WD615柴油机维护保养指南及内容课件

1、WD615柴油机维护保养Maintenance for WD615 Diesel Engines车用Vehicle Engines第1页，共45页。第 2页 共 页尊敬的用户： Respected customers: 感谢您选择了潍柴动力系列柴油机。Thank you for using Diesel engine series of WeiChai Power. 潍柴动力友情提示： 为了提高您的运营效率，降低使用成本，请您仔细阅读手册内容，进行正确的使用保养，采用正宗配件、专用油品。 潍柴动力Friendly tips from Wei Chai Power: In order to im

2、prove your operation efficiency and reduce cost, please read the manual carefully for proper use and maintenance. Special fittings and oil should be adopted. Wei Chai Power第2页，共45页。柴油机操作人员，必须认真阅读使用保养说明书，熟悉柴油机结构，严格遵守说明书规定的技术操作和保养规程。Operators of diesel engines must carefully read Operation and Mainten

3、ance Manual, and well understand the structure of diesel engines, strictly comply with the operation and maintenance stipulated in the Operation and Maintenance manual.在本手册提出的保养要求基础上，请根据使用工况按柴油机说明书要求定期进行柴油机例行检查，并更换柴油机油。Based on the maintenance requirements stipulated in the manual, please periodical

4、ly inspect diesel engines and replace oil in accordance with work condition.第3页，共45页。 合理的保养可以有效提高柴油机的使用寿命,降低故障率，减小使用成本。 Proper maintenance can effectively prolong service life of diesel engines, decrease trouble rate and reduce cost.保养内容： Maintenance contents : 更换柴油滤芯、机油滤芯； Replace fuel filter eleme

5、nt and oil filter element; 清理检查空气滤芯，每清理5次后必须更换。 Clean and check air filter element. Replace it every 5 times of cleaning. 保养周期：Maintenance interval: 可参考如下要求按时到潍柴动力授权服务站保养。 Maintenance should be done in time at service stations authorized by Wei Chai Power according to the following requirements:第4页，

6、共45页。潍柴动力系列柴油机推荐使用CF-4机油。允许高品质机油替代低品质机油常用机油规格如下所示：Recommend CF-4 oil to be used in Wei Chai Power diesel engine series. High quality oil is allowed to replace low quality oil. The specification of common oil is as follows: 粘 度级 别Viscosity grade0W-305W-3010W-3015W-4020W-50适 用温 度applied temperature-40

7、30-3035-2535-2040-1550第5页，共45页。 请根据环境温度选择使用正确牌号的机油，否则易造成柴油机故障。 Please use right oil according to ambient temperature, otherwise, engine trouble can occur.第6页，共45页。1、日常维护 Daily Maintenance2、定期保养 Periodic Maintenance3、维护保养周期 Maintenance Interval 4、维护保养内容 Maintenance Contents5、机油和机油滤清器的更换 Replacement o

8、f Oil and Oil Filter6、更换燃油滤清器 Replace Fuel Filter7、检查空气滤清器 Check Air Filter Element8、检查调整气门间隙 Check and Adjust Valve Clearance 9、检查调整供油提前角 Check and Adjust Fuel Supply Advance Angle目 录Contents第7页，共45页。1、日常维护Daily Maintenance检查:Inspection:机油液面是否在油尺的刻线范围；Check the oil level；冷却液液面；Check the coolant lev

9、el；燃油液面；Check the fuel level；风扇有无破损；Check whether the fan is damaged；传动三角皮带有无裂纹、擦伤；Check whether the V-belt is cracked or scratched；第 8页 共 页第8页，共45页。1、日常维护Daily Maintenance附件紧固情况是否良好；Check whether the accessories are fixed well;水油有无泄漏 ;Check whether the water or oil is leaking;充电指示灯是否正常 ;Check wheth

10、er the charging indicator light is in order;水泵油腔内润滑脂是否充足 ;Inspect sufficient grease;机油压力，水温是否正常 ;Inspect oil pressure and water temperature are normal condition；柴油机排气温度、声音、振动是否正常 ;Inspect that exhaust temperature, sound and vibration are normal condition；转速是否平稳。Inspect rotary speed is stable.第 9页 共

11、页第9页，共45页。启动前查看冷却液液面,检查柴油机冷却系统有无泄漏。 Before starting the engine should check coolant level, check whether the cooling system is leaking or not.运行中注意观察柴油机水温是否在合适的范围内。 Check whether water temperature is at the required range or not when the engine is running. 1、日常维护Daily Maintenance当水温过高时，请检查：When wate

12、r temperature is too high, please check: 水泵皮带张紧度the tension of water pump belt 风扇皮带张紧度 the tension of fan belt 节温器thermostat驾驶室水温表示意图diagram of water temperature in cab 海拔3000米以下正常水温8095The normal water temp. under the sea-level of 3000 meters is 8095第10页，共45页。2、定期保养Periodic Maintenance定期保养参照下表进行，若柴

13、油机在多尘环境或在频繁停车情况下工作，须根据情况相应缩短保养周期。Regular maintenance should be done as per the following table. If the operating condition is heavy dust content or the engine running on starting-stopping frequently, the regular maintenance period should be shortened accordingly第 11页 共 页第11页，共45页。3、维护保养周期Maintenance

14、 Interval(WG)(WG)(WG)使用条件恶劣(气候严寒或酷热,含尘量高,短距离运输,在工地使用以及公共汽车,市政工程车,扫雪车,消防车)或汽车年行驶里程不足2104km 或年工作时间不足600hUnder tough operating condition (e.g. cold or hot weather, high dust content, short-distance transportation, service in construction site and bus, municipal engineeringvehicle, snow sweeper, fire br

15、idge vehicle), annual running mileage of the vehicle less than 2104km or annual operated time less than 600h.年行驶里程不足6104km,短中距离运输（用于送货）Annual running mileage of the vehicle less than 6104km,for short- or medium-distancetransportation (for goods).年行驶里程超过6104km的远距离运输汽车Annual running mileage of thevehi

16、cle more than 6104km for long distance transportation.第 12页 共 页第12页，共45页。表 2-2第一次检查,例行检查和 保养周Table 2-2 The first inspection, routine inspection and maintenance interval 使用条 件 Operating项目 Condition Item WG1年行使里程不到2x104kmAnnual running mileage 2104 kmWG年行使里程不到6x104kmAnnual running mileage 6104 kmWG年行使

17、里程超过6x104kmAnnual running mileage 6104 km第1次检查 The first inspection行使10001500km时或行使3050h Running 1,0001,500km or3050h行使15002000km时 Running 1,5002,000km 行使15002000km时 Running 1,5002,000km 例行检查Periodical inspection每隔5000km或每隔150h Every 5,000km or 150h每隔10000km Every10,000km 每隔15000km Every15,000km 1级保

18、养Level 1 maintenance每隔10000km或每隔300h Every 10,000km or 300h每隔20000km Every20,000km 每隔30000km Every30,000km 2级保养Level 2 maintenance每隔20000km或每隔600h Every 20,000km or 600h每隔40000km Every40,000km 每隔60000km Every60,000km 3级保养Level 3 maintenance每隔40000km或每隔1200h Every 40,000km or 1200h每隔80000km Every80,0

19、00km 每隔120000km Every120,000km 4级保养Level 4 maintenance每隔80000km或每隔2400h Every80,000km or 2400h每隔160000km Every16,000km 每隔240000km Every240,000km 第 13页 共 页第13页，共45页。表2-3 汽车保养制度的机油换油期Table 2-3 Oil Replacement Period in Nehicle Maintenance System 使用条 件 Operating项目 Condition Item (WG)(WG)(WG)年行使里程不2x104

20、kmAnnual running mileage2104 km年行使里程不6x104kmAnnual running mileage 6104 km第1次检查The first inspection行使10001500km时Running 10001500km行使15002000km时Running 15002000km行使15002000km时Running 15002000km 例行检查Periodical inspection每隔5000kmEvery 5000km每隔1x104kmEvery 1104 km每隔1.5x104kmEvery 1.5104 km 1级保养Level 1 m

21、aintenance每隔1x104km每隔300hEvery 1104 km or300h每隔2x104kmEvery 2104 km每隔3x104kmEvery 3104 km 2级保养Level 2 maintenance每隔2x104km每隔600hEvery 2104 km or600h每隔4x104kmEvery 4104 km每隔6x104kmEvery 6104 km 3级保养Level 3 maintenance每隔4x104km每1200hEvery 4104 km or1,200h每隔8x104kmEvery 8104 km每隔12x104kmEvery 12104 km

22、4级保养Level 4 maintenance每隔8x104km每2400hEvery 8104 km or2,400h每隔16x104kmEvery 16104 km每隔24x104kmEvery 24104 km第 14页 共 页第14页，共45页。保养项目 Maintenance Items保养项目Items更换Replacement调 整Adjustment检查Inspection3级保养WD 3机油Oil机油滤清器Oil filter燃油滤清器Fuel filter冷却液Coolant空气滤清器Air filter气门间隙Valve clearance空气滤清器Air filter进

23、气系统Air intake system紧固管路管夹Tighten pipe clamps紧固三角皮带Tighten V-belts在试验台上检查调整喷油泵Inspect and adjust theInjection fuel pump on test bench第 15页 共 页第15页，共45页。保养项目 Maintenance Items保养项目Items更换Replacement调 整Adjustment检查Inspection4级保养WD 4机油Oil机油滤清器Oil filter燃油滤清器Fuel filter冷却液Coolant空气滤清器Air filter气门间隙Valve

24、clearance空气滤清器Air filter进气系统Air intake system紧固管路管夹Tighten pipe clamps紧固三角皮带Tighten V-belt检查增压器轴承间隙Check the bearingclearance of turbocharger在试验台上检查调整喷油泵Inspect and adjust theInjection fuel pump on test bench第 16页 共 页第16页，共45页。4、柴油机保养内容Maintenance Contents1.日常保养 Daily Maintenance预防性保养从每天做起，了解柴油机工作状况

25、。 Preventive maintenance should be done everyday in order to understand the engines condition.起动柴油机以前需检查机油液面、冷却液液面和柴油液面。 Before starting the engine should check the oil level 、 coolant level and the fuel level.检查机油油面高度Inspect the oil level height当油面低于油尺的下刻线或高于油尺的上刻线时，决不允许开动柴油机。When the oil level is

26、lower than thelower limit or higher than the upperlimit，it is not allowed to start the engine第 17页 共 页第17页，共45页。4、柴油机保养内容Maintenance Contents在 柴 油 机 停 车 后 检 查 油 面，至少等 5 分钟后进行，使机油有充分时间流回油底壳。After the engine stopped， inspectthe oil level at least 5 minutes laterin order to ensure the oil can flowback

27、to the oil sump油尺低位至高位的油量差为3 升。The oil volume tolerance betweenthe lower limit and the upper limit is 3 liters第 18页 共 页第18页，共45页。4、柴油机保养内容Maintenance Contents检查冷却液液面Inspect the coolant level玻璃视孔观察冷却液面，冷却液不够时，可打开加水口盖加入冷却液。Inspect the coolant level through thevitreous view hole，if the coolant isnot su

28、fficient，open the inlet coverand fill into the coolant.注意：打开加水口盖时，必须先按下排气按钮，以免发动机热状态时热冷却液会伤人。Note: When opening the inletcover，must press down theexhaust button firstly to preventhot coolant from injuring people第 19页 共 页第19页，共45页。4、柴油机保养内容Maintenance Contents检查燃油液面Inspect the fuel level检查风扇 Inspect

29、the fan 检查塑料风扇是否变形，铁风扇铆钉是否松动，叶片是否弯曲，确保风扇工作可靠。Check whether the plastic fan is distorted扭曲. For steel fan，check whether the rivet loosened and the vane is curved弯曲 to ensure reliable running第 20页 共 页第20页，共45页。4、柴油机保养内容Maintenance Contents检查三角皮带Inspect the V-belts用肉眼检查三角皮带，有无裂纹或擦伤，必要时应更换。Inspect the V

30、-belts with your eyes to find if there is any crack or scratch on the V-beltsReplace them if necessary第 21页 共 页第21页，共45页。4、柴油机保养内容Maintenance Contents从喷油泵的输油泵小滤杯排出水和沉淀物。 Drain off the water and deposit from the small filtercup fitted on the fuel delivery pump.拧开输油泵小滤杯底座螺钉，拿下小滤杯，将水和沉淀物排除 后重新装好，拧紧。 Un

31、screw the bottom bolt of the small filter cup，dismount it anddrain off the water and deposit，then re-install the cup again第 22页 共 页第22页，共45页。5、机油和机油滤清器的更换Replacement of oil and oil filter2. 各级保养的保养内容 Maintenance items of various maintenances机油和机油滤清器的更换Replacement of the oil and oil filter注意：正常使用的柴油机

32、更换机油的周期无论如何不可超过250h(1万公里)。 Note: The replacement intervalof oil under proper using condition cannot beyond 250h(10,000Kilometers) 第 23页 共 页第23页，共45页。5、机油和机油滤清器的更换Replacement of oil and oil filter32mm 开口扳手 Tool:32mm open-ended wrench 拆下放油螺塞，准备收集 20L机油。 Remove the whorl plug，prepare a container to col

33、lect 20L of oil 注意：应在机油是热的时候放油, 热机油会伤人 Note：The oil should be drained off when it is hot Hot oil can injure people.第 24页 共 页第24页，共45页。5、机油和机油滤清器的更换Replacement of oil and oil filter滤清器专用扳手Tool: The special wrench for filter清洁滤清器头部四周，拆下滤清器。Clean the end surrounding of the filter，and remove it装上新的机油滤清器

34、 Install the new oil filter注 意： 安 装 机 油滤清器 时 ,密封圈要校正 - 且要在密封圈上涂上滑油。Note：Adjust the seal ringandsmear some lubricating oil on itwhile fitting the oil filter第 25页 共 页第25页，共45页。5、机油和机油滤清器的更换Replacement of the oil and oil filter32mm 开口扳手 Tool:32mm open-endedwrench 检查和清洁放油螺塞螺纹及 密封表面，并装上放油螺塞。 Check and cl

35、ean the screw threadand seal ring，and then install the whorl plug . 将清洁的机油注入柴油机到 油尺的上刻度线，油底壳容量为20L。 Fill the clean oil up to the upperlimit，the capacity of the oil sump is 20L第 26页 共 页第26页，共45页。5、机油和机油滤清器的更换Replacement of the oil and oil filter发动机怠速运转，检查滤清器和放油螺塞处是否漏油。Run the engine at idling speed a

36、ndcheck the filter to find whether it leaks or not停车后约 5min 让机油自上部零件流人油底壳，再检查油面高度，必要时补充机油至油尺的上刻线。Stop the engine and make the oil runinto the sump from the upper parts5 minutes later，then check the oillevel，fill oil up to the upper limit ifnecessary第 27页 共 页第27页，共45页。6、更换燃油滤清器Replace fuel filter更换燃油

37、滤清器Replace the fuel filter13mm 开口扳手Tool：13mm open-ended wrench清 洁 燃 油 滤 清 器 头 部 周 围。松开上部螺钉，拆下燃油滤清器。Clean the end surrounding of thefuel filter，unloosen the upper boltand disassemble the fuel filter.装上新的燃油粗滤芯和精滤芯。 Install the new fuel pre-filterelement and filter element第 28页 共 页第28页，共45页。6、更换燃油滤清器Re

38、place fuel filter将更换的燃油滤清器安装在滤清器支架上,并拧紧螺钉。Install the replaced fuel filter on thebracket and tighten the bolt. 排出低压油路和燃油滤清器中的空气。 Drain off the air from the fueldelivery pipe and fuel filter 拧开喷油泵进油口放油螺钉。 Open the fuel draining bolt of theinlet of injection pump.第 29页 共 页第29页，共45页。6、更换燃油滤清器Replace fu

39、el filter 按动输油泵柱塞，直到从放油螺钉处流出的柴油没有空气为止 , 然后拧紧放油螺钉。 Press the fuel delivery pump plugtill the fuel drained off from thedraining bolt outlet does not containair，then tighten the bolt 检查进气系统 Check the air intake system 检查进气胶管是否老化有裂缝、环箍是否松动， 必要时紧固或更换零件，确保进气系统密封性。 Check whether the air intake rubberpipes

40、are aging or cracked，the steel wire hoop is looseningIf it is necessary, tighten or replace the parts to ensure good sealingperformance第 30页 共 页第30页，共45页。7、检查空气滤清器滤芯Check air filter element检查空气滤清器滤芯Check the air filter element柴油机最大允许进气阻力为7kPa，柴油机必须在标定转速和全负荷运转时检查最大进气阻力，当进气阻力达到最大允许极限时，应按制造厂的规定清洁或更换滤芯。

41、The maxi. air intake resistance of the engine is 7kpa. Air intake resistance must be checked when diesel engines run at rated speed and in full load. When the resistance reaches the max. limit permitted, should clean or replace air filter element as per relevant requirements from suppliers. 第 31页 共

42、页第31页，共45页。7、检查空气滤清器滤芯Check air filter element注意：决不允许在没有空滤器时使用发动机 , 否则灰尘和杂质进入柴油机会导致发动机早期磨损。Note： lt is not allowed to use the engine without air filter，otherwise the dust and impurity will cause early wearing of the engine.从空滤器中拆下空滤芯，轻拍端面使灰尘落下，也可用压缩空气反吹 ( 由内向外吹 )。Remove the filter core from the airf

43、ilter element and beatthe side ofthe element lightly to make dust falldown, or blow the element backward(blow back from inside to outside)by compressed air第 32页 共 页第32页，共45页。7、检查空气滤清器滤芯Check the air filter element注意：Note：不得吹破滤纸Dont blow off the air filtering Paper不得用水和油清洗滤纸Dont clean the air filteri

44、ng paper by water and oil不得用力拍打或敲打滤芯Dont beat the core forcibly第 33页 共 页第33页，共45页。8、检查调整气门间隙 Check and adjust valve clearance检查调整气门间隙 Check and adjust the valve clearance 13mm 套筒扳手 Tool：1 3mm sleeve wrench 拆下 6 个气缸盖罩Disassemble 6 cylinder head covers32mm 盘车扳手 Tool: 32mm wrench for turning the cranks

45、haft 用盘车扳手慢慢转动柴油机 使飞轮壳上刻线对准飞轮上的 OT刻度线，此时使第一缸活塞处于压缩行程的上止点位置 ( 一缸进排气阀处于关闭状态 ) Turn the flywheel until its OTscale and the mark on its housingare aligned, push the piston to theposition of TDC of compressionstroke of 1st cylinder (the intake andexhaust valve of 1st cylinder are closed)第 34页 共 页第34页，共45

46、页。8、检查调整间隙 Check and adjust the valve clearance塞尺Tool：Clearance gauge进气门间隙 0.30mmThe clearance of intake valve is 0.30mm排气门间隙 0.40mmThe clearance of exhaust valve is 0.40mmWEVB 系统间隙 0.25mmThe Clearance of WEVB system is 0.25mm注意：检测气门间隙时，柴油机应为冷态一一低于 60，塞尺在气门杆顶和摇臂间滑动时,有阻滞发粘感觉时，所测间隙值为准确值。Note: When che

47、ck the clearance of valve，the engine should be at the cool conditionits temperature is less than 60.When the clearance guage glides between the top of valve rod and rocker arm and can be felt retarded and sticky，themeasuring result is proper第 35页 共 页第35页，共45页。8、检查调整气门间隙 Check and adjust valve cleara

48、nce采用 WEVB 系统后，排气门间隙的调整方法 ( 零件序号参见图 1)： After WEVB system is used, the adjustment method of exhaust valve clearance is as follows (see Fig. 2 for part serial numbers)1.气门间隙调整螺母 2.调节螺栓总成 3.排气门摇臂总成 4.钢球 5.气门摇臂活塞 6.摇臂活塞弹簧 7.滚针 8.球阀弹簧 9.气门摇臂座总成 10.气门间隙调整螺钉 11.六角头螺栓 12.支撑臂1. Valve clearance adjusting nut

49、 2. Regulating bolt assembly 3. Exhaust valve rocker arm assembly 4. Steel ball 5. Valve rocker arm piston 6. Rocker arm piston spring 7. Needle 8. Ball valve spring 9. Valve rocker arm seat assembly 10. Valve clearance adjusting screw 11. Hexagonal bolt 12. Support arm第 36页 共 页第36页，共45页。8、检查调整气门间隙

50、Check and adjust valve clearance1、所要调整的气缸的活塞位于压缩行程上止点； 1. The cylinder piston to be adjusted is located on the top dead center of the compression travel. 2、如图2所示,在序号2调节螺栓总成松开,不压紧排气门摇臂封油平面的情况下先通过调整推杆端序号10气门间隙调整螺钉,将总气门间隙调整为 0.4mm,将防松螺母拧紧。 2. As shown in Fig. 2, loosen No. 2 adjusting bolt assembly. In

51、 case that the oil seal plane of exhaust valve rocker arm is not pressed, first by using No. 10 valve clearance adjusting screw at the push rod end, adjust the total valve clearance to 0.4mm. Tighten check nut. 图2 冷态排气门总气门间隙0.4mm 图3冷态排气门端气门间隙0.25mm Fig. 2 Total Valve Clearance of Cold-State Fig. 3 E

52、nd Valve Clearance of Cold-State Exhaust Valve 0.4mm Exhaust Valve 0.25mm第 37页 共 页第37页，共45页。8、检查调整气门间隙 Check and adjust valve clearance3、然后如图3所示,在序号气门摇臂活塞与排气门杆端或气门杆帽之间再放入0.25mm 的塞规，通过调整序号2调节螺栓总成,将气门端间隙调整为 0.25mm,将防松螺母拧紧。 3. Then as shown in Fig. 3, insert the clearance gauge between No. 5 valve rock

53、er arm piston and the exhaust valve rod end or valve rod cap. By turning No.2 regulating bolt, adjust the valve clearance to 0.25mm. Tighten check nut.注意：调整过程中应转动序号2调节螺栓总成直到将塞规夹住，从而保证使序号 5气门摇臂活塞压到底，与排气门摇臂中的活塞安装孔底部平面之间无间隙。 Caution: During adjustment, turn No. 2 regulating bolt until clearance gauge i

54、s clamped so that No. 5 valve rocker arm piston is pressed to its bottom. There is not clearance between No.5 valve rocker arm piston and the piston installation hole bottom plane in exhaust valve rocker arm.第 38页 共 页第38页，共45页。8、检查调整气门间隙 Check and adjust valve clearance6# 螺丝刀、14mm 梅花扳手 Tools：6#screw

55、driver and14mm double offset ring wrench 第一缸活塞位于压缩行程上止点位置 。 The piston of 1 cylinder is at TDC of the compression stroke 如步骤A所示检查或调整气门间隙 (I 表示进气，E 表示排气 )。 Check and adjust the valve clearance as step A(I-air intake Valve E-air Exhaust valve) 用塞尺调整好间隙后拧紧摇臂锁紧螺母,并复查气门间隙,直到到要求为止。 Adjust the clearance by

56、 guage and tighten the fixing nut of rocker arm，re-check theclearance till it meets the requirement 步骤 A Step A第 39页 共 页第39页，共45页。8、检查调整气门间隙 Check and adjust valve clearance用 盘 车 扳 手 再 转 动 曲 轴360；也可以在减震器上做标记后转动 360。Turn the crankshaft 360 bythe spanner；it can also be turned360 after marking on the v

57、ibration damper.按步骤 B 所示调整气门间隙 Adjust the valve clearance as step B同样松动摇臂锁紧螺母，用塞尺调整 好后重新拧紧摇臂锁紧螺母。Loosen the fixing nut of rocker arm，adjust the c|earance by guage 步骤 B then tighten the nut again step B.第 40页 共 页第40页，共45页。8、检查调整气门间隙 Check and adjust valve clearance13mm 套筒扳手 Tool:13mm sleeve wrench 安装气缸盖罩垫片和气缸盖罩。 Install the gasket and cylinder head cover 螺栓拧紧力矩 23Nm( 推荐数值 )。 The tightening torque of bolt is 23Nm(recommended)视频 19:42 D:work为整理发动机维修光碟WD615使用保养MUSIC03.DAT第 41页 共 页第41页，共45页。9、供油提前角的调整 Adjustment of fuel supply advance angle供油提前角的调整