SOFIM欧3发动机的使用说明书

WD615欧Ⅲ系列柴油机电气使用说明书杭州汽车发动机厂2006年4月杭州汽车发动机厂WD615欧Ⅲ发动机是由英国RICARDO公司总体设计，开发标定工作由荷兰TNO公司完成，燃油喷射系统采用了日本电装电控共轨燃油系统。

电控共轨燃油系统的特点是：通过各种传感器和开关检测出发动机的实际运行状态，通过计算机计算和处理后，对喷油量、喷油时间、喷油压力、和喷油率等进行最佳控制。

一、ECU（Electronic Control Unit电子控制单元）外部接线图详见附图一：杭发欧ⅢECU外部接线图.pdf。

电气系统由ECU、传感器、开关、继电器、执行器（喷油器电磁阀、排气制动阀、泄气式制动装置电磁阀）、灯、通讯数据连接和DC24电源装置等组成。

1、ECU尺寸：236×171×33，要求安装在驾驶室内。

2、传感器装在发动机上的传感器有：(由发动机厂家提供)⑴ Ne Sensor转速传感器；⑵ G Sensor缸判别传感器；⑶ Coolant Temp. Sensorl冷却液温度传感器；⑷ Intake Temp.Sensor进气温度传感器；⑸ Fuel Temp.Sensor燃油回油温度传感器；⑹Intake Press. Sensor进气压力传感器；⑺Rail Press. Sensor共轨压力传感器；⑻Oil Press. Sensor机油压力传感器（可选装电子式机油压力传感器）；⑼柴油水分报警传感器（安装在柴油粗滤芯器上）（选装）。

装在整车上的传感器有：（由整车厂提供）⑴Accel Pedal Sensor1、2 加速踏板传感器1、2；⑵Vehicle Speed Sensor车辆速度传感器；⑶ PTO Accel Sensor动力输出加速传感器；⑷Idle Speed Control V olume怠速控制量传感器。

3、开关：（由整车厂提供）⑴ Key SW钥匙开关；⑵ Starter SW启动开关（钥匙开关组合在一起）；⑶Exhaust Brake SW排气制动开关；⑷ Clutch SW离合器开关；⑸ Brake SW制动开关；⑹ Neutral SW空档开关；⑺ Diag SW诊断开关；⑻ AC SW空调开关；⑼Cruise Main SW巡航主开关，要求用点触式（按钮式）开关；⑽Cruise 2 SW巡航设置开关(Set, “-”)，要求用点触式（按钮式）开关；⑾ Cruise 1 SW巡航复位开关(Resume, “+”)，要求用点触式（按钮式）开关；⑿Warm Up SW暖机开关，要求用点触式（按钮式）开关；⒀ Tractor SW拖挂车开关；⒁ PTO SW动力输出开关；⒂Engine Stop SW发动机停止开关；⒃ Reverse SW倒档开关；⒄Stop Lamp SW 停止灯开关4、继电器：（由整车厂提供）⑴ Glow Relay空气加热继电器；⑵ Main Relay主继电器；⑶ PCV Relay泵驱动继电器；⑷ Starter Relay启动继电器；⑸ Exhaust Brake排气制动继电器；⑹ Relay1、Relay2泄气式制动继电器（选装）；⑺ Brake Relay制动继电器（为了常开触点转常闭而设）；⑻ Neutral Relay空档继电器{为了起动线路上串接空档开关而设}。

CONTENTSSAFE OPERATION (1)SERVICING OF THE ENGINE (1)NAMES OF PARTS (2)PRE-OPERATION CHECK (3)BREAK-IN (3)DAILY CHECK (3)OPERATING THE ENGINE (4)STARTING THE ENGINE(NORMAL) (4)COLD WEATHER STARTING (5)STOPPING THE ENGINE (6)CHECKS DURING OPERATION (6)Radiator Cooling water(Coolant) (6)Oil pressure lamp (6)Fuel (7)Color of exhaust (7)Immediately stop the engine if; (7)REVERSED ENGINE REVOLUTION AND REMEDIES (7)How to tell when the engine starts running backwards (7)Remedies (7)MAINTENANCE (8)SERVICE INTERVALS (9)PERIODIC SERVICE (12)FUEL (12)Fuel level check and refueling (12)Air bleeding the fuel system (13)Checking the fuel pipes (14)Cleaning the fuel filter pot (14)Fuel filter cartridge replacement (15)ENGINE OIL (15)Checking oil level and adding engine oil (15)Changing engine oil (16)Replacing the oil filter cartridge (17)RADIATOR (17)Checking coolant level, adding coolant (18)Changing coolant (19)Remedies for quick decrease of coolant (19)Checking radiator hoses and clamp bands (19)Precaution at overheating (19)Cleaning radiator core(outside) (19)Anti-freeze (20)Radiator cement (20)AIR CLEANER (21)Evacuator valve (21)For the air cleaner with a dust cup (optional) (21)Dust indicator (optional) (22)BATTERY (22)Battery charging (22)CONTENTSDirection for long term storage (23)ELECTRIC WIRING (23)FAN BELT (24)Adjusting Fan Belt Tension (24)CARRIAGE AND STORAGE (25)CARRIAGE (25)STORAGE (25)TROUBLESHOOTING (26)SPECIFICATIONS (28)WIRING DIAGRAMS (31)1SAFE OPERATIONE N G L I SSAFE OPERATIONCareful operation is your best assurance against an accident. Read and understand this section carefully before operating the engine. All operators, no matter how much experience they may have, should read this and other related manuals before operating the engine or any equipment attached to it. It is the owner's obligation to provide all operators with this information and instruct them on safe operation.Be sure to observe the following for safe operation.1.OBSERVE SAFETY INSTRUCTIONSA Read and understand carefully this "OPERATOR'S MANUAL" and "LABELS ON THE ENGINE" before attempting to start and operate the engine.A Learn how to operate and work safely. Know your equipment and its limitations. Always keep the engine in good condition.A Before allowing other people to use your engine, explainhow to operate and have them read this manual beforeoperation.A DO NOT modify the engine. UNAUTHORIZEDMODIFICATIONS to the engine may impair the functionand/or safety and affect engine life. If the engine does notperform properly, consult your local Kubota EngineDistributor first.2.WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE)A DO NOT wear loose, torn or bulky clothing around themachine that may catch on working controls andprojections or into fans, pulleys and other moving partscausing personal injury.A Use additional safety items-PPE, e.g. hard hat, safetyprotection, safety goggles, gloves, etc., as appropriate orrequired.A DO NOT operate the machine or any equipment attachedto it while under the influence of alcohol, medication, orother drugs, or while fatigued.A DO NOT wear radio or music headphones whileoperating the engine.SAFE OPERATION23.CHECK BEFORE STARTING & OPERATING THE ENGINEA Be sure to inspect the engine before operation. Do notoperate the engine if there is something wrong with it.Repair it immediately.A Ensure all guards and shields are in place beforeoperating the engine. Replace any that are damaged ormissing.A Check to see that you and others are a safe distancefrom the engine before starting.A Always keep the engine at least 3 feet (1 meter) awayfrom buildings and other facilities.A DO NOT allow children or livestock to approach themachine while the engine is running.A DO NOT start the engine by shorting across starterterminals. The machine may start in gear and move. Donot bypass or defeat any safety devices.4.KEEP THE ENGINE AND SURROUNDINGS CLEANA Be sure to stop the engine before cleaning.A Keep the engine clean and free of accumulated dirt,grease and trash to avoid a fire. Store flammable fluids inproper containers and cabinets away from sparks andheat.A Check for and repair leaks immediately.A DO NOT stop the engine without idling; Allow the engineto cool down, first. Keep the engine idling for about 5minutes before stopping unless there is a safety problemthat requires immediate shut down.5.SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIREA Always stop the engine before refueling and/orlubricating.A DO NOT smoke or allow flames or sparks in your workarea. Fuel is extremely flammable and explosive undercertain conditions.A Refuel at a well ventilated and open place. When fueland/or lubricants are spilled, refuel after letting theengine cool down.A DO NOT mix gasoline or alcohol with diesel fuel. Themixture can cause a fire or severe engine damage.A Do not use unapproved containers e.g. buckets, bottles,jars. Use approved fuel storage containers anddispensers.3SAFE OPERATION6.EXHAUST GASES & FIRE PREVENTIONA Engine exhaust fumes can be very harmful if allowed toaccumulate. Be sure to run the engine in a well ventilatedlocation and where there are no people or livestock nearthe engine.A The exhaust gas from the muffler is very hot. To preventa fire, do not expose dry grass, mowed grass, oil or anyother combustible materials to exhaust gas. Keep theengine and muffler clean at all times.A To avoid a fire, be alert for leaks of flammablesubstances from hoses and lines. Be sure to check forleaks from hoses or pipes, such as fuel and hydraulicfluid by following the maintenance check list.A To avoid a fire, do not short across power cables andwires. Check to see that all power cables and wirings arein good condition. Keep all electrical connections clean.Bare wire or frayed insulation can cause a dangerouselectrical shock and personal injury.7.ESCAPING FLUIDA Relieve all pressure in the air, the oil and the coolingsystems before disconnecting any lines, fittings orrelated items.A Be cautious of possible pressure relief whendisconnecting any device from a pressurized system thatutilizes pressure. DO NOT check for pressure leaks withyour hand. High pressure oil or fuel can cause personalinjury.A Escaping fluid under pressure has sufficient force topenetrate skin causing serious personal injury.A Fluid escaping from pinholes may be invisible. Use apiece of cardboard or wood to search for suspectedleaks: do not use hands and body. Use safety goggles orother eye protection when checking for leaks.A If injured by escaping fluid, see a medical doctorimmediately. This fluid can produce gangrene or severeallergic reaction.4SAFE OPERATION8.CAUTIONS AGAINST BURNS & BATTERY EXPLOSIONA To avoid burns, be cautious of hot components, e.g.muffler, muffler cover, radiator, hoses, engine body,coolants, engine oil, etc. during operation and after theengine has been shut off.A DO NOT remove the radiator cap while the engine isrunning or immediately after stopping. Otherwise hotwater will spout out from the radiator. Wait until theradiator is completely cool to the touch before removingthe cap. Wear safety goggles.A Be sure to close the coolant drain valve, secure thepressure cap, and fasten the pipe band before operating.If these parts are taken off, or loosened, it will result inserious personal injury.A The battery presents an explosive hazard. When thebattery is being charged, hydrogen and oxygen gasesare extremely explosive.A DO NOT use or charge the battery if its fluid level is belowthe LOWER mark.Otherwise, the component parts may deteriorate earlierthan expected, which may shorten the service life orcause an explosion. Immediately, add distilled water untilthe fluid level is between the UPPER and LOWER marks.A Keep sparks and open flames away from the battery,especially during charging. DO NOT strike a match nearthe battery.A DO NOT check the battery charge by placing a metalobject across the terminals. Use a voltmeter orhydrometer.A DO NOT charge a frozen battery. There is a risk ofexplosion. When frozen, warm the battery up to at least16C (61F).9.KEEP HANDS AND BODY AWAY FROM ROTATING PARTSA Be sure to stop the engine before checking or adjustingthe belt tension and cooling fan.A Keep your hands and body away from rotating parts,such as the cooling fan, V-belt, fan drive V-belt, pulley orflywheel. Contact with rotating parts can cause severepersonal injury.A DO NOT run the engine without safety guards. Installsafety guards securely before operation.5SAFE OPERATION10.ANTI-FREEZE & DISPOSAL OF FLUIDSA Anti-freeze contains poison. Wear rubber gloves to avoidpersonal injury. In case of contact with skin, wash it offimmediately.A DO NOT mix different types of Anti-freeze. The mixturecan produce a chemical reaction causing harmfulsubstances. Use approved or genuine KUBOTA Anti-freeze.A Be mindful of the environment and the ecology. Beforedraining any fluids, determine the correct way to disposeof them. Observe the relevant environmental protectionregulations when disposing of oil, fuel, coolant, brakefluid, filters and batteries.A When draining fluids from the engine, place a suitablecontainer underneath the engine body.A DO NOT pour waste onto the ground, down a drain, orinto any water source. Dispose of waste fluids accordingto environmental regulations.SAFE OPERATION611.CONDUCTING SAFETY CHECKS & MAINTENANCEA When inspecting the engine or servicing, place theengine on a large flat surface. DO NOT work on anythingthat is supported ONLY by lift jacks or a hoist. Always useblocks or the correct stands to support the engine beforeservicing.A Disconnect the battery from the engine beforeconducting service. Put a "DO NOT OPERATE!" tag onthe key switch to avoid accidental starting.A To avoid sparks from an accidental short circuit alwaysdisconnect the battery's ground cable (-) first andreconnect it last.A Be sure to stop the engine and remove the key whenconducting daily and periodic maintenance, service andcleaning.A Check or conduct maintenance after the engine, coolant,muffler, or muffler cover have cooled off completely.A Always use the appropriate tools and fixtures. Verify thatthey are in good condition before performing any servicework. Make sure you understand how to use them beforeservice.A Use ONLY correct engine barring techniques formanually rotating the engine. DO NOT attempt to rotatethe engine by pulling or prying on the cooling fan and V-belt. This practice can cause serious personal injury orpremature damage to the cooling fan and belt.A Replace fuel pipes and lubricant pipes with their hoseclamps every 2 years or earlier whether they aredamaged or not. They are made of rubber and agegradually.A When servicing is performed together by two or morepersons, take care to perform all work safely.A Keep a first aid kit and fire extinguisher handy at all times.7SAFE OPERATION 1.Keep warning and caution labels clean and free from obstructing material.2.Clean warning and caution labels with soap and water, dry with a soft cloth.3.Replace damaged or missing warning and caution labels with new labels from your local KUBOTA dealer.4.If a component with warning and caution label(s) affixed is replaced with a new part, make sure the new label(s) is (are) attached in the same location(s) as the replaced component.5.Mount new warning and caution labels by applying to a clean dry surface and pressing any bubbles to the outside edge.12.WARNING AND CAUTION LABELSPart No.19077-8724-1 or 16667-8724-1(55mm in diameter) (37mm in diameter)Part No.TA040-4957-1Do not get your hands closeto engine fan and fan belt.13.CARE OF WARNING AND CAUTION LABELS8SAFE OPERATIONSERVICING OF THE ENGINE1 SERVICING OF THE ENGINEYour dealer is interested in your new engine and has the Array desire to help you get the most value from it. After readingthis manual thoroughly, you will find that you can do someof the regular maintenance yourself.However, when in need of parts or major service, be sureto see your KUBOTA dealer.For service, contact the KUBOTA Dealership from whichyou purchased your engine or your local KUBOTA dealer.When in need of parts, be prepared to give your dealerthe engine serial number.Locate the serial number now and record them in thespace provided.Type Serial No.(1) Engine serial numberEngineDate of PurchaseName of Dealer(To be filled in by purchaser)2NAMES OF PARTS NAMES OF PARTS(1) Intake manifold(2) Speed control lever(3) Engine stop lever(4) Injection pump(5) Fuel feed pump(6) Cooling fan(7) Fan drive pulley(8) Oil filter cartridge(9) Water drain cock (10) Oil filler plug(11) Exhaust manifold(12) Alternator(13) Starter(14) Oil level gauge(15) Oil pressure switch(16) Flywheel(17) Oil drain plug(18) Oil pan(19) Engine hook3PRE-OPERATION CHECK PRE-OPERATION CHECKBREAK-INDuring the engine break-in period, observe the following by all means:1.Change engine oil and oil filter cartridge after the first 50 hours of operation. (See "ENGINE OIL" in "PERIODICSERVICE" section.)2.When ambient temperature is low, operate the machine after the engine has been completely warmed up. DAILY CHECKTo prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.To avoid personal injury:A Be sure to install shields and safeguards attached to the engine when operating.A Stop the engine at a flat and wide space when checking.A Keep dust or fuel away from the battery, wiring, muffler and engine to prevent a fire.Check and clear them before operating everyday. Pay attention to the heat of the exhaust pipe or exhaust gas so that it can not ignite trash.Item Ref. page1. Parts which had trouble in previous operation-2. By walking around the machine(1) Oil or water leaks15 to 20(2) Engine oil level and contamination15,16(3) Amount of fuel12(4) Amount of coolant18 to 20(5) Dust in air cleaner dust cup21(6) Damaged parts and loosened bolts and nuts-3. By inserting the key into the starter switch (1) Proper functions of meters and pilot lamps; no stains onthese parts-(2) Proper function of glow lamp timer-4. By starting the engine(1) Color of exhaust fumes7(2) Unusual engine noise7(3) Engine start-up condition5(4) Slow-down and acceleration behavior74OPERATING THE ENGINE OPERATING THE ENGINESTARTING THE ENGINE(NORMAL) To avoid personal injury:A Do not allow children to approach themachine while the engine is running.A Be sure to install the machine onwhich the engine is installed, on a flatplace.A Do not run the engine on gradients.A Do not run the engine in an enclosedarea. Exhaust gas can cause airpollution and exhaust gas poisoning.A Keep your hands away from rotatingparts (such as fan, pulley, belt,flywheel etc.) during operation.A Do not operate the machine whileunder the influence of alcohol ordrugs.A Do not wear loose, torn or bulkyclothing around the machine. It maycatch on moving parts or controls,leading to the risk of accident. Useadditional safety items, e.g. hard hat,safety boots or shoes, eye andhearing protection, gloves, etc., asappropriate or required.A Do not wear radio or musicheadphones while operating engine.A Check to see if it is safe around theengine before starting.A Reinstall safeguards and shieldssecurely and clear all maintenancetools when starting the engine aftermaintenance.A Do not use ether or any starting fluid for starting theengine, or a severe damage will occur.A When starting the engine after a long storage (of morethan 3 months), first set the stop lever to the "STOP"position and then activate the starter for about 10 seconds to allow oil to reach every engine part.1.Set the fuel lever to the "ON" position.(1) Fuel lever(A) "ON"(B) "OFF"2.Place the engine stop lever to the"START" position.3.Place the speed control lever at morethan half "OPERATION".(1) Engine stop lever(2) Speed Control lever(A) "STOP"(B) "START"(C) "IDLING"(D) "OPERATION"5OPERATING THE ENGINE (with lamp timer in use)A The glow lamp goes out in about 5 seconds when thelamp timer is up. Refer to this for pre-heating.Even with the glow lamp off, the glow plug can be pre-heated by turning the starter switch to the "PREHEATING" position.A If the oil pressure lamp should be still on, immediatelystop the engine and check; - if there is enough engine oil. - if the engine oil has dirt in it.- if the wiring is faulty.A If the glow lamp should redden too quickly or tooslowly, immediately ask your KUBOTA dealer to check and repair it.A If the engine does not catch or start at 10 secondsafter the starter switch is set at "STARTING" position,wait for another 30 seconds and then begin the engine starting sequence again. Do not allow the starter motor to run continuously for more than 20 seconds.COLD WEATHER STARTINGIf the ambient temperature is below -5C(23F)* and the engine is very cold, start it in the following manner:Take steps (1) through (4) above.A Shown below are the standard preheating times forvarious temperatures. This operation, however, is not required, when the engine is warmed up.A Do not allow the starter motor to run continuously formore than 20 seconds.A Be sure to warm up the engine, not only in winter, butalso in warmer seasons. An insufficiently warmed-up engine can shorten its service life.A When there is fear of temperature dropping below-15C (5F) detach the battery from the machine, and keep it indoors in a safe area, to be reinstalled just before the next operation.4.Insert the key into the key switch andturn it to the "OPERATION" position.(A) "OFF" SWITCHED OFF (B) "ON" OPERATION (C) "GL" PREHEATING (D) "ST" STARTING(A) "GL" PREHEATING (B) "OFF" SWITCHED OFF (C) "ON" OPERATION (D) "ST" STARTING5.Turn the starter switch to the"PREHEATING" position to allow the glow lamp to redden.6.Turn the key to the "STARTING"position and the engine should start. Release the key immediately when the engine starts.7.Check to see that the oil pressure lampand charge lamp are off. If the lamps are still on, immediately stop the engine, and determine the cause.(See "CHECKS DURING OPERATION" in "OPERATING THE ENGINE" section.)8.Warm up the engine at medium speedwithout load.5.Turn the key to the "PREHEATING"position and keep it there for a certain period mentioned below.Ambient temperature Preheating time Above 10C (50F)NO NEED10C (50F) to -5C (23F)Approx. 5 seconds *Below -5C (23F)Approx. 10 secondsLimit of continuous use20 seconds6.Turn the key to the "STARTING"position and the engine should start.(If the engine fails to start after 10 seconds, turn off the key for 5 to 30 seconds. Then repeat steps (5) and (6).)OPERATING THE ENGINE6STOPPING THE ENGINEA If equipped with a turbo-charger, allow the engine toidle for 5 minutes before shutting it off after a full load operation.Failure to do so may lead to turbo-charger trouble.CHECKS DURING OPERATIONWhile running, make the following checks to see that all parts are working correctly.B Radiator Cooling water(Coolant)To avoid personal injury:A Do not remove radiator cap until coolant temperature is well below its boiling point. Then loosen cap slightly to the stop position, to relieve any pressure, before removing cap completely.When the engine overheats and hot coolant overflows through the radiator and hoses, stop the engine immediately and make the following checks to determine the cause of trouble:Check item1.Check to see if there is any coolant leak;2.Check to see if there is any obstacle around thecooling air inlet or outlet;3.Check to see if there is any dirt or dust betweenradiator fins and tube;4.Check to see if the fan belt is too loose;5.Check to see if radiator water pipe is clogged; and6.Check to see if anti-freeze is mixed to a 50/50% mix ofwater and anti-freeze.B Oil pressure lampThe lamp lights up to warn the operator that the engine oil pressure has dropped below the prescribed level. If this should happen during operation or should not go off even after the engine is accelerated more than 1000rpm,immediately stop the engine and check the following:1.Engine oil level (See "ENGINE OIL" in "PERIODICSERVICE" section.)2.Lubricant system (See "ENGINE OIL" in "PERIODICSERVICE" section.)1.Return the speed control lever to lowidle, and run the engine under idling conditions.2.Set the engine stop lever to the "STOP"position.3.With the starter switch placed to the"SWITCHED OFF" position, remove the key. (Be sure to return the engine stop lever to the "START" position to be ready for the next start.)(1) Engine stop lever(2) Speed control lever(A) "STOP" (B) "START" (C) "IDLING"(D) "OPERATION"7 OPERATING THE ENGINEB FuelTo avoid personal injury:A Fluid escaping from pinholes may beinvisible. Do not use hands to searchfor suspected leaks; Use a piece ofcardboard or wood, instead. Ifinjured by escaping fluid, see amedical doctor at once. This fluid canproduce gangrene or a severeallergic reaction.A Check any leaks from fuel pipes orfuel injection pipes. Use eyeprotection when checking for leaks. Be careful not to empty the fuel tank. Otherwise air may enter the fuel system, requiring fuel system bleeding. (See "FUEL" in "PERIODIC SERVICE" section.)B Color of exhaustWhile the engine is run within the rated output range:A The color of exhaust remains colorless.A If the output slightly exceeds the rated level, exhaustmay become a little colored with the output level kept constant.A If the engine is run continuously with dark exhaustemission, it may lead to trouble with the engine.B Immediately stop the engine if;A The engine suddenly slows down or accelerates.A Unusual noises are suddenly heard.A Exhaust fumes suddenly become very dark.A The oil pressure lamp or the water temperature alarmlamp lights up.REVERSED ENGINE REVOLUTION AND REMEDIESTo avoid personal injury:A Reversed engine operation can makethe machine reverse and run itbackwards. It may lead to serioustrouble.A Reversed engine operation maymake exhaust gas gush out into theintake side and ignite the air cleaner;It could catch fire.Reversed engine revolution must be stopped immediately since engine oil circulation is cut quickly, leading to serious trouble.B How to tell when the engine starts running backwards1.Lubricating oil pressure drops sharply. Oil pressurewarning light, if used, will light.2.Since the intake and exhaust sides are reversed, thesound of the engine changes, and exhaust gas will come out of the air cleaner.3. A louder knocking sound will be heard when theengine starts running backwards.B Remedies1.Immediately set the engine stop lever to the "STOP"position to stop the engine.2.After stopping the engine, check the air cleaner, intakerubber tube and other parts, and then replace parts as needed.8MAINTENANCE MAINTENANCETo avoid personal injury:A Be sure to conduct daily checks,periodic maintenance, refueling orcleaning on a level surface with theengine shut off and remove the key.A Before allowing other people to useyour engine, explain how to operate,and have them read this manualbefore operation.A When cleaning any parts, do not usegasoline but use regular cleanser.A Always use proper tools, that are ingood condition. Make sure youunderstand how to use them, beforeperforming any service work.A When installing, be sure to tighten allbolts lest they should be loose.Tighten the bolts by the specifiedtorque.A Do not put any tools on the battery,or battery terminals may short out.Severe burns or fire could result.Detach the battery from the enginebefore maintenance.A Do not touch muffler or exhaustpipes while they are hot; Severeburns could result.9MAINTENANCE SERVICE INTERVALSObserve the following for service and maintenance.The lubricating oil change intervals listed in the table below are for Class CF lubricating oil of API classification with a low-sulfur fuel in use. If the CF-4, CG-4, CH-4 or CI-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition. (approximately half)IntervalItemRef. page Every 50 hours Check of fuel pipes and clamp bands14@See NOTEChange of engine oil (depending on the oil pan)15 to 17 Every 100 hours Cleaning of air cleaner element 21*1@Cleaning of fuel filter14Check of battery electrolyte level 22,23Check of fan belt tightness 24Draining water separator-Every 200 hoursCheck of radiator hoses and clamp bands19Replacement of oil filter cartridge (depending on the oil pan)17Check of intake air line-@Every 400 hoursReplacement of fuel filter cartridge 15@Cleaning of water separator -Every 500 hours Removal of sediment in fuel tank -Cleaning of water jacket (radiator interior)18 to 20Replacement of fan belt24Every one or two months Recharging of battery22,23Every year Replacement of air cleaner element 21*2@Every 800 hours Check of valve clearance26Every 1500 hours Check of fuel injection nozzle injection pressure -*3@Every 3000 hoursCheck of turbo charger -*3@Check of injection pump-*3@Every two years Change of radiator coolant (L.L.C.)18 to 20Replacement of battery22,23Replacement of radiator hoses and clamp bands 19Replacement of fuel pipes and clamp bands 14*3@Replacement of intake air line-*4@10MAINTENANCEAThe jobs indicated by must be done after the first 50 hours of operation.*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 After 6 times of cleaning.*3 Consult your local KUBOTA Dealer for this service. *4 Replace only if necessary.A When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery's only)AThe items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S. EPAnonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.Please see the Warranty Statement in detail.AChanging interval of engine oil* 90 mm (3.54 in.) oil pan depth is optional.**Standard replacement intervalAAmerican Petroleum Institute (API) classification: above CF AAmbient temperature: below 35C (95F)Lubricating oilWith strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number (a minimum TBN of 10 is recommended).A Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed. : Recommendable X : Not recommendable* TBN: Total Base Number **FuelA Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emissionregulations for the area in which the engine is operated.A Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.A If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change the engineoil and oil filter at shorter intervals. (approximately half).A DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).A Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards, the use oflow sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA regulated areas.Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below -10 (14 ).1) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.% No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%A CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is NotRecommended for use in Kubota E3 specification engines.Models*Oil pan depth124 mm (4.88 in.)*90 mm (3.54 in.)D1503-M-E3 D1703-M-E3 D1803-M-E3 V2003-M-E3 V2203-M-E3 V2403-M-E3 V2403-M-T-E3200 Hrs 150 HrsInitial 50 HrsLubricating oil classification**FuelRemarks Low-sulfur High-sulfurCF *TBN10CF-4X CG-4X CH-4X CI-4X。

前言中国重汽WD615欧III发动机运用世界上最先进的设计手段和测试方法，在RICARDO公司庞大的数据库和富有经验的设计师的支持下，运用三维有限元、WA VE燃烧分析、CFD流体动力计算分析等软件和零部件测试设备，对重要零部件内部结构进行全新设计，对机体和缸盖的内部结构进行了质的改进，通过WA VE燃烧模拟及流体动力计算以及最佳的增压器匹配，合理地组织了燃烧室、喷雾和气流，对气缸体与缸盖的水流及热负荷进行了根本的改善，改善了热负荷和机械负荷，大大提高了抗震动性。

连杆、曲轴、活塞、活塞环、轴瓦等关键零部件在材料选用和关键结构尺寸进行了优化，其抗热冲击和机械冲击的能力大幅提升。

对提高可靠性，降低噪声，提升功率奠定了基础。

发动机B10寿命不低于12000小时，整机噪声低于97分贝。

采用第二代电控共轨喷油系统及四气门结构，优良的燃烧和充气使发动机获得了很高的动力性能。

在发动机的排量不变的情况下，发动机的最大功率可达294kw即400马力。

共轨压力稍作调整，加上必要的处理系统，即可满足欧IV排放要求。

整机的安装尺寸不变，大大方便了主机厂的匹配。

目录1．WD615欧Ⅲ柴油机主要技术性能指标和参数-------------------------------3 2．柴油机主要螺栓、螺母扭紧力矩和扭紧方法--------------------------7 3．1）机体、曲轴箱、飞轮壳------------------------------------------------------------------92)正时齿轮系-----------------------------------------------------------------------------113)主要运动件-----------------------------------------------------------------------------134)气缸盖与配气系统--------------------------------------------------------------------155)润滑系统--------------------------------------------------------------------------------186)冷却系统--------------------------------------------------------------------------------197)进排气系统-----------------------------------------------------------------------------208)排气泄气制动装置--------------------------------------------------------------------21 4.电控共轨燃油系统------------------------------------------------------------------231）传感器及继电器---------------------------------------------------------------------25 2）各种传感器的正常值----------------------------------------------------------------283)输油泵---------------------------------------------------------------------------314)油轨-------------------------------------------------------------------------------375)喷油器----------------------------------------------------------------------------40 5.拆装时的注意事项------------------------------------------------------------------441)油轨的拆装---------------------------------------------------------------------462)输油泵的拆装------------------------------------------------------------------513)喷油器的拆装------------------------------------------------------------------58 6.附件------------------------------------------------------------------------------------63WD615欧Ⅲ柴油机主要技术性能指标和参数3.WD615系列欧Ⅲ柴油机基本型型号表示WD 6 15. 3 XX机型特征号（一般用两位阿拉伯数字表示）指满足欧Ⅲ排放（公司内部机型无这一位）单缸排量约1.5L6缸水冷柴油机WD615欧III柴油机的结构特点由于柴油机具备高扭矩、高寿命、低油耗、低排放等特点，柴油机成为解决汽车及工程机械能源问题最现实和最可靠的手段。

欧Ⅲ（韩国）发动机功能及使用说明：一、输入信号：1、水温传感器2、燃油传感器3、增压压力传感器4、机油压力传感器5、曲轴旋转测定传感器6、凸轮轴旋转传感器7、共轨压力传感器8、车架联接线：9、启动开关10、离合器开关11、驻车制动开关12、脚制动开关13、巡航开关—控制车辆保持按照驾驶员设定的速度行驶14、巡航清零开关15、巡航状态选择开关16、怠速选择开关—根据驾驶员的需要调整发动机怠速转数17、门开信号开关18、排气制动开关19、故障诊断开关二、输出信号：A—输出到发动机1、喷油器2、CP-燃油计量装置B—输出到车架1、巡航/PTO选择开关2、预热继电器—控制安装在发动机吸气歧管里的空气加热器3、预热指示灯4、故障信息指示灯5、排气制动继电器6、发动机转数及车速指示灯7、发动机转速表及记录表8、诊断通信接口9、控制器区域网络（CAN）通信接口三、发动机安全功能：1、限制加速功能：防止汽车在车门打开的状态下开动车辆2、长时间处于怠速状态时发动机自动停止3、返回功能：发生故障时，在保证安全的状态下，以最低车辆行驶条件行驶到修理所的功能4、故障诊断5、行驶记录四、怠速调整三、踩住刹车踏板不放四、将巡航打开开关（C ON）按下2-3秒钟后放开五、点动巡航（怠速）调整开关（带上下箭头）将转速调整到需要值六、再将巡航打开开关（C ON）按下2-3秒钟后放开—保存调整好的数据七、放开刹车踏板五、巡航速度使用在行驶过程中要保持一定速度行驶(40-100km)，可将巡航打开开关（C ON）按下2-3秒钟后放开，这时车辆将对按下开关时的车速对发动机进行控制，使其维持在按下开关时车速行驶，如果对设定的车速不满意，可通过两个方式解决：1、点动巡航（怠速）调整开关（带上下箭头）小范围调整转速。

2、按压巡航关闭开关（C OFF），解除巡航设定，重新设定巡航速度。

六、发动机故障码清除1、按住检测开关不放2、关闭钥匙开关3、关闭总电源开关4、打开钥匙开关2秒钟左右后断开，2秒钟后又打开，重复10次—12次。

起动发动机养成在起动发动机之前必先直观检查发动机和发动机房的习惯。

这有助于你及时发现已经发生和将要发生地各种异常情况。

发动机起动后，还要检查仪表的示值是否正常。

起动之前·检查润滑油油位是否在MIN（最低）和MAX（最高）标记之间，见“润滑系统的维护保养”。

·打开燃油开关·确认冷却液、燃油或润滑油无泄漏·检查空气滤清器的阻塞指示器，见“发动机一般保养”。

·检查冷却液液位和散热器的外部有无堵塞，见“冷却系统的维护保养”。

警告提示！发动机高温时不要打开冷却液加液口盖，蒸汽或高温冷却液会喷射出来。

·接通主电源开关重要事项！发动机运行时切勿用主电源开关断开电源，以免损坏充电发动机。

·将发动机的转速设置在怠速，脱开分离式离合器/齿轮箱（如果装有）。

EDC4的起动方法起动前，必须将发动机的转速控制杆置于怠速位置。

EDC4系统保证发动机始终接受到精确地燃油量—即使在冷起动时。

起动发动机。

如果发动机装有预热器，预热时间可根据发动机的温度来调整。

严寒环境下起动发动机为有助于发动机的启动和一定条件下使发动机能够起动成功，必须作好以下准备工作。

使用经认可适用于当地气温的冬季燃油（知名品牌），这可以减少在燃油系统内产生蜡质沉淀的危险。

在环境温度极低的情况下，建议使用燃油加热器。

为了确保有足够的润滑，建议使用粘度适合于当地温度的合成润滑油，见“润滑系统的维护保养”：合成润滑油比矿基润滑油能适应更大的温度范围。

用外加配置的发动机电加热器预热冷却液。

在极端情况下，可能需要使用燃烧柴油的发动机加热器。

请向你的V olvo Penta 经销商咨询。

重要事项！确保冷却系统内已加注乙二醇混合液，见“冷却系统的维护保养”。

蓄电池必须处于良好状态。

低温会降低蓄电池的容量，可按需要增加蓄电池的总容量。

切勿使用起动喷射液警告提示！切勿使用起动喷射液或类似物品来帮助发动机起动。

TIM(技术信息手册)组别标题0概述11发动机11A发动机机械11B发动机机械12发动机润滑13燃油13A多点燃油喷射（MPI）<4B1>13B多点燃油喷射（MPI）<6B3>13C燃油供给14发动机冷却系统15进气和排气16发动机电气17发动机和排放控制系统21离合器22手动变速器23自动变速器23A无级变速器（CVT）23B自动变速器25传动轴26前桥27后桥31车轮和轮胎32发动机 - 变速器总成支架33前悬架34后悬架35行车制动器35A基本制动系统35B防抱死制动系统（ABS）35C主动稳定控制系统（ASC）36驻车制动器37动力转向42车身42A车身42B无钥匙操作系统（KOS）42C无线控制模块（WCM）51外部件52内部件及辅助乘员保护系统（SRS）52A内部件52B辅助乘员保护系统（SRS）(见下页)TIM(技术信息手册)(续)组别标题54底盘电气系统54A底盘电气系统54B本地互联网络（LIN）54C控制器区域网络（CAN）55暖风、空调和通风装置17-117发动机和排放控制系统CONTENTS发动机控制. . . . . . . . . . . .17-2加速踏板系统. . . . . . . . . . . . . 17-2自动巡航控制系统. . . . . . . . .17-2概述. . . . . . . . . . . . . . . . . 17-2结构和操作. . . . . . . . . . . . . . 17-5排放控制 . . . . . . . . . . . . 17-7概述. . . . . . . . . . . . . . . . . 17-7曲轴箱通风系统. . . . . . . . . . . . 17-13蒸发排放物控制系统. . . . . . . . . . 17-14 EGR 系统 <4B12 −装配 EGR 阀的车辆，6B31 −巴西版车辆> . . . . . . . . . . . . . . . . . . 17-16排放物还原装置. . . . . . . . . . . . 17-18目录第组发动机控制发动机和排放控制系统17-2发动机控制加速踏板系统M2170003000882对于加速踏板系统来说，采用电子节气门控制系统，去除了加速踏板拉线。

玉柴电控欧III 柴油机原理、使用和维护2004-8-251. 单体泵电控系统的基本工作原理1．1燃油喷射系统玉柴G6000电控欧III 柴油机采用目前世界上先进的电控单体泵燃油喷射系统，包括低压、高压燃油系统。

其中低压油路部分包括燃油箱、油水分离器和手油泵、输油泵、精滤器、单体泵总成、供油管、调压阀、燃油分配器、燃油温度感应器、回油管等构件，主要任务是燃油的吸入、过滤，并给单体泵提供足够量的0.4~0.7MPa 的低压燃油；高压燃油系统包括电控单体泵、高压油管和喷油器，主要任务是燃油的加压、分配和喷射。

电控单体泵在ECU 的控制下，将一定数量的燃油加压（高达160MPa 以上），并通过单体泵上的电磁阀接收来自ECU 的控制指令决定开启或关闭时刻，从而决定各个气缸当前喷射过程，即喷油压力、喷油量、喷油正时。

1．2电控系统电控系统是玉柴G6000电控欧III 柴油机的“神经中枢”，包括感应器、控制器、执行器和控制线束。

图1 欧III 柴油机电控单体泵燃油喷射系统燃油输油泵喷油器单体泵总成燃油 分配器油水分离器 和手油泵燃油滤清器出油箱回到油箱燃油进口燃油调压阀出口凸轮轴转速感应器单体泵电磁阀燃油温度感应器增压压力感应器冷却水温度感应器进气温度感应器控制器ECU曲轴转速感应器加速踏板感应器、车辆开关、执行器、电源等图 2 电控单体泵柴油机控制系统框图感应器：实时采集柴油机、车辆的运行信息并传递给控制器ECU，是ECU控制柴油机运行的基本信息。

考虑到对柴油机及车辆驾驶性能的控制，G6000电控欧III柴油机电控系统中配置的感应器有柴油机曲轴转速感应器、凸轮轴转速感应器、加速踏板感应器、增压压力感应器、进气温度感应器、燃油温度感应器、冷却水温度感应器以及空调、排气制动、怠速控制等开关。

感应器输入信号包括数字信号、模拟信号和脉冲信号。

控制器ECU：是电气控制部分的核心，它集中了柴油机和车辆的控制策略，通过接受感应器等传递的发动机信息，进行分析、判断和处理，并根据预先写入的控制策略和程序，向执行器（单体泵电磁阀等）发出驱动信号，除了管理喷油以外还具有其它一些功能如故障诊断、网络通讯、标定与监测等。

F o r p e s n a u s e o n y s u d y a n d r e s a c h n o f r c m me r c a u s eF o r p e s n a u s e o n y s u d y a n d r e s a c h n o f r c m me r c a u s e5MT车型自动启停系统（常规运用版）自动启停系统有助于节省燃油和减少尾气排放。

当车辆处于低速或静止状态时，发动机可自动停止。

车辆仅需踩下离合器踏板，发动机就会自动重新启动。

1.自动启停(Auto Stop/Start)启用条件：●自动启停系统未手动解除●发动机舱盖完全关闭●驾驶员侧车门关闭或驾驶员安全带系好（实车没检测安全带）●蓄电池电量充足且状况良好●发动机已变热（水温70℃以上），仪表温度指示约一半●发动机冷却液温度没有过高●环境温度没有过低或过高（车外温度）●温度控制系统没有禁用自动启停系统（电喷模块没有温度故障代码）●制动器真空度充足●发动机自动启动后，车辆已经以超过系统设定的最低速度行驶过（10Km/h以上）2.自动启停(Auto Stop/Start)功能启用步骤(满足上述条件后)：a. 第一次车速高于20公里/小时以后，（依据标准习惯）先踩刹车踏板减速b. 踩下离合器踏板到底c. 排档杆置于空挡d. 车速到0以后，松开离合器踏板e. 发动机自动关闭，进入停机状态，仪表发动机转速表指针指在“A uto Stop”自动停止位置●要开始前行：f. 踩下离合器踏板到底，发动机自行启动到怠速（不需使用钥匙再启动）Q1.可以先排进空挡，再踩离合器踏板，接着踩刹车踏板减速到停车（0公里/小时），最后松开离合器踏板，会进入自动停机吗？A.这种方式也会进入自动停机状态！Q2.可以先踩离合器踏板，再排进空挡接着松开离合器踏板，接着踩刹车踏板减速到停车（0公里/小时），会进入自动停机吗？A.这种方式也会进入自动停机状态！3.自动启停(Auto Stop/Start)功能解除（发动机自行再启动）：⏹开启空调行驶，依据上述步骤操作，当自动停机启用后，等待5分钟，发动机启动！⏹未开空调，依据上述步骤操作，当自动停机启用后，按下AC空调需求按键，发动机启动！⏹依据上述步骤操作，当自动停机启用后，开启驾驶侧车门，发动机启动！⏹依据上述步骤操作，当自动停机启用后，踩踏刹车踏板2次以上，发动机启动！⏹按下自动启停关闭开关（开关上黄灯启亮）⏹车辆滑动，发动机启动！⏹打开机盖，发动机启动！5MT车型自动启停系统（新手福音版）当新手驾驶手动赛欧3车型，因为离合器踏板与油门应用还不太配合时，造成发动机是在档位内（1,2,3,4,5，R档）发动机熄火，仅需再踩下离合器踏板就可以自行启动发动机。

SOFIM发动机地得意之作有两处：一是附件箱,前面已经介绍过；二是燃油供给系统,这正是SOFIM发动机与其它汽车柴油机地不同之处.一、供给系地组成与油路、气路任何一台汽车柴油机地供给系都由四部分组成：燃油供给、空气供给、混合气形成及废气排除装置.SOFIM发动机地燃油供给装置基本组成如图5-1所示.它由油箱、输油泵、低压油管、柴油滤清器、喷油泵、高压油管、喷油器及回油管等组成.还有起动预热油路.发动机工作时,柴油经过沉淀和滤清,被输油泵5从油箱中吸出并泵向柴油滤清器8,滤清后地柴油进入喷油泵3,从油箱至喷油泵进油管接头之前地油管均为低压油管.喷油泵将吸人地低压柴油加压,经高压油管11送入喷油器2内.喷油器则将高压柴油以雾状喷入燃烧室,与燃烧室内已被压缩地高温高压空气混合,自行燃烧.发动机工作中多余地柴油分别经喷油泵地回油管1和喷油器地回油管9流回油箱.在图5-1中还有一条油路尚未表示,那就是起动预热油路.当冬季汽车因低温难以起动时,只要冷却液温度低于规定值时,起动预热油路即接通,来自喷油器回油管路中地柴油经起动预热油路喷入发动机进气歧管进气口,因电热起动器地作用生成火焰,进而实现预热进气.图5-2、图5-3分别是SOFIM发动机地燃油供给油路和燃油供给管路系统.有关起动预热部分详见起动系统.SOFIM发动机地空气供给装置由空气滤清器、涡轮增压器、中冷器、进气歧管以及缸盖内地进气道组成.图5-4、图5-5分别是空气供给装置和气路.图5-4中没有表示中冷器.新鲜空气经过空气滤清器滤清后,被涡轮增压器吸入,因为经过增压器增压后地空气温度有所升高,所以,从增压器压气机流出地压缩空气又经管道流入中间冷却器,进行降温.这样,经过增压、降温处理地空气通过进气歧管流入气缸,增加了发动机每次循环地进气量.柴油机地混合气形成装置都是燃烧室.燃烧室地结构形式也很多. SOFIM发动机地燃烧室采用直喷式ω形.参见图2-69.直喷式燃烧室是由凹形活塞顶部与气缸盖底面所包围地单一内腔,其容积几乎都在活塞顶部.因此,直喷式燃烧室也称作统一式燃烧室.这种燃烧室柴油从喷油器直接喷入燃烧室内,借喷射油注地形状与燃烧室形状匹配,以及燃烧室内地空气涡流运动,迅速形成可燃混合气.在直喷式燃烧室中又可分为ω形、球型等结构型式.SOFIM发动机选用地是ω形.其燃烧室地活塞顶面呈ω形,配螺旋进气道,可以组织中等强度绕气缸轴线转动地进气涡流,发动机工作时,喷入燃烧室地柴油一部分散布在空间,另一部分被空气涡流甩至壁面上形成油膜.可见,其可燃混合气地形成以空间混合为主.一部分柴油在空间先形成混合气发火燃烧,而壁面上地油膜吸收先燃烧地混合气热量也逐层蒸发,雾化,相继作好燃烧前地物理化学准备进行燃烧.因此,采用ω形燃烧室地柴油机起动性能较好.ω形燃烧室具有形状简单、易于加工；结构紧凑、散热面积小、热效率高等特点.但同时我们也清楚ω形燃烧室要求高,主要是喷油压力较高,SOFIM发动机喷油系统地喷射压力为24MPa；要求使用加工精度高地孔式喷油器；还要求喷注地形状、射程、锥角等必须与燃烧室地形状相匹配或吻合. SOFIM发动机为了解决汽车冬季起动困难地问题,采用了辅助热起动措施,这就使得该机起动性能良好地优点更加突出,更加完善.废气排出装置由气缸盖内地排气道、排气歧管、涡轮增压器以及排气消声器组成.见图5-6及图5-5.发动机工作时,燃烧室地废气在排气压力地作用下,经排气道和排气歧管,冲击涡轮增压器地涡轮壳,高温高速地废气气流将能量传递给涡轮,并通过涡轮带动压气机,以便吸入滤清过地新鲜空气.通过涡轮地废气再经排气消声器地平衡、降压、降噪排入大气.在供给系中还有油门操纵装置.汽车在使用过程中,经常需要改变车速或功率,这些都要依靠对供油系统地控制和调节以及操纵来实现.驾驶员欲改变车速或功率时,通过油门踏板带动加速拉丝等一系列传递部件控制调速器,再由调速器根据转速控制油量控制滑套,调节喷油泵地喷油量,进而改变可燃混合气地浓度和数量,从而达到改变汽车车速或功率地目地.油门操纵装置见图5-7.二、供给系各总成结构1.油箱SOFIM发动机油箱装载容量是70升.布置在底盘支架地左侧.如图5-8所示.油箱由薄铁皮冲压焊接而成,内焊隔板.油箱上部设有加油管,管内带有可拉出地延伸管,管地底部有滤网,加油管一般由油箱盖盖住.油箱表面上还装有油量传感器和出油开关,出油开关经低压油管与柴油滤清器相通.油箱底部有磁性放油螺塞.为了防止柴油在行驶中因振荡而溅出等,油箱是密闭地,但柴油输出过多油面降低将产生真空度,这会影响供油系统地正常工作.为此,SOFIM发动机在喷油器地回油管路口串联一个油箱吸气阀,以保证油箱在必要时能与大气相通.参见图5-1.2.输油泵输油泵是低压油泵.它地作用是将柴油从油箱输送到喷油泵.因此它必须有足够地输油量和适当地压力.SOFIM发动机地输油泵是膜片式地,安装在附件箱上平面,由喷油泵驱动轴上地偏心凸轮驱动.参见图5-9和图2-66.发动机工作时,喷油泵驱动轴上地偏心凸轮旋转,通过推杆使输油泵地摇臂摆动,摇臂地另一端与泵膜组件地拉杆相连接,因此,拉杆带动膜片上、下往复运动.当膜片下移时,柴油经进油阀被吸人腔内；当膜片上拱时,柴油又经出油阀流出,流向柴油滤清器.当发动机长时间停机后欲再起动时,可通过手摇臂推动手泵动作.此前应先将柴油滤清器和喷油泵地放气装置打开,反复抽动手泵驱除系统内地空气,并将柴油泵入柴油滤清器和喷油泵.一般喷油泵地供油量总是小于输油泵地供油量,因此,多余地柴油经回油管流回油箱.3.柴油滤清器柴油在运输、贮存过程中,不可避免地混入灰尘、水分、机械杂质,还会生成胶质.为了保证供油系统中精密偶件不被卡死,减少运动部件地磨损,防止系统锈蚀,延长喷射装置地使用寿命,除了在使用前将柴油严格沉淀外,在供油系统中还必须装置柴油滤清器.SOFIM发动机采用地滤清器是双体式柴油滤清器.两个柴油滤清器串联而成,装在整体式滤清器盖上,两者间用密封垫圈密封.参见图5-3.盖上还有进、出油口和油道以及放气螺塞.滤芯总成由外壳、滤芯、中心油道和放水螺塞组成.两外壳底部装有积水传感器.滤芯采用折叠滤纸在中心油管外缠绕而成,来自输油泵地柴油从滤芯上端流入,经滤纸过滤后从滤芯下端流出,再沿中心油管流走.滤芯外壳底部可沉积水分,一旦积水达到规定值,积水传感器地警告灯则亮,此时应旋松放水螺塞,积水即可沿放水螺塞上地轴向凹槽排出.4.喷油泵喷油泵是高压油泵.其功用是按照柴油机地工作循环和发火次序定时、定量地向喷油器输送高压柴油.喷油泵地结构型式很多,SOFIM发动机采用地是德国波许公司(BOSCH>生产地VE型轴向压缩式转子分配泵.图5-10(a>、(b>分别是SOFIM 发动机采用地VE4/11F1900R294型喷油泵地纵剖面和装用VE泵地柴油供给系统示意图.该泵采用单柱塞、端面凸轮、滚轮机构、带有机械式全程调速器,泵内还装有供油提前角自动调节机构和叶片式输油泵.VE泵地结构与工作原理较复杂,下面分别述之.1>叶片式输油泵：叶片式输油泵装在泵地前端,与传动轴键连接.柴油机工作时,曲轴通过正时齿轮、齿形皮带、喷油泵正时齿轮驱动喷油泵驱动轴(也称附件箱主轴>,参见图2-66.而附件箱主轴又通过内、外齿套带动传动轴旋转.叶片式输油泵有四个叶片,油泵转子每转一周,完成一个输出和吸入定量柴油地循环,泵油地压力由调节阀控制,当压力超过规定值时,柴油便从调节阀地入口处分流.叶片式输油泵地结构及油路见图5-11(a>、(b>.2>分配泵地结构与动作过程：传动轴1支承在铝合金压铸地泵壳上,端面凸轮即凸轮盘4与分配转子5连成一体,通过联轴节3与传动轴相连.分配转子通常称柱塞.因为柱塞回位弹簧12地作用,参见图5-10(b>.凸轮盘4和柱塞5始终抵靠在滚轮环2上地滚轮上.凸轮盘4左侧端面上地凸峰数与发动机缸数对应.当传动轴1旋转时,凸轮盘4地凸峰若与滚轮相抵靠,凸轮盘4和柱塞5因受推力而向右移动至极限位置；若凸峰转过,柱塞回位弹簧又使凸轮盘4左移,直至端面凸轮地凹谷与滚轮相抵靠为止.就这样柱塞既随传动轴连续转动,又不断地受凸轮盘地作用左右移动.凸轮盘每转一周,柱塞也转一周,其间又各向左右移动四次,从而完成了进油、泵油和配油.其结构见图5-12.3>分配泵地工作原理. VE型分配泵地工作原理分为四个过程：(1>进油过程.如图5-13(a>所示.柱塞4地右端均布四个进油地轴向槽12；在与出油道相对应地柱塞断面上均布四个出油地分配孔7；轴向槽12与分配孔7相错45°,即进油道1与轴向槽12相通,则分配孔7与出油道8相隔绝.油量控制滑套6在调速器起动杠杆2地作用下可在柱塞4上滑动.当柱塞左移时,分配孔7与四个出油道相隔绝,泄油孔5被油量控制滑套6封死,压缩腔容积增大,产生真空度,四个进油轴向槽中地一个对准进油道时,来自叶片式输油泵地柴油便在真空度地作用下经泵体进油道1、进油阀13、轴向槽12流入压缩腔,并充满柱塞纵油道.(2>泵油过程.如图5-13(b>所示.当柱塞4转动时进油口关闭,凸峰转起与滚轮抵靠,柱塞右移,泄油孔5仍被封死,压缩腔11容积减小,油压增高,分配孔7与相应地出油道8相通,高压柴油即推开出油阀9向喷油器10供油,再经喷油器喷入燃烧室.因为柱塞回转,柱塞上地分配孔依次与泵体上地四个出油道相通,并按气缸作功顺序分配柴油.(3>喷油结束.如图5-13(c>所示.柱塞在凸轮盘地作用下继续右移,当柱塞4上地泄油孔5与压缩腔11相通时,压缩柴油迅速经泄油孔5流回泵壳内,油压急剧下降,出油阀9在出油阀弹簧作用下迅速左移关闭,停止向喷油器供油.停止泵油过程持续到柱塞向右极限位置.因此VE泵每次循环最大泵油量取决于柱塞地直径和最大有效行程.(4>均压过程.参见图5-13(b>.柱塞上还开有压力平衡槽15.当柱塞转动180°后,该槽对准出油道,使出油道中地燃油压力与泵壳内地油压相平衡,这将有助于改善各缸分配地不均匀性.(5>发动机熄火.如图5-13(d>所示.当需要发动机停车熄火时,可转动点火开关,关闭电磁阀电路,线圈对阀芯即进油阀吸引力消失,弹簧件张,进油阀下移关闭泵体进油道1,停止供油,则发动机熄火.起动发动机时,也必须先打开点火开关,接通电磁阀4地电路,吸起进油阀,打开进油道.4>分配泵地供油提前角自动调节器：供油提前角自动调节器安装在泵体下部,其结构如图5-14(a>、(b>所示.柱塞5通过连接销4、传动销3与滚轮架7相连,因而柱塞5地往复运动便转化成滚轮架7地旋转运动.滚轮架7上装有与缸数相同地滚轮1.柱塞地右侧与泵腔相通,左侧与柴油滤清器地油道相通.当发动机在常用转速下工作时,叶片式输油泵输送至泵腔内地低压柴油流到柱塞右腔,柱塞受到低压柴油向左地推力与柱塞左侧向右地弹簧力及来自滤清后柴油压力之合力相平衡.当发动机转速升高时,叶片式输油泵地泵油压力也随之升高,柱塞5两端受力失衡而左移,经连接销4、传动销3推动滚轮架7绕其轴线顺时针转过某一角度,使凸轮盘地凸峰提前一个角度与滚轮1相接触,使VE泵地供油时刻提前.反之,迟后接触,使VE泵供油时刻迟后.5>LDA气动供油量调节装置：LDA装置也有人称为增压补偿器.其作用是根据进气歧管内地增压压力地大小,自动增加或减少各缸地供油量,以提高发动机功率和燃料经济性,并减少有害气体地产生.其结构如图5-15所示.橡胶膜片固定在LDA装置上,下体之间,将装置分成上,下两腔.上腔与进所歧管相通,由废气涡轮增压器形成地增压空气作用在膜片上表面,下腔经通气孔与大气相通.膜片1与调节销4联成一体,其下面呈锥形,传动销5可在其锥面滑动.补偿杆6地上端与传动销5相靠,且可绕销轴7转动.当进气管中增压压力升高时,LDA地上腔压力大于弹簧2地弹力,使膜片1连同调节销4一同向下运动,下腔空气经通气孔排气,与调节销相接触地止动杆便绕销轴7转动,带动调速器地张力杠杆等油量调节机构,使供油量适当增加,发动机功率增大.反之,供油量则减少,发动机功率降低.5.调速器VE泵每次循环地供油量主要取决于分配转子地直径和最大有效行程,对于规格已定地VE泵,其直径已定.故在使用中供油量与有效行程有关.此外,还受发动机转速影响.转速增加将使供油时刻略有提前；反之,供油时刻稍延迟.为了克服喷油泵在油量控制滑套位置不变时,供油量随转速变化地特性,柴油发动机上都采用调速器.SOFIM发动机采用地是机械离心式全程调速器,它不仅能稳定怠速和限制超速,而且能控制在允许转速范围内地任何转速下稳定工作.其结构如图5-16所示.传动轴5通过调速器啮合齿轮4将动力传给调速器飞块.预调杠杆14可绕安装在泵体上地支承销O1转动,起动杠杆9支承销O2安装在预调杠杆14上,起动杠杆9和张力杠杆11均可绕其转动,在起动杠杆9地下端固装着一个嵌入油量控制滑套7凹槽内地球形销.当起动杠杆9摆动时或张力杠杆11推动起动杠杆9摆动时,球形销拨动油量控制滑套7在分配转子上作轴向移动,从而改变了泵油量地大小.操纵杆1地下端偏心安装着一个销轴,调速弹簧16地左端挂在偏心轴地连接板上,右端通过怠速弹簧12与张力杠杆11相接,在调速弹簧16地拉力作用下,张力杠杆11绕O2逆时针转动,从而推动油量控制滑套7向右移动,使供油量增大.反之,在离心飞块2和推力滑套3作用下,通过起动杠杆9、起动簧片10,又可使张力杠杆11绕O2顺时针摆动,使油量控制滑套7向左移动,使供油量减小.由此可见,离心式调速器地工作原理是利用飞块地离心力与各种弹簧相互作用,移动油量控制滑套,从而控制发动机转速.调速器地工况有几种：1>起动加浓工况.起动工况如图5-17(a>所示.打开点火开关,电磁阀5通电,柴油流入压缩腔.此时,飞块处于向心位置,操纵杆被推至全负荷供油位置,在调速弹簧和起动簧片地作用下,张力杠杆6推动起动杠杆2绕O2逆时针方向转动,将油量控制滑套3推向右极限位置,即加浓位置.使VE泵柱塞地整个行程成为有效供油行程.2>怠速稳定工况.怠速稳定工况如图5-17(b>所示.发动机起动后,释放油门,将操纵杆推至怠速位置.因为飞块离心力地作用,飞块1张开推动推力滑套2右移,推力滑套2推动起动杠杆3压缩起动簧片4,与张力杠杆8相接触,怠速弹簧7被压缩.此时,油量控制滑套5上作用有：向右地推力滑套地推力和向左地起动簧片和怠速弹簧地弹力,三力相平衡油量控制滑套便稳定在某一位置,发动机就在相应地怠速下稳定运转.即获得怠速供油量.3>中间转速地调节：当把操纵杆由怠速位置向最大供油量方向推至某一位置时,逆时针转动,推动油量控制滑调速弹簧9被拉伸,参见图5-17(b>,整个杆系绕O2套右移,供油量增大,发动机由怠速工况转入中间转速工况.此时,发动机转速升高,飞块离心力增大,推力滑套右移.油量控制滑套上作用有调速弹簧地向左拉力和推力滑套向右地推力,两力平衡,发动机地转速便稳定在某一转速上,在操纵杆位置不变情况下,若发动机外界阻力变化导致转速变化时,调速过程同前.4>限制最高转速.当把操纵杆推至最大供油位置时,则发动机进入全负荷状态,此时,推力滑套向右推力和调速弹簧向左拉力平衡,发动机地转速为规定地最大转速.若发动机因外界阻力变化而引起超速时,离心飞块只能张至离心飞块罩内圆面为止并与之相靠,同时,推力滑套右移,油量控制滑套左移,使供油量减少,从而限制发动机超速.6.喷油器喷油器地功用是将喷油泵提供地高压柴油按一定要求雾化,喷入燃烧室.因此,喷油器必须具有一定地喷射压力和射程,以及合适地喷注锥角.另外应断油迅速不滴漏.SOFIM发动机所用喷油器为波许(BOSCH>公司生产地DLLA型4孔喷油器.其结构如图5-18所示.喷油器由喷油器体2、螺套10、针阀组件、调压弹簧11、对中圈6、回油螺钉1等组成.喷油器体2地上端有进油螺纹口,侧面有回油螺钉口,并与体内回油道相通.体上还加工有倾斜地纵向油道.对中圈6装在螺套10内,该圈有两个空心定位销孔,一个与体内进油道相通地通油孔,还有对中地中心孔.弹簧座以此为安装中心,调压弹簧11装在座上.两个空心定位销是回油通道,少量漏出地高压油从针阀组件地配合间隙挤出,沿空心定位销6内流至体内回油道,经回油螺钉1流回油箱.针阀体8上也有两个定位销孔,中心装配针阀9,该销孔与对中圈5联接,与对中圈通油孔相应,针阀体8上也加工有进油道.针阀体8底部是4个直径为0.296mm地喷孔.当发动机工作时,喷油泵将高压油送至喷油器进油管接头,高压油沿体内油道流至针阀9中部地环状空间—高压油腔,油压作用在针阀锥面上形成一个向上地轴向推力,当此力克服调压弹簧11地预紧力后,针阀9上移,打开喷孔,高压油即喷射到燃烧室.当喷油泵供油停止,油压下降时,针间在调压弹簧11作用下及时回位,将喷孔关闭.7.空气滤清器空气滤清器地作用是清除流入进气系统地砂粒与尘土,保护发动机地气缸、活塞及活塞环,延长发动机地使用寿命. SOFIM发动机使用地空气滤清器为干式过滤式.其结构如图5-19所示.滤芯2是用树脂处理地微孔滤纸作成地.其上下两端用密封圈4密封.发动机工作时,空气由进气口流入外壳1内,经纸滤芯滤清后,经出气口流向增压器.空气滤清器上装有堵塞传感器,一旦滤芯被堵,仪表板处地警告灯亮,提醒驾驶员更换滤芯.参见图5-4.8.进、排气歧管进气歧管地功用是将来自增压器地空气分别送至发动机地各个气缸.排气歧管地功用是将各缸燃烧后地废气集中后送至排气消声器,再经排气管排出.SOFIM发动机地进、排气管地结构参见图5-4、图5-6.进、排气歧管一般由铸铁制造,然后用螺栓分别固定在机体上.增压发动机因增压器不仅与进气系统相连接,还要利用废气余能,所以,将进、气歧管布置在机体地同侧,而非增压发动机地进、排气歧管则布置在机体两侧. SOFIM发动机进气歧管前端有连接凸缘,以便与增压器相接.各支管出口与缸盖进气道相通.排气歧管地前端上方也连接凸缘,直接与增压器管路相接.各支管出口与缸盖上地排气道相通.进、排气歧管与机体固定时,装有密封衬垫.9.排气消声器废气在排气管中流动时,因排气门地开闭和活塞地往复运动,气流呈脉动形式,并且具有一定能量.排气消声器地功用就是消耗废气能量、减少噪声、消除废气地火焰.消声器及排气管参见图5-4.消声器结构如图5-20所示.外壳1用薄钢板卷成筒形,内管4为多孔管,通过几块隔板3支承于外壳内,前后端分别与排气管、排气尾管相接.排气尾管直通大气.废气排入消声器后多次往返多孔管4、消音室5,这样废气受到反射,并膨胀冷却,最终废气压力减弱,噪声显著降低。

Sofim Diesel EngineSOFIM8140.43/23/45系列欧Ⅱ排放发动机SOFIM系列发动机具有世界先进的设计和卓越的特性，是意大利IVECO公司的骄子，始终保持世界一流水平的技术性和可靠性。

南京依维柯汽车有限公司发动机分公司更是重视产品研发的力度。

1996年开始，在原有8140.27S直喷增压柴油机的基础上，追加投资3亿人民币以开发新品，提高产品质量，成功推出体积小、性能优、排放好的8140.43和8142.43型2.8L直喷增压中冷柴油机，功率超过87Kw，最大扭矩可达269Nm，顺利通过了意大利IVECO试验中心2000小时强化试验和可靠性试验。

根据GB17691-2001和北京DHJB3-1999第二阶段要求的标准测试，其排放指标低于国家排放及北京地方排放法规的规定值，全负荷烟度符合GB14761.7-1993、DB11/046-94标准，完全达到“欧洲Ⅱ号”排放标准，并通过生产一致性认证，是具有国际先进品质的、成熟的环保柴油机，2004年又成功地向市场推出了符合“欧洲Ⅱ号”排放适用范围更广的8140.45型3.0L直喷增压中冷柴油机, 功率超过95Kw，最大扭矩可达300Nm，为中国南京IVECO汽车和欧洲、非洲、东南亚地区及国内一些享有知名度的中高档整车提供了更环保、更强劲的动力保障。

SOFIM8140.43S/43N系列欧III排放发动机SOFIM 8140.43S/43N系列发动机是南京依维柯汽车有限公司研制、生产的第3代柴油发动机，它是在SOFIM 2.8升柴油机的基础上采用当今世界上最先进的柴油机共轨电子控制燃油喷射和可变喷嘴增压器以及增压中冷等技术，利用发动机进气、燃油供给、冷却等系统上的各种传感器测量发动机的工作参数，通过电子控制单元ECU进行精确的计算，并精确地控制喷油量和喷油提前角，使发动机在各种工况下都能以最佳状态工作，从而有效地控制排放，降低发动机噪音。

第二部分玉柴欧III 发动机使用、保养及相关注意事项1. 发动机的操作此处只是列出电控发动机与传统的机械泵发动机不同的或应加以注意的步骤、方法和注意事项，其它步骤、方法和注意事项与传统的机械泵发动机相同。

1.1 起动发动机•将车辆的电源总开关闭合（若车辆无此开关则省略此步骤），再按常规起动方式与注意事项起动发动机。

•起动时踩油门是不允许的，也是没有用的。

•冷起动：在较冷的环境下，起动操作与常规一样，但是发动机的控制器会根据环境温度以及车辆上的附件发出一些控制指令，以利于起动顺利，发动机在起动过程中的动作会有所不同。

如：控制器可自动控制喷油提前角、喷油量、是否喷油；可自动控制进气预热器进行预热和后热；可自动控制排气制动阀、起动马达来帮助起动；这些控制动作将有利于发动机的顺利起动，使电控发动机的起动性能大大优于传统的机械泵发动机。

当然，由于不同的车辆提供给控制器控制的附件不同，因此控制器采用的起动控制策略（方法）也不尽相同。

在起动过程中若有预热，则预热指示灯会亮。

1.2发动机和车辆的操作•车辆起步：按常规操作，避免在高速档位上起步, 尽量档起步。

•加速油门踏板的操作：按常规操作，但在一些条件下，控制器为了保护发动机免受过热、过载的伤害，或为避免发动机冒烟，猛踩踏油门并不能得到想象中的急速加速。

•换档点的推荐：为了使发动机获得更好的动力性和更省油，建议发动机的换挡转速应在1200-2000 转/ 分钟左右。

•涉水行驶的注意事项：当车辆过积水路面时，车辆应遵循以下规定，避免电控系统因进水而受到损害和失效。

原则上控制器离水面的高度应超过200mm并且在水面接近此高度时车辆应以小于10公里/小时的时速通过，在路面积水较浅时车辆亦应慢速通过。

•排气制动：按常规操作，若车辆的排气制动装置由发动机的控制器控制时，必须满足如下条件排气制动才能执行。

♦油量需求为零（意味着不能踩油门踏板）♦发动机转速高于某个转速（此转速通常较低）♦如果将来车辆生产商需要将排气制动与车辆缓速器或变速箱等动力装置的控制相关时，排气制动还需取决于这些装置的情况，由控制器自动判断是否执行。