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WD615、WD618、WD12柴油机故障案例介绍


WD615、WD618、WD12柴油机 故障案例介绍
Introduction of fault case for WD615、 WD618、WD12 Diesel Engine

潍柴动力股份有限公司 Weichai Power Co Co, Ltd

目录
Content
? ? ? ? ? ? ? ?

? 1.柴油机起动困难 Diesel engine starts hard 2 起动不久就停车 Stop soon after staring 2. 3.功率不足 4.燃油消耗过大 5.排气冒黑烟 Insufficient output Fuel consumption is too high Black smoke exhaust

6.增压器进、排气口vent,进、排气管附集机油 Oil is gathered in inlet and exhaust vents of turbocharger and inlet and exhaust pipe 7.机油压力过低 8.冷却水温过高 9.柴油机油水混合 Lub-oil pressure is too low Cooling g water temperature p is too high g The oil mixed with the water

第 2页 共 页

故障诊断与排除原则
Failure diagnosis and remedy principle
? 柴油机出现故障时,采用先易后难逐一排除法 ? 在未弄清楚问题前,不要轻易更换任何配件

? When a diesel engine has faults, we apply a method that the easier part first and remove faults one by one. ? Do not replace any part haphazard until find root of the fault.

第 3页 共 页

1 柴油机起动困难 1.
1 、检查档位是否处于空档位置、空档开关是 否正常;检查副熄火开关(车下熄火开关) 是否正常 检查熄火电磁阀是否损坏 若 是否正常,检查熄火电磁阀是否损坏,若 仍无法起动转下一步。 2、检查整车起动线路及电瓶是否正常,若仍 无法起动转下一步。 3、判断起动机工作是否正常,如问题仍未解 决,应进一步检查柴油机转动是否灵活, 配气正时是否正确等。若仍无法起动转下 步。 一步。 4、检查低压油路是否有气、漏气或堵塞现象。 若仍无法起动转下一步 5、检查是否高原高寒引起 6、联系特约维修站维修人员检测:

空档开关

车下停车开关 高原、高寒

第 4页 共 页

1 1.

Diesel engine starts hard

1 、 Inspect whether gear shift is at neutral position and neutral position switch is normal; inspect whether shut-down switch under vehicle is normal and flameout electromagnetism valve is damaged. Come into next step if it still can’t be started. 2 、 Inspect whether vehicle starting line and battery are normal. Come into next step if it still can’t be started. 3 、 Judge whether engine works normally. Inspect whether the rotation of engine is flexible and Initial angles of valve gear are correct if the fault still does not be solved. Come into next step if it still can’t be started. 4 Inspect p whether there is air in low p pressure fuel passage. Come into next step if it still can’t be started. 5 、 Inspect whether the fault is caused by plateau and low temperature 6、 Contact professional maintenance personnel from professional maintenance station to check for you.

Neutral position switch

Shut-down switch under vehicle

高原、高寒

第 5页 共 页

1.柴油机起动困难。
案例一、柴油机无法起动案例描述 1、起动线路、起动机、电瓶正常,用起动机多次带动柴油机均无法起动, 因此排除起动系统故障 2、进一步检查低压及高压部分油路,并排除油路内空气,可以顺利起动;但熄火5分钟 后,再次出现起动困难现象,检查发现油路内仍有空气,因此确定低压油路存在进空 气现象。 3、经仔细对低压油路部件逐一检查,发现燃油粗滤器进油口螺纹处有损伤,空气进入油 路 从而导致柴油机无法正常起动 路,从而导致柴油机无法正常起动。

案例分析
装配不当或频繁拆装导致燃油低压油路密封不严

案例处理
更换燃油粗滤器或更换低压低压油路部件至密封性良好。

第 6页 共 页

1. Diesel engine starts hard
1、Case description about Diesel Engine cannot be started 1、Starting line, starter and battery are normal, but Diesel Engine cannot be started by starter for several times, so eliminate starting system failure. 2、Check low and high pressure fuel passage and exhaust air and engine can start; but 5 minutes of flameout later, later engine starts hard again again, if there is still air in fuel passage passage, it may be judged that there is air in low pressure fuel passage. 3、After checking low pressure fuel passage carefully, find that thread of fuel inlet of coarse filter is damaged and air enters into Fuel passage, which causes Diesel Engine cannot start normally.
case analysis

Improper assembly of frequent dismantlement and assembly causes that sealing of low pressure fuel passage is not good.
remedy

Replace coarse fuel filter or parts of low pressure fuel passage till sealing is good

第 7页 共 页

1、柴油机起动困难 Diesel Engine starts hard
粗滤的进油口螺纹有损伤,且进 油口有细微裂纹
Thread of fuel inlet of coarse filter is damaged and its fuel inlet is cracked

er 除除水放心滤 water filte

第 8页 共 页

1.柴油机起动困难。 柴油机起动困难
1.3、柴油机无法起动案例描述

1、起动机正常运转,柴油机无法起动。 2、检查低压油路发现油箱结蜡,造成燃油失去流动性,堵塞油路和滤芯。 3、询问客户知在北京提车时加注-10#柴油,回到辽宁停车后次日无法起动, 因当时辽宁比北京地区气温更低,辽宁地区当时需加注-35#柴油。 案例分析 未根据不同环境温度选择不同标号的柴油,柴油结蜡导致进油管堵塞。 跨温差较大区域运行车辆应根据实际情况及时更换符合气温要求的柴油 车辆 实 换符

案例处理 疏通油路,更换-35#柴油

第 9页 共 页

1.

Diesel Engine g starts hard

1.3、 Case description about Diesel Engine cannot be started 1、Starter operates normally, but engine can not be started.
2、 We find there is wax in low pressure fuel passage after checking, which causes fuel loses fluidity and blocks fuel passage and filter element. 3、After inquiring customer we know that he (she) filled up -10 10#fuel when he (she) bought a car, and the 2nd day it could not be started after he (she) got to Liaoning and parked the car. That is because the temperature in Liaoning is lower than Beijing, and the vehicle of Liaoning area need to fill up -35#fuel. case analysis
Select diesel fuel of different grade in accordance with different temperature, but customer didn’t do so, which causes fuel curdle and block intake fuel pipe. When a vehicle is operating in several different temperature areas, replace fuel in time which can reach temperature requirement in accordance with actual temperature condition in local area.

remedy dredge fuel passage,replace -35#fuel

第 10页 共 页

1 柴油机起动困难 1.
点火 钥匙 开关
igniti on key switc h

Diesel Engine starts hard

起动机
starter

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1.柴油机起动困难
附表:柴油机不能起动故障检查与排除 fault cause and remedy
故障原因 cause 排除方法 remedy d 检查清除污物,检查燃油的清洁度 Clear away the dirt and check if the fuel is clean 排除空气,检查接头密封,修复之 Drain off the air,check the sealing of the connector and repair it 检查柱塞、出油阀修理或更换损坏件 检查柱塞 出油阀修理或更换损坏件 Check plunger,fuel outlet valve and repair or replace the broken parts 检查喷油器雾化情况,修复之 Check the atomization of injector,and p it repair

1.输油泵进油滤网或软管等油路堵塞 Fuel intake filter screen of supply pump or hose clogged 2.燃油系统内有空气 air entered into the fuel system 3.喷油泵有故障 3 Injection pump damaged 4.喷油器有故障 Injector damaged

1 柴油机起动困难 1.
附表:柴油机不能起动故障检查与排除 fault cause and remedy
5.配气或供油初始角不对 5 检查并调整之 Initial angles of valve gear or fuel delivery is wrong Check and adjust if 6.高压油管损坏及漏油 High pressure line damaged or leaked 7.气缸压缩压力不足 Insufficient pressure in cylinder 修复与更换 Repair or replace 检查气门密封性,缸垫的密封性,活塞环的磨 损,修理或更换 Check the sealing of the valve and cylinder gasket and the wear of the piston ring. Repair or 增加起动辅助设备措施 With the addition of start-assist device

8.气温过低 The temperature is too low

2 起动不久就停车. Stop soon after staring 2.
1、检查低压油路是否有气、漏气或堵塞现象。 若仍无法起动转下 步 若仍无法起动转下一步 2、检查输油泵是否工作,若仍无法起动转下一步. 3、检查怠速调速过低,若仍无法起动转下一步 4 联系特约维修站维修人员检测 4、联系特约维修站维修人员检测
1. Check whether air entered or leaked or choked in low p press fuel p passage. g Come into next step p if it still can not be started. Check whether gear pump is working. Come into next step if it still can not be started. Check whether idling speed and adjusting speed are too low. Come into next step if it still can not be started. Contact professional maintenance personnel from professional maintenance station to check for you.

2. 3 3.

4.

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2 起动不久就停车. Stop soon after starting 2.
2、1起动不久就停车案例描述

1、柴油机能启动但是启动后冒黑烟,检查空气滤芯及气路畅通、增压器正常。 2、检查低压油路及油品,发现柴油里有水。拆检喷油器发现,油头有水锈 可判定为由于柴油中有水导致六只喷油器针阀生锈卡死。 可判定为由于柴油中有水导致六只喷油器针阀生锈卡死 案例分析

油品不合格,油中有水,且未加装除水放心滤, 导致喷油器针阀锈蚀卡死,燃油雾化不良 致 案例处理

更换合格柴油,更换喷油器,加装除水放心滤

除水放心滤
第 15页 共 页

2 起动不久就停车. Stop soon after starting 2.
2、1 Case description about stop soon after starting 1、Diesel Di l engine i can b be started, t t d b but t after ft starting t ti it exhausted h t d bl black k smoke. k I Inspect t Air filter element and air passage are circulated and turbocharger is normal. 2、Find fuel is mixed in water after inspecting low pressure fuel passage and fuel. p injector, j , and then find head of injector j has water rust. Dismantle and inspect We can judge that fuel is mixed in fuel ,which causes 6 needle valves of injector are rusted and seized.
case analysis Fuel is disqualification, there is water in fuel and water filter is not installed, installed which causes needle valve of injector rust and atomization of fuel is not good remedy

Replace quality fuel and injector, add water filter

water t filter filt
第 16页 共 页

2 起动不久就停车. Stop soon after starting 2.

喷油器已经 生锈
Injectors have rusted

左侧为原车上用油
left side represents fuel used in the car

右侧为正常油。
Right side is normal fuel

第 17页 共 页

2.起动不久就停车. Stop p soon after staring g
附表:起动不久就停车故障检查与排除

故障原因

cause

排除方法

remedy d

1.燃油滤清器堵塞 Fuel filter clogged 2.燃油系统内有空气 air entered into the fuel system

拆卸滤清器体,清除内部污物及水份,必要时更换 Dismantle and clean away dirt and water,replace the filter element if necessary 检查油管及接头的密封性,放气螺钉是否拧紧,排除残留的空气. Check fuel pipe and sealing of the connector,tighten air venting bolt, and drain off the air 检查输油泵活塞 阀们,清理及修复. Check piston and valve of supply pump,clean and repair 清洗滤清器,更换燃油 Clean fuel filter and renew fuel 重新调整 Readjust j it

3.输油泵不不工作 Supply pump doesn’t work 4.燃油质量差,含水过多 Poor quality of fuel 5.怠速调速过低 g speed p is too low Idling

3.功率不足 Insufficient 3 su c e t output
1:检查低压油路与油质是否正常,若正常转下一步。 2:检查空气滤芯、进气管路、增压器工作是否正常,若正常转下一步。 3:检查气门间隙是否正常,若正常转下一步 4:检查排气背压过高,若正常转下一步 5:联系特约维修站维修人员检测 1. 2 2. 3. 4 4. 5. Check whether low pressure fuel passage and quality of fuel are normal. Come into next step if normal. Ch k whether Check h th air i filt filter element, l t air i i inlet l t pipe i and dt turbocharger b h are normal. l C Come i into t next step if normal. Check whether valve clearance is normal. Come into next step if normal. Check whether air exhaust pressure is too high high. Come into next step if normal normal. Contact professional maintenance personnel from professional maintenance station to check for you.

第 19页 共 页

3.功率不足 Insufficient output
3.1、柴油机动力不足案例描述
1、柴油机动力不足 2、检查油路及油品也都正常。 3、检查空气滤芯及进气管路发现中冷器下端裂开了大约15cm的口子 案例分析

进气管路漏气
案例处理

更换中冷器

第 20页 共 页

3.功率不足 Insufficient output
3.1、Case description about Insufficient output 1、Insufficient output. 2、Inspect fuel passage and fuel are normal. 3、Inspect air filter element and air inlet pipe, and then find there is an opening i of f 15cm 15 under d i intercooler. t l
Case analysis

air inlet pipe leaks air
remedy

Replace intercooler

第 21页 共 页

3. 功率不足
中冷器开裂
intercooler is cracked

Insufficient output

第 22页 共 页

3.功率不足 Insufficient output p
3.2、柴油机动力不足案例描述
1、柴油机在大负载使用时动力不足,没有明显烟大现象 . 2、检查空滤、增压器、供油提前角等均无故障 3、检查低压油路,各管路无漏气漏油现象,当检查柴滤器时发现柴滤和油泵过油螺钉滤网 很脏堵塞 油路 很脏堵塞,油路不通畅 畅,造成高压油泵泵不上油 高 油 油.引起功率不足 起功率 案例分析 柴滤芯和油泵 过油螺钉滤网堵塞 螺 案例处理 加装除水放心滤 更换柴油滤芯清洗 油泵过油螺钉滤网
滤芯堵 塞

滤芯 堵塞

第 23页 共 页

3.功率不足

Insufficient output p

3.2、Case description about Insufficient output
1、There is Insufficient output when engine is in large load, but there is no big smoke. 2、Inspect air filter, turbocharger and initial angle of fuel supply are normal. 3、Inspect whether low pressure fuel passage and every pipe are leaked. When check fuel filter, we find that fuel filter and fuel-passed p screw filter net of fuel p pump p are dirty y and blocked and that fuel passage isn’t circulated, which causes high pressure fuel pump can’t supply fuel and output is insufficient. Case analysis

Block fuel filter element and fuel-passed screw filter net of fuel pump p p

remedy
block filter element

block filter element

Add water filter, replace fuel filter element and fuel-passed screw filter net of fuel pump

第 24页 共 页

3.功率不足 Insufficient output
3.3、柴油机动力不足案例描述
1、柴油机动力不足,柴油机无明显黑烟 2、检查燃油油路、油品、供油提前角也都正常。 3、客户在沙漠地带工作,随检查空气滤芯及进气管路发现空滤堵塞、进气管脏。 案例分析

进气管路堵塞
案例处理

加装复合式空滤 清洗进气管路

第 25页 共 页

3. 功率不足

Insufficient output

3.3、 Case description about Insufficient output
1、Output of the engine is insufficient, but engine doesn’t exhaust black smoke clearly. 2、Check fuel passage, fuel and initial angle of fuel supply are normal. 3、Customers work in desert area, they find air filter elements are blocked and air i l t pipes inlet i are very di dirty t after ft checking. h ki
Case analysis

block air inlet pipe

remedy

add compound air filter to clean air inlet pipe

第 26页 共 页

3.功率不足 Insufficient output
附表:功率不足故障 检查与排除 fault cause and remedy
1.进气管堵塞(空滤器堵塞) 1 Air intake clogged (air cleaner clogged) 2.排气背压过高 2 Exhaust back pressure is too high 3.增压系统压力不足 3 Insufficient pressure in supercharging system 4.增压器工作失常 Faults in turbocharger 5.中冷器损坏,漏气 g Intercooler damaged 6.燃油管路漏油或堵塞 Leakage or choke of fuel line 检查清除污物,检查燃油的清洁度 Check air cleaner and air intake pipe, clean or replace filter element 检查气门定时,排气管道是否堵塞,调整及修理之 Check the valve-timing and exhaust pipe,adjust and repair 检查,排除管路连接处的泄露 Check and block up the leakage of pipeline 更换总成 Replace the turbocharger assembly 更换或修补 p or repair p Replace 检查油管及接头的密封性,滤清器的污染度及燃油管 道,修复或清除污物,更换滤芯 g of fuel p pipe p and connector,fuel , filter Check the sealing and fuel line,repair,clean or replace the filter element

3.功率 功率不足 Insufficient output p
附表:功率不足 故障检查与排除 fault cause and remedy
7.喷油泵或调速器磨损过大 Excessive wear for injection pump or governor 8..喷油泵冒烟限制器膜片破损 Smoke-limiter diaphragm of injection pump damaged 9.喷油器雾化不良 Poor atomizing 10.配气或供油定时不对 Incorrect timing of valve gear or fuel d li delivery 11.油底壳机油油面过高 Oil level in the oil sump is too high 修理或更换 Repair or replace 更换修理 Repair or replace

检查喷油压力,喷油嘴积炭,调整及修理之 Check the injecting pressure,clean away the carbon d deposit it in i nozzle,adjust l dj t and d repair i injector i j t 检查并调整之 Check and adjust it 检查油尺,放出多余的机油 Check the oil-dipstick,and drain off unnecessary oil

3.功率不足 Insufficient output
附表:功率不足故障 检查与排除 fault cause and remedy
12气缸垫漏气 Leakage in cylinder gaskets 13.活塞环磨损断裂,轴瓦间隙过大 Piston ring broken,the clearance of main bearing is too large 14.缸套或活塞磨损或拉缸 Cylinder liner or piston worn,or piston scuffing 热车时检查压缩压力,更换损坏的气缸垫 Check the compressed pressure at hot state,replace cylinder gaskets 更换磨损零件,或大修发动机 Replace worn parts or overhaul the engine

检查喷油压力,喷油嘴积炭,调整及修理之 Check the injecting pressure,clean away the carbon deposit in nozzle,adjust and repair injector

4 燃油消耗过大 4.

Fuel consumption is too high

1:检查低压油路与油质是否正常,若正常转下一步。 2 检查空气滤芯 进气管路 增压器工作是否正常 若正常转下 步 2:检查空气滤芯、进气管路、增压器工作是否正常,若正常转下一步。 3:检查气门间隙是否正常,若正常转下一步 4:检查排气背压过高,若正常转下一步 5:联系特约维修站维修人员检测

1 1. 2. 3. 4. 5.

Check whether low pressure fuel passage and quality of fuel are normal normal. Come into next step if normal. Check whether air filter element, air inlet pipe and turbocharger are normal. Come into next step if normal. Check whether valve clearance is normal. Come into next step if normal. Check whether air exhaust pressure is too high. Come into next step if normal. Contact p professional maintenance p personnel from p professional maintenance station to check for you.

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4 燃油消耗过大 4.

Fuel consumption is too high

4.1、燃油消耗量过大案例描述

1、柴油机在运转过程中感觉烟大,燃油油耗高 2、检查空滤、增压器、供油提前角等均无故障 3、检查低压油路、高压油管等均无燃油泄露。 检查低压油路 高压油管等均无燃油泄露 4、校验高压油泵正常,校验喷油器发现有2个缸喷油器雾化不良,判断喷油器故障。

案例分析

喷油器针阀磨损严重,燃油雾化不良 案例处理 加装除水放心滤 更换喷油器油头
第 31页 共 页

4 燃油消耗过大 4.

Fuel consumption is too high

4.1、case description about fuel consumption is too high 1、When diesel engine is operating, there is a lot of smoke and fuel consumption is too high. 2、Inspect air filter, turbocharger and initial angle of fuel supply are normal. 3、There is no fuel leakage in low pressure fuel passage and high pressure fuel pipe. 4、High pressure fuel pump is normal, but atomization of 2 injectors is not good, so we judge there is fault in injector.

Case analysis

Needle vale of injector is worn heavily, and fuel atomization is bad.
remedy

Add water filter and replace fuel head of injector 第 32页 共 页

4 燃油消耗过大 4.

Fuel consumption is too high

checkout process of the injector

第 33页 共 页

4 燃油消耗过大 4.
1.进气管堵(空滤器堵塞) Air intake clogged(air cleaner choked) 2.排气背压过高 2 Exhaust back pressure is too high 3.燃油质量差 Poor quality of fuel 4.燃油管路堵塞 Fuel line choked 5.燃油管路漏油 Fuel line leaked 6.喷油器雾化不良 Poor atomizing

Fuel consumption is too high
检查空滤器、进气管路、清理之 Check air cleaner and air intake pipe, then clean them 检查排气管道及制动阀,清理之 检查排气管道及制动阀 清理之 Check exhaust pipe and brake valve, then clean them 按规定更换燃油 Renew the fuel according to requirements 检查并修复之 Check and repair 检查并修复之 Check and repair 检查并调整或修复之 Check, adjust and repair

附表:燃油消耗过大 故障检查与处理 fault cause and remedy

4.燃油消耗过大

Fuel consumption is too high
按规定调整气门间隙及供油提前角 Adjust valve clearance and injection advance angle according to requirements 检查压缩压力 Check compressed pressure 检查及大修 Check and overhaul 更换气缸套、活塞及活塞环 Replace cylinder liner liner, piston and piston ring 检查排除管路和连接处泄露 Check and block up the leakage of pipeline 检查更换总成 Check and replace 更换或修补 Replace or repair

附表:燃油消耗过大 故障检查与处理 fault cause and remedy
7.配气或供油定时不对 Incorrect timing of valve gear or fuel delivery 8.缸垫漏气 Leakage in cylinder gasket 9.轴瓦间隙过大,发动机需大修 The clearance of main bearing shell is too large.Engine need to overhaul 10活塞涨缸 Piston scuffing 11.增压系统压力不足 Insufficient pressure in supercharging system 12.增压器工作失常 12 Faults in turbocharger 13.中冷器损坏或漏气 Intercooler damaged or leaked

5.排气冒黑烟 Black smoke exhaust
? 柴油机排烟是表征燃油情况的重要指标.排烟不正常说明燃烧有问题.不正常排烟一般有黑 色,蓝色和白色,柴油机冒黑烟说明柴油燃烧不好, 可从空气和燃油两方面查找原因.蓝烟是 烧机油,可从机油方面查找原因,白烟分两种情况,持续的灰白烟是燃油中有水,启动时白烟 一般是没有燃烧的雾化的柴油微小油滴,柴油机排烟不正常是其他故障的伴随特征, 所以需 要根据柴油机运行情况分析判断和解决.

?

Smoke emission is a very important target representing the fuel condition. The abnormal smoke emission indicates that there is p problem with the combustion. The colors of the abnormal smoke are usually black, blue and white. Emitting black smoke indicates that the diesel fuel does not burn very well 。Try to locate the reason on air and fuel. Emitting blue smoke suggests oil burning. Look for the reason on the oil. Emitting white smoke can be divided into two categories: continuous gray smoke indicates there is water in the fuel. The white smoke during startup is generally consisted of the tiny diesel fuel particles. The abnormal smoke emission is the incidental phenomenon of other failures. The diagnosis g and the removal of relevant failure run through g this material.

第 36页 共 页

5 排气冒黑烟 Black smoke exhaust 5.
5.1、排气冒黑烟案例描述

1、柴油机在运转过程中感觉烟大,燃油油耗高 2、检查空滤、增压器、供油提前角、气门间隙等均无故障 3、检查低压油路、高压油管等均无燃油泄露。 检查低压油路 高压油管等均无燃油泄露 4、校验喷油器正常,校验高压油泵发现高压油泵供油量不均匀,判断高压油泵故障。

案例分析

油泵柱塞磨损严重,造成油泵各缸共有两不均匀 案例处理 加装除水放心滤 更换油泵柱塞
第 37页 共 页

5 排气冒黑烟 Black smoke exhaust 5.
5.1、Case description about Black smoke exhaust 1、When diesel engine is operating, there is a lot of smoke and fuel consumption is too high. 2、Inspect air filter, turbocharger, valve clearance and initial angle of fuel supply are normal. 3、There is no fuel leakage in low pressure fuel passage and high pressure fuel pipe. 4、Injector is normal normal, but high pressure fuel pump cannot supply average fuel in every cylinder cylinder, so we judge that there is fault in high pressure fuel pump.

Case analysis

Fuel pump pole plug is worn heavily, which causes fuel pump cannot supply average fuel in every cylinder. remedy Add water filter and replace p fuel p pump pp pole p plug g 第 38页 共 页

5 排气冒黑烟 Black smoke exhaust 5.

校验油泵 check fuel pump

油泵图 fuel pump

除水放心滤 water filter

第 39页 共 页

5.排气冒黑烟 Black smoke exhaust
附表:排气冒黑烟故障检查与处理 fault cause and remedy
1.进气堵塞或排气背压高 Air intake is not free or exhaust back pressure is too high 2.燃油质量差 P Poor quality lit of f fuel f l 3.供油或配气定时不对 Incorrect timing of valve gear or fuel supply 4.喷油嘴雾化不良 Poor atomizing 5.喷油泵油量过多 Excessive injection quantity 清理之 Clean 清理及更换 Cl Clean and d renew 按规定调整 Adjust according to requirements 检查,修复或更换 Check ,repair repair or replace injector 检查并调整(由专业厂进行) Check and adjust (by manufacturer)

5 排气冒黑烟 Black smoke exhaust 5.
附表:排气冒黑烟故障检查与处理 fault cause and remedy

6.增压器系统压力不足 Insufficient pressure in supercharging system

检查排除管路和连接处漏 Check and block up the leakage of pipeline and connector

7.增压器工作失常 Faults in turbocharger 8.中冷器损坏或漏气 8 Intercooler damaged or leaked 9.冒烟限制器起作用点不对 9 Incorrect working point of smoke-limiter

检查更换总成 Check and replace 更换或修补 Replace or repair 重新调整(由专业厂进行) Readjust (by manufacturer)

6.增压器进、排气口,进、排气管附集机油
oil is gathered in inlet and exhaust vents of turbocharger and inlet and exhaust pipe i
1、检查机油尺,油底壳机油面不高,进入下一步。 2 、检查增压器完好,进入下一步。 3、联系特约维修站维修人员检测 1. Check oil dipstick. p Come into next step p if oil level of oil pan is not high. 2. Check whether turbocharger is good. Come into next step if yes. 3. Contact professional maintenance personnel from professional maintenance station to check for you.

第 42页 共 页

6.增压器进、排气口,进、排气管附集机油
6.1、增压器进、排气口,进、排气管附集机油案例描述

1、新机磨合柴油机在空载运转过程中感觉烟大,增压器进、排气口,进、排气管附集机油。 2、检查机油尺,油底壳机油面不高 3、检查增压器完好。 检查增压器完好 4、检查增压器回油管有皱褶,呼吸起出气管折弯。

案例分析 增压器回油管有皱褶,造成增压器回油不畅 呼吸器出气管折弯,造成呼吸器失灵 案例处理 重新安装增压器回油管 和呼吸器出气管
第 43页 共 页

7 机油压力过低 7.

Lub oil pressure is too low Lub-oil

7.1、case description about Lub-oil pressure is too low 1、Lub-oil pressure is low. Oil level of oil pan is normal, but oil brand is not satisfied to requirement. 2、Fault is not removed after replacing oil and oil filter and cleaning oil cooler. 3、Inspect turbocharger, strainer, oil pipe and connecting washer are not blocked or broken 4、Inspect limiter valve of main oil passage and then find that limiter valve dirty.

Case analysis

Users didn’t replace oil, which causes limiter valve of main oil passage dirty remedy Replace limiter valve of main oil p passage g 第 44页 共 页

6.增压器进、排气口,进、排气管附集机油

出气管折弯
Air exhaust pipe is folded

增压器回油管 Oil return pipe of turocharger

第 45页 共 页

6.增压器进、排气口,进、排气管附集机油
附表:增压器进、排气口,进、排气管附集机油故障检查与处理 1.增压器密封环失效 The sealing of turbocharger cease to be in effort 2.油气分离器失效 The gas-oil separator cease to be in effect 修理或调换增压器 Repair or replace turbocharger

调换 Replace

3.油底壳机油面过高,加入机油过多 Lub-oil level in oil sump is too high

检查放出适量机油符合规定 Drain off unnecessary oil according to requirements q

7.机油压力过低

Lub-oil pressure is too low

1、检查油底壳油面是否过低或缺油。否 进入下一步 2、检查机油牌号是否符合规定。否 进入下一步 3、机油滤清器是否阻力过大。否 进入下一步 4、机油冷却器是否阻力过大。否 进入下一步 5、冷却系统水温过高,机油温度过高。否 冷却系统水 高 机油 度 高 否 进 进入下一步 下 步 6、联系特约维修站维修人员检测 1. Check whether oil level of oil pan is too low or insufficient. Come into next step if not. 2. Check whether oil brand is satisfied to relent rules. Come into next step if not. 3. Check whether the resistance of oil filter is too large. Come into next step if not. 4 Check whether the resistance of oil cooler is too large 4. large. Come into next step if not not. 5. Check whether water temperature in cooling system and oil temperature is too high. Come into next step if not. 6. Co 6 Contact ac p professional o ess o a maintenance a e a ce pe personnel so e from o p professional o ess o a maintenance a e a ce s station a o to o check for you

第 47页 共 页

7 机油压力过低 7.
7.1、机油压力过低案例描述

Lub oil pressure is too low Lub-oil

1、柴油机机油压力低,检查油底壳油面正常,原机油牌号不符合要求。 2、更换机油、机油滤清器,清洗机油冷却器故障未排除。 3、检查增压器完好,集滤器,机油管路,接头垫片等,没有堵塞或破裂 检查增压器完好 集滤器 机油管路 接头垫片等 没有堵塞或破裂 4、检查主油道限压阀,发现限压阀垫阀

案例分析

用户每按说明书更换机油造成主油道限压阀垫阀 案例处理

更换主油道限压阀 更换 油道限压阀
第 48页 共 页

7 机油压力过低 7.

Lub oil pressure is too low Lub-oil

7.1、case description about Lub-oil pressure is too low 1、Lub-oil pressure is low. Oil level of oil pan is normal, but oil brand is not satisfied to requirement. 2、Fault is not removed after replacing oil and oil filter and cleaning oil cooler. 3、Inspect turbocharger, strainer, oil pipe and connecting washer are not blocked or broken 4、Inspect limiter valve of main oil passage and then find that limiter valve dirty.

Case analysis

Users didn’t replace oil, which causes limiter valve of main oil passage dirty remedy Replace limiter valve of main oil p passage g 第 49页 共 页

7.机油压力过低

Lub-oil pressure is too low

主油道限压 阀垫阀
Limiter valve of main oil passage

主油 道限 压阀
Limiter valve of main oil passage

第 50页 共 页

7 机油压力过低 7.
7.1、机油压力过低案例描述

Lub oil pressure is too low Lub-oil

1、柴油机机油压力低,检查油底壳油面正常,原机油牌号不符合要求。 2、更换机油、机油滤清器,清洗机油冷却器故障未排除。 3、检查增压器、主油道限压阀完好 检查增压器 主油道限压阀完好. 4、检查集滤器,机油管路,接头垫片等,发现集滤器堵塞

案例分析

用户没按说明书更换机油造成集滤器堵塞 案例处理

清洗集滤器
第 51页 共 页

7 机油压力过低 7.

Lub oil pressure is too low Lub-oil

7.1、case description about lub-oil pressure is too low 1、Lub-oil pressure is low. Oil level of oil pan is normal, but oil brand is not satisfied to requirement. 2、Fault au is s not o removed e o ed a after e replacing ep ac g o oil a and do oil filter e a and dc cleaning ea g o oil coo cooler. e 3、turbocharger and limiter valve of main oil passage are good 4、Inspect strainer, oil pipe and connecting washer, and then find strainer is blocked.

Case analysis

Customers C t did didn’t ’t replace l strainer t i i in accordance d with operation manual ,which causes strainer was blocked. remedy

clean strainer
第 52页 共 页

7.机油压力过低

Lub-oil pressure is too low

清洗集滤 器
Clean strainer

机油滤清 器
Oil filter 第 53页 共 页

7.机油压力过低
1.油底壳油面过低或缺油 Oil level in oil sump is too low

Lub-oil Lub oil pressure is too low
检查油面及是否有漏油处,添加机油 Check oil leakage,add oil 检查限压阀,清洗或修复 Check valve,clean and repair 检查集滤器,管路接头,油道中是否有铸造疏松, 修复 Check strainer and connector,check if 、 y sponge p g in oil p passage g ,repair p there is any 按规定更换机油,选用合适牌号机油 Renew the lub-oil according to requirements 检查油管、接头、修复或更换 Check the oil pipe and connector,repair or replace

附表:机油压力低故障检查及处理 fault cause and remedy

2.主油道限压阀有故障 Faults in pressure regulating valve of main oil passage p g 3.集滤器,机油管路,接头垫片等,是否有堵 塞或破裂 Strainer,oil pipes,connector gasket choked or broken 4.机油牌号不符合规定 Lub-oil doesn’t conform to specifications 5.机油泵进油管漏 Intake pipe of oil pump leaked

7 机油压力过低 7.

Lub-oil pressure is too low
检查冷却系统工作,纠正之 Check cooling system,and correct it 更换新滤芯 Renew the filter element 检查并清理 Check and clean 检查并清理 Check and clean 检查并更换 Check and replace 检查发动机工作时间,大修 Check the working time of the engine,overhaul

附表:机油压力低故障检查及处理 fault cause and remedy
6.冷却系统水温过高,机油温度过高 6 Water temperature in cooling system and oil temperature are too high 7.机油滤清器阻力过大 7 Excessive resistance of oil filter 8.机油冷却器阻力过大 Oil cooler choked 9.主油道堵塞 Main oil passage choked 10.轴瓦间隙过大,或轴瓦损坏 The clearance of bearing is too large or bearing damaged 11.部件磨损过大,要大修 Excessive wear of parts,need to overhaul

8 冷却水温过高 Cooling water temperature is too high 8.
1、检查水箱水面、水泵皮带、油底壳油面正常进入下一步 2、检查节温器工作正常进入下 、检查节温器工作正常进入下一步 步 3、检查连接水管、水泵正常进入下一步 4、检查水温表、水温传感器工作正常进入下一步 5、联系特约维修站维修人员检测 1. 2 3 4 5 Check whether water level of water tank, water belt and oil level of oil pan are normal. Come into next step if normal normal. Check thermostat. Come into next step if normal. Check whether connecting water pipe and water pump are normal. Come into next step if normal. o a Check whether water temperature meter and water sensor are normal. Come into next step if normal. Contact p professional maintenance p personnel from p professional maintenance station to check for you.

第 56页 共 页

8 冷却水温过高 Cooling water temperature is too high 8.
8.1、水温高案例描述

1、柴油机高负荷运转水温高,检查油底壳油面、水箱水面、水泵皮带正常 2、检查节温器、连接水管、供油提前角正常 3、检查水温表、水温传感器工作正常 检查水温表 水温传感器工作正常. 4、检查风扇时发现该机水箱外表面很脏,被脏东西把散热口堵死。

案例分析 该机在整车厂发动机罩壳没有通风口,造成风扇吸风 时将地面泥土吹向水箱,引起水箱散热口堵塞 案例处理 发动机罩壳加装通风口 清洗水箱
第 57页 共 页

8.冷却水温过高 Cooling water temperature is too high
8.1、Cooling water temperature is too high
1、Cooling water temperature is high when diesel engine is operating with high load. Check oil level of oil pan, water level of water tank and water pump belt are normal. 2、Check thermostat, joint pipe and initial angle of fuel supply are normal. 3、Check Ch k water t temperature t t meter t and d water t temperature t t sensor work k normally. ll 4、We find outer surface of water tank is dirty and heat-sinking vents are blocked when check the fan.

Case analysis

There is Th i no intake i t k went t on engine i cover, which hi h causes f fan blows dirt from ground to water tank so that heat-sinking of water tank is blocked. remedy Add air intake on engine shell and clean water tank

第 58页 共 页

8 冷却水温过高 Cooling water temperature is too high 8.
罩壳两边加装通风口(左侧) add air vents on both sides of shell ( left side) )

风扇从地面吸风造成水箱面太 脏,堵死水箱散热孔。造成发 动 机 过 热 。 Because fan sucks air from ground, water tank is too dirty and radiator vent of water tank is choked, which cause engine too hot

罩壳中间上部加装通风口
add air vent in the middle of shell

原车没有通风口只能从地面通风
vehicle has no air vent, , so it only y ventilates from ground

检查结温器 check thermostat

检查水温传感器 check water temperature sensor

检查皮带用4~5kg力,按下 15~20mm check belt pulley with 4-5kg f force and d press d down 15 1520mm 第 59页 共 页

8.冷却水温过高 Cooling water temperature is too high
1.水箱水面过低 W t level Water l l in i water t tank t k is i too t low l 2.水箱堵塞 Water tank clogged 3.水泵皮带松驰 The belt of water pump loosened 检查有无漏水处,加水 Ch k water Check t leakage, l k add dd water t 检查水箱,清理或修复 Check or repair 按规定调整张紧力 Adjust tension according to requirements

水泵垫片损坏,水泵叶轮磨损 片损坏 水泵叶轮磨损 检查并修复或更换 检 并修复或更换 4.水泵 Water pump gasket damaged, water pump impeller Check and repair, or replace worn 5.节温器故障 Faults in thermostat 6.水管损坏,漏入空气 Surge in turbocharger 7.油底壳油面过低或缺油 The oil level in oil sump is too low 更换 Replace it 检查水管、接头、垫片等,更换损坏件 Check wash compressor streets,clean Check,wash streets clean away the carbon deposit from exhaust passage 检查油面及漏油处,修复并加油 Check oil leakage, leakage repair and add oil

9 柴油机油水混合。 9. 柴油机油水混合 the oil mixed with the water
? ? 1.机油中有水,首先检查空压机气缸盖,如有裂纹需要换相关零部件,检查气缸垫是否冲掉或 损坏使冷却水漏入机油中.更换缸垫. 2.冷却水中有油.如果的确是柴油机机油,可按以下步骤检查处理.首先检查机油冷却器是否 损坏,可将柴油机内的水放掉,拆下冷却器盖,让柴油机怠速运行10—20秒,若观察到机油冷 却器芯子有渗漏或损坏应更换. 1.There is water in the oil. First check the cylinder head and the air compressor. Change the relevant components if there is any crack. Check whether the cylinder gasket is washed off or damaged letting cooling water mix with the oil. Change the gasket. 2.There is oil in the cooling water. If it is indeed the oil, follow these steps: first, check whether the oil cooler is damaged. Drain off the water in the diesel engine, dismantle the cooler lid and let the engine run idly for 10-20 seconds. If there is leakage or damage on the cooler element, change it.

?

?

第 61页 共 页

9.柴油机油水混合 the oil mixed with the water

检查空压机盖 检查空压机盖、 垫片是否破损
Check whether air compressor p cover and washer are broken.

检查气缸盖垫片 是否破损
Check whether cylinder head washer is broken.

将柴油机内的水放掉,拆下 冷却器盖,让柴油机怠速运 行10—20秒
Drain D i water t f from engine, i and d remove oil cooler cover. Conduct 10-20s run-in with idling speed.

第 62页 共 页


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卡车用柴油机 潍柴 WD12 系列卡车用柴油机 WD615 系列 卡车用柴油机 226B ...用柴油机 发电的: 潍柴道依茨 226B 系列发电用柴油机 潍柴 WD615/WD618 系列...
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9、 其它未说明的问题,请参照随车发放的《WD615 欧 III 系列柴油机使用与...12.5bar 2.8 配气定时(1mm 余隙时) (见图 5-1) 进气门开: 上止点 进气门...
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潍柴发动机 潍柴道依茨 226B 系列欧Ⅱ WD615 系列欧Ⅱ WD618 系列欧Ⅱ WD12 系列欧Ⅱ WP4 系列国Ⅲ WP6 系列国Ⅲ WP10 系列国Ⅲ WP12 系列国Ⅲ/国 IV ...
汽车发动机
潍坊动力主要生产 WD615WD618WD12、WP12、226B、 170 等 10 大系列柴油机,共 1000 多个产品,功率范围 8—2250 千瓦,产品主要应用于 重型汽车、大型客车...
WD615系列柴油机工艺守则
二、装配工艺守则—一般要求 装配工艺守则 一般要求1.适应范围 适应范围 本技术条件适应于在潍坊柴油机厂生产的WD615系列柴油机WD618WD615系列柴油机WD618系列...
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wd618 wd615 | 潍柴wd615柴油机参数 | wd615柴油机 | wd615发动机 | wd615.47 | wd615.95e | wd615 | wd615.87 |