. 53Cargo Area Light........................... 127Cargo Net....................................... 194Carrying Cargo (191)Cassette PlayerCare............................................. 178Operation........................... 154, 175CAUTION, Explanation of.............. ii CD Changer...........................157, 171CD Player ...............................157, 169Center Pocket................................ 122Center Table................................... 117Certification Label......................... 314Chains............................................. 263Change OilHow to.........................................235When to....................................... 224Changing a Flat Tire..................... 287Changing Engine Coolant............. 239Charging System Indicator .... 58, 302CheckingAutomatic TransmissionFluid........................................ 243Battery Condition...................... 251Brake Fluid................................. 244Drive Belts.................................. 256Engine Coolant........................... 187Engine Oil................................... 186Fuses........................................... 306Power Steering Fluid.................245Checklist, Before Driving............. 196Childproof Door Locks................... 85Child Safety...................................... 22Cleaner Element, Air..................... 246CleaningAluminum Wheels..................... 279Carpeting.................................... 280Exterior....................................... 278Fabric.......................................... 280Interior........................................ 280Seat Belts.................................... 280Vinyl............................................280Windows..................................... 281Climate Control System................ 138Clock, Setting the.......................... 117Coat Hook....................................... 123Code, Audio System...................... 180CO in the Exhaust......................... 323Coin Holder.................................... 122Cold Weather, Starting in............. 197Compact Spare............................... 286Consumer Information*................ 328Controls, Instruments and.............. 55CoolantAdding......................................... 237Checking. (187)Proper Solution.......................... 237Replacing.................................... 239Temperature Gauge.................... 63Corrosion Protection..................... 282Crankcase Emissions ControlSystem.........................................323Cruise Control Operation............... 73Customer Relations Office.. (328)DANGER, Explanation of................. ii Dashboard.................................... 2, 56Daytime Running Lights................. 67Dead Battery, What to Do............ 297Defects, Reporting Safety............. 332Defogger, Rear Window................. 71Defrosting the Windows.......135, 144DEXRON ® III AutomaticTransmission Fluid.................... 243Dimensions..................................... 316Dimming the Headlights................ 66DipstickAutomatic Transmission........... 243Engine Oil................................... 186Directional Signals (68)Disabled, Towing YourVehicle If..................................... 311Disc Brake Wear Indicators......... 204Disposal of Used Oil...................... 236DoorsLocking and Unlocking............... 79Lockout Prevention..................... 80Manual Sliding Doors.................. 88Monitor Light............................... 60Power Door Locks....................... 79Power Sliding Doors.................... 90DOT Tire Quality Grading........... 319Drive Belts...................................... 256Driver and Passenger Safety............ 5Driving............................................ 195Economy..................................... 188In Bad Weather.......................... 210In Foreign Countries.. (322)Economy, Fuel............................... 188Emergencies on the Road............. 285Battery, Jump Starting.. (297)CONTINUEDEmergencies on the RoadBrake System Indicator............ 304Changing a Flat Tire................. 287Charging System Indicator...... 302Checking the Fuses................... 305Low Oil Pressure Indicator...... 301Malfunction Indicator Lamp.... 303Overheated Engine................... 299Emergency Brake.......................... 116Emergency Flashers....................... 70Emergency Towing....................... 311Emissions Controls........................ 323EngineCoolant Temperature Gauge ..... 63Drive Belts.................................. 256Malfunction IndicatorLamp............................... 58, 303Oil Pressure Indicator........58, 301Oil, What Kind to Use............... 233Overheating................................ 299Specifications............................. 317Ethanol in Gasoline ....................... 321Evaporative Emissions Controls.. 323Exhaust Fumes................................ 53Exhaust Gas RecirculationSystem (324)Expectant Mothers, Use of SeatBelts by......................................... 20Exterior, Cleaning the. (278)Fabric, Cleaning............................. 280Fan, Interior...........................130, 142Features, Comfort andConvenience............................... 129Filling the Fuel Tank..................... 183FiltersAir................................................246Air Conditioning........................ 256Oil................................................ 235First Gear Position......................... 201Flashers, Hazard Warning.............. 70Flat Tire, Changing a.................... 287FluidsAutomatic Transmission........... 243Brake...........................................244Power Steering........................... 245Windshield Washer................... 242FM Stereo RadioReception............................150, 162Folding the Third Seat (110)Foreign Countries, Driving in...... 322Four-way Flashers........................... 70Front End, Towing by Emergency Wrecker...................................... 311Fuel..................................................182Fill Door and Cap....................... 183Gauge............................................ 63Octane Requirement................. 182Oxygenated................................ 321Reserve Indicator......................... 61Tank, Filling the......................... 183Fuses, Checking the. (306)Gas Mileage, Improving................ 188Gasohol........................................... 321Gasoline.......................................... 182Fuel Reserve Indicator................ 61Gauge............................................ 63Octane Requirement................. 182Tank, Filling the......................... 183Gas Station Procedures................. 183GaugesEngine Coolant Temperature .... 63Fuel................................................63GAWR (Gross Axle WeightRating)........................................ 213GCWR (Gross Combined Weight Rating)........................................ 213Gearshift Lever Positions............. 199Glass Cleaning............................... 281Glove Box......................................... 87GVWR (Gross Vehicle WeightRating) (213)Halogen Headlight Bulbs.............. 266Hazard Warning Flashers............... 70Headlights......................................... 66Aiming......................................... 266Automatic Lighting Off............... 67Daytime Running Lights............. 67High Beam Indicator................... 61High Beams, Turning on............ 66Low Beams, Turning on............. 66Reminder Chime.......................... 66Replacing Halogen Bulbs ......... 266Turning on.................................... 66Head Restraints............................. 104Heated Mirror.. (116)Heating and Cooling...................... 130High Altitude, Starting at.............. 197High-Low Beam Switch .................. 66HomeLink UniversalTransmitter.................................. 95Hood Latch..................................... 248Hood, Opening the ........................ 184Horn................................................... 65Hot Coolant, Warning about........ 237Hydroplaning. (211)Identification Number, Vehicle.... 314If Your Vehicle Has to beTowed......................................... 311IgnitionKeys...............................................76Switch............................................78Timing Control System............. 324Immobilizer System......................... 77Important Safety Precautions .......... 6Indicator Lights, InstrumentPanel.............................................. 57Individual Map Lights................... 127Infant Restraint.. (30)Inflation, Proper Tire .................... 257Inside Mirror.................................. 115Inspection,Tire.............................. 259Instrument Panel........................ 2, 56Instrument Panel Brightness......... 67Interior Cleaning............................ 280Interior Lights................................ 125Introduction.. (i)Jacking up the Vehicle.................. 290Jack, Tire........................................ 288Jump Starting (297)Keys (76)Label, Certification........................ 314Lane Change, Signaling.................. 68Lap/Shoulder Belts.................. 15, 45CONTINUED。
潍柴wp10h发动机维修手册
潍柴wp10h发动机维修手册潍柴WP10H发动机维修手册第一章：引言1.1 介绍潍柴WP10H发动机是一款高性能、高可靠性的柴油发动机，广泛应用于工程机械、重型卡车和船舶等领域。
本手册将为您提供该发动机的维修指南。
1.2 维修手册的目的本手册的目的是为维修人员提供详细的维修指导，使其能够快速、准确地诊断和修复发动机故障。
通过正确的维修方法和技巧，确保发动机的正常运行和长期可靠性。
第二章：发动机的基本结构2.1 发动机的组成部分潍柴WP10H发动机由缸体、缸盖、曲轴箱、活塞、连杆、气门机构、燃油系统、冷却系统等组成。
本章将详细介绍各个部件的结构和功能。
2.2 发动机的工作原理本节将解释发动机的工作原理，包括吸气、压缩、爆燃和排气等过程。
了解发动机的工作原理对于故障诊断和维修至关重要。
第三章：维修前的准备工作3.1 安全注意事项在进行维修工作之前，必须遵守一些安全规定，包括穿戴个人防护装备、确保工作区域安全、使用正确的工具等。
3.2 维修工具和设备本节将列出进行发动机维修所需的工具和设备清单，包括常见的手工工具、测量仪器、维修设备等。
3.3 维修文档和资料在进行维修工作之前，需要准备相关的维修文档和资料，包括发动机的技术手册、维修手册、零件目录等。
第四章：故障诊断与排除4.1 故障诊断流程本节将提供一套系统的故障诊断流程，帮助维修人员准确地找出故障的原因。
从听、看、闻、摸等多个角度进行故障诊断。
4.2 常见故障与排除方法本节将列举常见的发动机故障和相应的排除方法，如发动机无法启动、动力不足、冒黑烟等。
第五章：维修操作指南5.1 发动机的拆装本节将详细介绍发动机的拆装步骤和注意事项，包括拆卸缸盖、曲轴箱、活塞等部件的方法。
5.2 发动机零件的更换本节将介绍常见发动机零件的更换方法，如活塞环、气门、油封等，包括拆装步骤和注意事项。
5.3 发动机的调试和调整本节将介绍发动机的调试和调整方法，包括喷油器的校正、气门间隙的调整等。
潍柴发动机使用说明
潍柴燃气发动机维护保养说明潍柴燃气发动机维护保养说明潍柴西港新能源发动机有限公司2012.21潍柴燃气发动机维护保养说明目录1发动机维护保养 (1)1.1天然气发动机主要部件说明 (1)1.2系统维护保养要求 (2)1.3电控部件维护保养要求 (4)1.4发动机日常操作要求 (6)2 附录 (8)2.1 Q/WCQTG0017潍柴燃气发动机保养规范 (9)2.2 Q/WCQTG0012《潍柴燃气发动机 REGO稳压器维修规范》 (11)2.3 Q/WCQTG0013《潍柴燃气发动机喷嘴清洗规范》 (15)2.4 Q/WCQTG5.27-2010《潍柴气体发动机机油用油规范》 (23)2.5 Q/WCQTG0007《潍柴燃气发动机火花塞拆装规范》 (25)2.6 《整车 LNG燃气系统使用规范》 (34)2.7 Q/WCQTG0011《潍柴燃气发动机燃气滤清器滤芯更换规范》 (46)2潍柴燃气发动机维护保养说明1 发动机维护保养1.1 天然气发动机主要部件说明部件 功能图示ICM控制各缸点混合 使空气和燃ECU 电控模块， 火时刻 器 气充分混合 综合分析控火花 产生电火 废气调节增压器制发动机运 花，点燃缸控制 行塞增压压力 内可燃气阀滤清 过滤燃气中节气 控制进入各 器 高压 传递高压电 （LN 杂质门 缸可燃气量G ）线 给火花塞稳压 控制进入喷电磁 控制燃气管氧传 测量排气中 器 射阀的燃气阀 路通断感器 氧气含量压力（LNG ）FMV向混合器中 点火产生高压电减压 控制进入喷喷射燃料，射阀的燃气 控制燃料的 线圈器压力（CNG ）喷射量1潍柴燃气发动机维护保养说明1.2 系统维护保养要求潍柴天然气发动机是高性能电控发动机，精细的电控部件多，需要精心的维护保养，才能使发动机动力性经济性得到充分发挥，延长其使用寿命。
潍柴气体发动机日常保养及例行保养周期及相关项目参见Q/WCQTG0017《潍柴燃气发动机保养规范》（见附录）。
潍柴智多星专用诊断软件用户手册V1.0(1)
产品介绍：介绍潍柴智多星服务工具的功能、使用环境等。
维修手册：发动机维修资料的链接，通过该链接可以学习发动机、维修相关诊断报告：该功能正在开发，敬请留意下一版更新快速诊断：该功能正在开发，敬请留意下一版更新系统配置：显示软件版本信息，升级软件及配置适配器。
柴油机控制器：用来引导进入柴油机诊断界面，如下图所示：气体机控制器：用来引导进入天然气发动机诊断界面，如下图所示：在柴油机控制器或气体机控制器中，点击选择需要诊断的发动机控制器图标进入控制器系统信息：该功能用来查看ECU、发动机、整车的系统信息。
点击窗口右下角的“读控制器信息”按钮，即可在控制器信息显示区获得要读取控制器的系统信息。
包括基础数据件号、整车数据件号、整车VIN号、整车数据号、整车车型、备用等，点击返回按钮即可退出该功能。
故障码：用来读取发动机系统当前存在的故障信息、每个故障对应的冻结帧信息冻结帧：单击选中故障码，然后点击窗口下方的“读冻结帧”按钮，即可得到选中故障码所对应的冻结帧，包括冻结帧的名称、值和单位。
如下图：数据流：发动机工作状态信息。
、在条目栏“监控变量选择区”中，选择要监控的变量、点击“开始监控”按钮，在“监控变量数字显示区”即可看到所要监控变量的相关信息，包括数值量的名称、值和单位，状态量的状态。
如下图所示：功能测试：用来测试发动机完成某个功能的能力。
在“功能测试选择区”选择要进行测试的功能项，使发动机满足测试初始条件，点击测试，开始测试。
如下图：参数标定：用来调整整车功能。
1、选择需要调整的整车参数；2、点击“生成ini”按钮，生成ini文件；3、刷写ini文件。
潍柴发动机维修专用工具手册—潍柴WP10发动机结构特点简介
潍柴发动机维修专用工具手册—潍柴W P10发
动机结构特点简介
work Information Technology Company.2020YEAR
潍柴发动机维修专用工具手册—潍柴WP10发动机结构特点简介
潍柴发动机维修专用工具手册—潍柴WP10发动机结构特点简介：潍柴WP10发动机整体结构布置及主要件结构与WD615基本相同。
因为采用了电控共轨燃油系统，所以相关的零部件结构进行了更改。
与WD615柴油机相比较，潍柴WP10发动机结构变化较大的部分包括：
1.1 电控燃油系统
主要组件：
共轨泵、共轨管、压力限制阀、喷油器、电控单元（ECU）、高压油管、低压油管、燃油滤清器、线束
传感器：
曲轴信号传感器、凸轮轴信号传感器—给ECU提供正确的曲轴转角，从而确定正确的喷油时间；
冷却水温传感器、进气压力温度传感器、轨压传感器
控制器：
燃油流量控制器、喷油器控制器
燃油的流向：
燃油箱——粗滤器——ECU——输油泵——精滤器—共轨泵——高压油管——共轨管——高压油管——喷油器
1.2 其余相关组件
飞轮、飞轮壳、气缸体、齿轮室、空压机、油底壳
WP10发动机维修专用工具与WD615发动机维修专用工具相比较，有的工具是通用的，另外一些基础工具的形式基本一致，尺寸略有差别。
潍柴发动机维修专用工具。
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目录
一. 说明 (3)
二．发动机专用维修工具 (4)
1. 连接板定位器（WPT001） (4)
2. 喷油器拆卸器（WPT002） (4)
3. 转换手柄（WPT003） (8)
4. 活塞安装锥套（WPT004） (5)
5. 液压挺柱安装器（WPT005） (5)
6. 前油封安装器（WPT006） (6)
7. 后油封安装器（WPT007） (7)
8. 气缸套拆卸器（WPT008） (7)
9. 气缸套安装器（WPT009） (9)
10. 气门油封安装器（WPT010） (8)
11. 气门弹簧压缩器（WPT011） (9)
12. 涡轮增压机油接口拆装器（WPT012） (10)
13. 铜锤（WPT013） (10)
14. 卡簧钳（WPT014） (11)
一、说明
适当的维修方法和正确的修理程序对所有发动机和操作人员都是安全和可靠的。
维修的程序、技术和所使用的专用工具及零部件是多种多样的，维修人员的技能也是不尽相同的，所以本专用工具说明未能对所有工具提供详细的说明或冲突之处，请参照维修手册进行。
在维修柴油机零配件时须知：本公司柴油机产品，是高性能的柴油机，用户在维修时请按照柴油机零件图册和维修手册的诸项要求进行工作。
用户在维修时购买有关零配件，必须采用主机厂鉴定认可的产品，以确保其性能及可靠性。
警告：
●维修时禁止吸烟。
●为避免严重灼伤，不要触碰任何高温金属表面。
●关闭点火开关，操作规程规定的除外。
●发动机须在通风良好的区域工作。
●避免在发动机工作时拆卸零部件。
●操作时必须戴安全防护眼镜。
二. 发动机专用维修工具
1. 连接板定位器（WPT001），如图1
配套使用工具：无
用途：给连接板做定位。
操作方法：如图2
把连接板定位器（WPT001）插入图中箭头所指处，进行连接板的定位。
图1 连接板定位器图2
2. 喷油器拆卸器（WPT002），如图3
配套使用工具：转换手柄（WPT003）
用途：拆卸喷油器。
操作方法：如图4
把转换手柄（WPT003）的螺纹接头旋入喷油器拆卸器（WPT002）的螺纹孔中，然后把喷油器拆卸器（WPT002）套在喷油器上，手握转换手柄（WPT003）向上提出喷油器。
向
上
1
提
2
3
图3 喷油器拆卸器图4
3. 转换手柄（WPT003），如图17
配套使用工具：可配合喷油器拆卸器（WPT002）使用。
用途：可做为加长手柄和惯性锤使用。
操作方法：如图4，或18
做为加长手柄的操作方法见图4，
做为惯性锤使用，见图18
图17转换手柄（WPT003）图18
4. 活塞安装锥套（WPT004），如图5
配套使用工具：无
用途：固定活塞环，以安装活塞，保护活塞不受损坏。
操作方法：如图6
先把活塞安装锥套（WPT004）套在活塞和活塞环上，将活塞对准气缸后轻轻向下敲击活塞，直至装入。
图5活塞安装锥套
活塞
图6
5. 液压挺柱安装器（WPT005），如图7
配套使用工具：无
用途：拆装液压挺柱。
操作方法：如图7和8
手握压挺柱安装器（WPT005）的手柄，且大拇指向下按液压挺柱安装器（WPT005）的压头（图7中圆圈所指处），然后把液压挺柱安装器（WPT005）的下端插入液压挺柱中（图8中圆圈所指处），松开大拇指，即可开始进行安装。
图7液压挺柱安装器图8
6. 前油封安装器（WPT006），如图9
配套使用工具：无
用途：安装发动机曲轴前油封。
操作方法：如图10
将专用工具-前油封安装器（WPT006）套上油封，然后一起装在曲轴前端（用拧上配套螺栓的方法进行安装），通过拧动前油封安装器（WPT006）自身的螺母，把前油封压入安装到位。
图9前油封安装器
7. 后油封安装器（WPT007），如图11
配套使用工具：无
用途：安装发动机曲轴后油封。
操作方法：如图12
将专用工具-后油封安装器（WPT007）套上油封，然后一起装在曲轴后端（用拧上配套螺栓的方法进行安装），通过拧动后油封安装器（WPT007）自身的螺母，把后油封压入安装到位。
图11后油封安装器
8. 气缸套拆卸器（WPT008），如图13
配套使用工具：无
用途：把缸套拔出汽缸。
操作方法：如图14
取出汽缸两侧的M16*2.0的两根螺杆，换上气缸套拆卸器（WPT008）配套的两根带销孔的光杆，并旋入被取出的两根螺杆的位置。
然后把气缸套拆卸器（WPT008）的支架架在两根带销孔的光杆上，把拔头在另一端套在缸套上，在两根带销孔的光杆上插上销钉。
最后通过拧动气缸套拆卸器（WPT008）上的螺母的方式，拔出缸套。
图13气缸套拆卸器
9. 气缸套安装器（WPT009），如图21
配套使用工具：无
用途：把缸套压入汽缸。
操作方法：如图22
换上气缸套安装器（WPT009）配套的两根带销孔的光杆（同气缸套拆卸器配套的两根光杆），并旋入汽缸侧的两个M16*2.0螺孔中。
然后把气缸套安装器（WPT009）的压头压在缸套上，并把气缸套安装器（WPT009）的主体支架架在两根带销孔的光杆上插上销钉。
最后用手柄摇动液压千斤顶，把缸套压入汽缸。
注意：当液压千斤顶行程不够时，可用手下压液压千斤顶把其行程重新归零，同时把销孔光杆上的销钉下移，这样可以弥补液压千斤顶的行程不够，同时又能继续下压缸套到合理的位置。
图21气缸套安装器
10. 气门油封安装器（WPT010），如图15
配套使用工具：无
用途：安装发动机气门油封。
操作方法：如图16
利用气门油封安装器（WPT010）在气门导管上安装气门油封（此安装工具的导杆为可拆卸式）。
注意：安装不当会引起泄漏，气门油封不能重复使用。
图15气门油封安装器图16
11. 气门弹簧压缩器（WPT011），如图19
配套使用工具：无
用途：压气门弹簧，安装气门锁夹。
操作方法：如图20
把气门弹簧压缩器（WPT011）螺纹连接端旋入图中箭头所指处，然后把气门弹簧压缩器（WPT011）的压头压在气门弹簧上，手握住手柄，并下压，直到手柄杆为水平状态，此时方可安装气门锁夹。
图19气门弹簧压缩器（WPT011）图20
12. 涡轮增压机油接口拆装器（WPT012），如图23
配套使用工具：1/2″棘轮扳手
用途：拆装涡轮增压机油接口的螺栓。
操作方法：如图24
把工具（WPT012）套在涡轮增压机油接口螺栓上，配合使用工具1/2″棘轮扳手，进行拆装。
图23涡轮增压机油接口拆装器图24
13. 铜锤（WPT013），如图25
配套使用工具：无
用途：敲击钣金件和敲击不希望被敲击变形、凹陷、破裂的部件。
操作方法：
握住铜锤（WPT013）的手柄，用锤头敲击希望被敲击的部件或部位。
图25铜锤（WPT013）
14. 卡簧钳（WPT014），如图26
配套使用工具：无
用途：拆装卡簧。
操作方法：如图27
用卡簧钳（WPT014）钳嘴的凹槽钳住卡簧，用力握压卡簧钳（WPT014）手柄，然后即可进行卡簧的拆装。
图26卡簧钳图27
本部分内容意在介绍专用工具的使用，具体装配要求请参阅配套维修手册！。