WD615

WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
注意事项
Points for Attention
1、本柴油机出公司时已按试验规范严格进行出公司试验，油门已铅封
限位，不得随意拆除铅封，加大油门。否则，我公司将不实行三包，敬请用户注
意。
1. This diesel engine has been tested strictly in accordance with the test
stipulations before delivery. The accelerator is lead sealed and limited. It is not
allowed to remove the lead seal and to expand the accelerator privately. Or our
company will not be responsible for guarantee of repair, placement and return of
the product. Please pay your attention to it.
2、用户在使用新机时，应进行 50 小时试运转 .
The user shall conduct a 50 hours run-in of the new engine
before operation.
3、柴油机冷车起动后应慢慢提高转速，不要猛然使它高速运转，也不要长时间
空转。大负荷运转后，不要立即停车，应低速空载运转 5 ～ 1 0 分钟后停车。
Provided the diesel engine is started from the cold state, its rotary speed
shall be increased gradually, rather than making it operate at high speed suddenly
or idle for a long time. At the end of running with heavy load, do not shut down
the engine immediately (other than under particular circumstance), but run at low
speed for 5 to 10 minute, then shut it down.
4、停车后，如果环境温度有可能低于 0℃而且未使用防冻添加剂时，应
将水箱和柴油机内的水放净。
After the engine is stopped, if the environmental temperature is lower than 0 ℃ and
no anti-freeze additive is used, the water in water tank and in diesel
engine should be drained off.
5、禁止柴油机在无空气滤清器的情况下工作，防空气未经过滤就进入
气缸。
Do not allow the diesel engine to operate without air filter for the sake of
10‐1
avoiding the air from entering into the cylinder directly without filtering.
6、向柴油机添加燃油和机油时，必须选用规定的牌号，并采用专用的
清洁容器，加入时都要经过滤网过滤。燃油要经过沉淀 72 小时以上。
The brands of engine oil or fuel added to the diesel engine shall comply
with the provision of Operation and Maintenance Manual, and be filtered by the
special filters. The fuel needs more than 72 hours sediment.
7、电气系统各部件的检修必须由熟悉电气知识的人员进行。
The inspection and repair of all the components in electric system shall be
done by professional electric technical personnel;
8、为防止锈蚀，柴油机出公司时进行油封，一般柴油机的油封期为一
年，凡超过一年的应进行检查并采取必要的补充措施。
For the sake of preventing corrosion, the diesel engine is oil sealed before
delivery from our company. Generally the oil seal period is one year. If the oil
seal period exceeds one year, inspection and necessary actions should be taken.
9、柴油机的功率修正按 GB ／ T18297，参见表 16。
The power of diesel engine is correct as per GB/T18297 by referring Table 16.
10、发动机质量信息反馈
Feedback of engine quality information
我公司对 WD6l5 系列柴油机产品实行质量跟踪建档，用户在使用产品
时请按卡片要求填写寄回我公司。凭卡建立用户联系关系。
The manufacturer has established quality files for WP615 series diesel
engine. Please fill in the card and post it to us，we will contact with user
according to the card．
11、在维修、更换发动机零配件时须知：
Notice to repairing and replacing parts:
WD6l5 系列柴油机产品，是高性能的柴油机，用户在维修时
请按WD6l5 系列柴油机零件图册和维修手册的诸项要求进行工作，但购
买有关零配件，必须采用主机厂鉴定认可的产品，以确保其性能，可靠性
和寿命。
WP615 series diesel engine is of high performance product. Maintenance
should be done in accordance with WP615 series diesel engine parts
10‐2
catalogue and specifications of maintenance manual. Purchased parts

must have ap-proved by us in order to ensure performance，reliability and
service life．
10‐3
Maintenance Manual for WD615 Series EuroⅡDiesel Engin
1．柴油机使用说明
Usage Instructions
1.1 新柴油机使用须知
Operating notice for new diesel engine
车用柴油机，在汽车使用的最初2000km（约60h）内应限制柴油机转速不超过标
定转速的80%。
For vehicle engines, the engine's rotating speed shoule be limited within 80% of its
rated speed during its initial 2000km running (approximately 60h).
新机经初期使用磨合后，需要更换机油，否则可能造成柴油机零件韵过度
磨损或损坏。正确地维护保养将使您的柴油机有更好的性能、更经济的运
转及更长的寿命。
The lubricating oil should be replaced after the primary running period，
otherwise the engine parts possibly be over worn or damaged．Proper
protection and maintenance will —ensure your engine with better
performance，more economical and longer service 1ife．
· 首次换油期的规定
对于年行驶里程不到 2 万公里的汽车，首次换油期：1000-1500 公里。
对于年行驶里程超过 2 万公里的汽车，首次换油期：1500-2000 公里。
每日检查油温表、油压表、报警装置和其它仪表，确保它们正常能工作。
First oil change period:
For vehicle the annual running mileage is less than 20,000km the first oil
change perild is
1,000-1,5000km.
For vehicle the annual running mileage is less than 20,000km the first oil
change perild is
1,500-2,000km
按说明书中要求进行日常维护和保养。
Perform daily maintenance work as specified in this manual.
1.2 柴油机的启封工作
Unpacking the Diesel Engine
1、当您打开您的柴油机包装箱之后，首先按文件清点柴油机及随机附
件，检查柴油机外表有无损伤，然后进行下述工作：
When opening the packing of engine, you should firstly check the surface of
engine and the amount of accessoried as per packing list, then proceed on as
following;
2、擦试外露件的防锈层、防蚀剂等。
Clean the anticorrosive coating and preservative of outer parts.
3、放出燃油滤清器及燃油系统零件内部油封油（也允许燃油系统的油封
1‐1
不经入出而启动，但必须等燃油系统油封油消耗完正常柴油已供应到才允
许发动机满负荷运行）。
Drain off the seal diesel oil from fuel filters and ruel supply system (the
engine is also allowed to be started before seal diesel oil draining, but not
allowed to be operated at full load until the seal diesel iol of fuel supply
system has been used up and the usral fuel has been provided)
4、转动飞轮并向进气管内喷溶剂到驱尽气内油封油为止。
Turn the flywheel and inject solvent to air intake manifold till the seal oil
of cylinder has been drained off.
5、向增压器排气口溶剂，直到驱尽油封油为止。
Inject solvent to the air outlet of turbocharger till the seal oil has been
drained off．
6、根据厂方与用户的协约，对油底内未注油的应按规定注油。
As per the agreement between Weichai and the customer，the engines
supplied with empty oilsumps should be filled with oil．
7、按厂方与用户的协议，出厂据用户需要，已加注满冷却液的应检
查冷却液的性能，
如果防冻能力满足 -30℃或 -35℃时，其 pH 值为７－８（中性），总
硬度值为５－１５０d[9-27℃ f( 硬度 )] 则可以使用这些冷却液，如不
合乎要求，则应放出，重新加注含冻剂的冷却液，发动机加约 40 升冷
却液。
As per the agreement between Weichai and the customer,and as
per customer’s requirementbefore delivery，coolant performance
should be checked if the engine has been filled up with coolant.The
coolant could be remained to use if its antifreezing performance could
meet-30℃ or-35℃ and pH is 7-8(1itmusless)，and its total rigidity
number is 5-15° d【9-27of(rigidity)]，otherwise it should be drained off
and replaced by new coolant containing antifreeze．Thevolume of
coolant filled to engine is approximately 40 liter．
1.3 起动前的检查
Inspection before starting
检查冷却液面
Inspect the coolant level．
检查燃油液面
Inspect the fuel level．
检查发动机机油液面
Inspect the lubricating oil level．
1.4 柴油机的起动
Starting
1‐2
将电源开关、电钥匙处于起动位置
Put the power switch and starting key at the starting position·
变速杆处于空档位置
Put the gearlever at empty gear-matching position．
踩下离合器踏板和油门踏板，然后拉动过量燃油装置的拉手开关 ( 若装有此
装置的话)，并操纵起动机，当发动机起动后应将过量燃油装置的拉手开关复
位，若发动机起动不了，则待约1分钟后再重复上述操作，发动机起动后，机
油压力表应立即显示压力，起动热发动机时，可不必使用过量燃油装置。
Step down footplate of clutch and footplate of accelerograph，pull the handle
of extra fuelsupply device for starting(if have)，and starting the engine．The
handle of the device should bereset after engine's started·If the engine can，t be
started，repeat the above operating after about l minute．Oil pressure gauge
should immediately indicate number values after engine started．The extra fuel
supply device for auxiliary starting device should not to be used during starting
in thermal state．
低温起动
Low temperature starting
装有电子控制火焰预热起动装置。
With electronic control flame preheating device
发动机水温低于 -23℃时，打开钥匙开关，预热指示灯亮，电热塞通电加
热，经 50S
后预热指示灯自动闪烁。电热塞已加热到 850-950℃，按下起动按钮，接通起
动机，电磁
阀自动打开油路，给电热塞供油，进行火焰预热起动，可使发动机在 -25℃下
顺利起动。
When the temperature of coolant inside the engine is lower than-23 ℃，turn
on the electronickey，the preheating indicator lighting，the heating plug is
heated，and the preheating indicatorwill be automatically flickered after
50S． When the heating plug is heated to 850-950 ℃， pressdown the
start button，connect the starter，the electromagnetic valve will be
automaticallyopened，and the heating plug will be provided with fuel to
proceed flame preheating，and theengine can be easily started under-25 ℃．
带有低温辅助起动装置
With low temperature auxiliary starting device
装有低温辅助起动装置的汽车上都备有一瓶起动燃料，它不能在 50℃以
上的温度下保存，在夏季应将它放在阴凉处，注意防火。
One bottle of starting fuel will be provided with the truck
which fitted with low temperatureauxiliary startlng device.It can't be
preserved when the ambient temperature is higher than 50℃．To prevent from
1‐3
fire，it should be put at a cool place in summer.
起动过程：
Starting process：
将起动燃料注入驾驶室仪表板下的储液罐里，在接通起动机之前，先将手
泵来回泵三下，接通起动机，在发动机转几圈后，连续拉动手泵，直到发
动机起动，但不要在发动机起动之前过多拉动手泵；气温很低时，发动机
起动后还要继续拉动手泵，直至发动机运转平稳，该装置能使发动机在一
40℃低温时顺利起动。
Input starting fuel to the tank under the instrument plate in the driver-cab，pull the
hand pump three times before connecting the starter，after the engine run several rotations
continue to pull the hand-pump till the engine started，but don，t pull too many times before
starting in the case of very low temperature，continue to pull the hand-pump after starting till
the engine runs smoothly．With this auxiliary device，the engine can be started easily
under-40℃ .
1.5 柴油机的运转
Engine's running
柴油机在低于最大扭矩的转速下，全油门持续运转不超过 1 min。
When the engine running at the speed lower than the speed of the biggest
torque，it is notallowed to continue running on full load over l min．
柴油机全负荷运转后，停车前要怠速运转 3-5 min。
After running on full load，the engine should run in idling speed for 3—5
minutes beforestopped．
经常注视油压表及冷却液温度表：
Often watch and check the oil pressure gauge and coolant temperature
meter．
若压力和温度不符合规定要求时应该将柴油机停车。
Stop the engine if the pressure and temperature cannot meet the standard
requirement．
注意：在冷却液温度低于 60℃或高于 100℃时连续运转将有损于发
动机。
Note：Diesel engine can not continue to run when the coolant
temperature is lower than 60℃ or higher than 100℃，because this
would damage the engine．
柴油机的停止
Engine'S running stop
拉动喷油泵手油门置于零位，停止发动机，重新调整手油门。
Put the hand-accelerograph of injection pump at zero position，stop the
engine，and
1‐4
readjust the hand-accelerograph．
注意：发动机在停止之前以怠速运转 1-2min 后再停车。
Note：The engine should run in idling speed for 1-2 minutes before
stopped．
1‐5
2.柴油机维护保养指南
Maintenance Guide
2.1 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 level；
◆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；
◆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 whether 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 toil 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.
2.2 定期保养
Regular Maintenance
定期保养参照下表进行，若柴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 can be conduct on as per the following table．If the
2‐1
operating condition is heavy dust content or the engine running on

started-stopped frequently，the regular maintenance period should be shortened
accordingly．
2.2.1 维护保养周期
Maintenance period
表 2-1 汽车配套三类使用条件
Three categories of operating conditions with vehicle
(WGⅠ) (WGⅡ) (WGⅢ)
使用条件恶劣（气候严寒年行驶里程不足年行驶里程
或酷热，含尘量高，短距 6×104km，短中距离运输超过 6×104km
离运输，在工地使用（用于送货）的远距离运输汽车
以及公共汽车，市政 Annual running mileage Annual running
工程车，扫雪车，消防车） of the vehicle less mileage of the
或汽车年行驶里程不足 2 than 6×104km,,for vehicle more than
×104km 或年工作时间 short- or 6×104km for long
不足 600h medium-distance distance
U n d e r s e v e r e transportation (for transportation.
o p e r a t i n g goods).
condition (e.g. cold
or hot weather, high
dust content,
short-distance
transportation,
service in
construction site and
bus, municipal
engineering
vehicle, snow sweeper,
fire bridge vehicle),
annual running mileage
of the vehicle less
than 2×104km or annual
operated time less than
600h.
2‐2
表 2-2第一次检查,例行检查和保养周期
Table 2-2 The first inspection,routine inspection and maintenance period
使用条件 (WGⅠ) (WGⅡ) (WGⅢ)
Operating 年行使里程不到年行使里程不到年行使里程超过

2x104kmAnnual 6x104kmAnnual 6x104kmAnnual
项目 running mileage running mileage running mileage
Condition <2×104 km <6×104 km <6×104 km
Item
第 1 次检查行使 1000～行使 1500～行使 1500～
The first inspection 1500km 时或行使 2000km 时 2000km 时
30～50h Running Running
Running 1,500~2,000km 1,500~2,000km
1,000~1,500km or
30~50h
例行检查每隔 5000km 或每每隔 10000km 每隔 15000km
Periodical 隔 150h Every Every10,000km Every15,000km
inspection 5,000km or 150h
1 级保养 Level 1 每隔 10000km 或每隔 20000km 每隔 30000km
maintenance 每隔 300h Every Every20,000km Every30,000km
10,000km or 300h
20,000km or 600h
40,000km or 1200h
maintenance 每隔 2400h Every16,000km Every240,000km
Every80,000km or
2400h
表2-3 北奔汽车保养制度的机油换油期
Table 2-3 Oil Replacement Period in BEIBE Nehicle Maintenance System
2‐3
使用条件 (WGⅠ) (WGⅡ) (WGⅢ)

Operating
年行使里程不2x104km 年行使里程不6x104km 年行使里程超2x104km
项目 Annual running Annual running Annual running
Condition mileage<2×104 km mileage< 6×104 km mileage> 6×104 km
Item
第1次检查行使1000～1500km时行使1500～2000km时行使1500～2000km时
The first inspection Running 1000~1500km Running 1500~2000km Running 1500~2000km
例行检查每隔5000km 每隔1x104km 每隔1.5x104km

Periodical inspection Every 500km Every 1×104 km Every 1.5×104 km
1级保养每隔1x104km每隔300h 每隔2x104km 每隔3x104km

4
Level 1 maintenance Every 1×104 km or300h Every 2×10 km Every 3×104 km
2级保养每隔2x104km每隔600h 每隔4x104km 每隔6x104km

4
Level 2 maintenance Every 2×104 km or600h Every 4×10 km Every 6×104 km
3级保养每隔4x104km每1200h 每隔8x104km 每隔12x104km

Level 3 maintenance Every 4×104 km or Every 8×104 km Every 12×104 km
1,200h
4级保养每隔8x104km每2400h 每隔16x104km 每隔24x104km

Level 4 maintenance Every 8×104 km or Every 16×104 km Every 24×104 km
2,400h
2.2.2 保养项目
Maintenance Items
2‐4
保养项目更换调整检查
Items Replacement Adjustment Inspection
第1次检查机油紧固管路管夹
气门间隙
The 1stinspection Oil Tighten pipe clamps
Valve clearance
机油滤清器紧固三角皮带
Oil filter Tighten V-belts
例行检查机油紧固三角皮带
Periodical inspection Oil Tighten V-belts
机油滤清器
Oil filter
1级保养机油气门间隙空气滤清器

WD1 Oil Valve clearance Air filter
机油滤清器进气系统
Oil filter Air intake system
燃油滤清器紧固管路管夹
Fuel filter Tighten pipe clamps
紧固三角皮带
Tighten V-behs
2级保养气门间隙空气滤清器

机油
WD2 Valve clearance Air filter
Oil
进气系统
机油滤清器
Air intake system
Oil filter
紧固管路管夹
燃油滤清器
Tighten pipe clamps
Fuel filter
紧固三角皮带
Tighten V-belts
2‐5
保养项目更换调整检查
Items Replacement Adjustment Inspection

WD 3 Oil Valve clearance Air filter
冷却液紧固三角皮带
Coolant Tighten V-belts
空气滤清器在试验台上检查调整
Air filter 喷油泵
Inspect and adjust the
injection
fuel pump on test
bench

WD 4 Oil Valve clearance Air filter
冷却液紧固三角皮带
Coolant Tighten V-belt
空气滤清器检查增压器轴承间隙
Air filter Check the bearing
clearance of
turbocharger
在试验台上检查调整
喷油泵
Inspect and adjust the
Injection
fuel pump on test
bench
2‐6
2.3 维护保养记录
Maintenance Record
柴油机编号柴油机型号
Engine number Engine model
用户名称设备名称
User name Equipment name
日期公里小时或间实际里程保养内容保养者备注

隔时间 Actual Maintenance
Date Operator Remark
Running Kilometers contents
Kilometers／
hours or
interval hours
2‐7
３柴油机保养内容
Maintenance Contents
3.1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。
Preventive maintenance should bedone everyday in order to understand the engme's
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 lower than the
lower limit or higher than the upper
limit，it is not allowed to start the
engine．
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， inspect
the oil level at least 5 minutes later
in order to ensure the oil can flow
back to the oil sump．
油尺低位至高位的油量差为
3 升。
The oil volume tolerance between
the lower limit and the upper limit is
3 liters．
3‐1
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 the
vitreous view hole，if the coolant is
not sufficient，open the inlet cover
and 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 inlet
cover，must press down the
exhaust button firstly to prevent
hot coolant from injuring people.
检查燃油液面
Inspect the fuel level
检查风扇
Inspect 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.For steel fan，check
whether the rivet loosened and the
vane is curved to ensure reliable
running
3‐2
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-belts with your
eyes to find if there is any crack or
scratch on the V-belts．Replace
them if necessary．
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。
Unscrew the bottom bolt of the
small filter cup，dismount it and
drain off the water and deposit，
then re-install the cup again
3‐3
3.2 各级保养的保养内容
Maintencnce items of various maintenances
除完成每日保养外，增加下
列检查项目：
The following contents will
be added except daily maintenance
items：
机油和机油滤清器的更换
Replacement of the oil and oil
filter
柴油机使用后机油将变脏，污染
物含量与燃油机油耗总量成正比。
The oil will be polluted after
using，the pollution contents is of
accordance with the consumption of
fuel and oil．
注意：正常使用的柴油机更
换机油的周期无论如何不可超过
250h(1 万公里 )。
Note:The replacement period
of oil under proper using
condition cannot beyond 250h
(10,000Kilometers)
3‐4
更换机油和机油滤清器，以
清除悬浮在机油中的杂质。
Replace the oil and oil filter to clean
the impurities containing in oil.
注意：应在机油是热的时候放油
Note:The oil should be drained
off when it iS hot．
32mm 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 tocollect 20L of oil．
注意：热机油会伤人
Note：Hot oil can injure people.
3‐5
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
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 ring and
smear some lubricating oil on it
while fitting the oil filter．
3‐6
32mm 开口扳手
Tool:32mm open-ended wrench
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 clean the screw thread
and 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 upper
limit，the capacity of the oil sump is 20L．
3‐7
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 and
check 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 run
into the sump from the upper parts
5 minutes later，then check the oil
level，fill oil up to the upper limit if
necessary．
3‐8
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 covers．
32mm 盘车扳手
Tool: 32mm wrench for turning the
crankshaft
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 )
Tum the flywheel until its OT
scale and the mark on its housing
are aligned,push the piston to the
position of TDC of compression
stroke of 1st cylinder(the intake and
exhaust valve of 1st cylinder are
dosed)．
3‐9
塞尺
Tool：Clearance guage
进气门间隙 0.30mm
The clearance of intake valve is
0.30mm
排气门间隙 0.40mm
The clearance of exhaust valve
is 0.40mm
WEVB 系统间隙 0.25mm
The Clearance of WEVB
systerm 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 check the clearance
of valve，the engine should
be at the cool condition—its
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，the
measuring result is proper．
3‐10
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、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 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.
注意：调整过程中应转动气门间隙调整螺钉直到将塞规夹住 , 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 the valve clearance adjusting screw until the
clearance gauge is 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.
3、然后如图 3 所示，在序号 5 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 rocker
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 is
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.
3‐11
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 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
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 End Valve Clearance of Cold-State Exhaust
Valve 0.4mm Exhaust Valve 0.25mm
3‐12
6# 螺丝刀、14mm 梅花扳手
Tools：6#screwdriver and14mm double
offset ring wrench
第一缸活塞位于压缩行程上止点
位置。步骤 A
The piston of 1 cylinder is at TDC of Step A

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 guage and
tighten the fixing nut of rocker arm，
re-check the clearance till it meets the
requirement．
3‐13
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 。 by
the spanner；it can also be turned
360。after marking on the vibration
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
then tighten the nut again.
3‐14
13mm 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 23N·m( 推荐
数值 )。
The tightening torque of bolt is
23N·m(recommended)
检查三角皮带涨紧力
Check the tension of V-belts
在三角皮带的最大跨距上测
量其挠度：一般要求在强有力的
大拇指压力下，皮带挠度不大于
l0mm。
Measure the flexibility of the V—
belt at the middle of its biggest
span，generally the requirement
result should be less than l0mm
under strong press by your thumb．
3‐15
16mm 开口扳手
16mm open-ended wrench
如果挠度大于 l0mm，说明三
角皮带松动，需松开张紧轮涨紧
螺母，重新涨紧皮带，然后拧紧涨
紧螺母。
If the flexibility is more than
l0mm，it means the V-belt has
been loosen．the nut for tension
pulley needs to be relaxed，strain
the V—belt again and tighten the
nut．
检查冷却管路橡胶管是否老
化有裂缝、软管卡箍是否松动，必
要时紧固或更换零件，确保其密
封性。
Check whether the rubber pipes of
cooling system is aging or cracked，
the steel wire hoop is loosening．
If it is necessary，tighten or replace
the parts to ensure good sealing
pertormance.
3‐16
更换燃油滤清器
Replace the fuel filter
13mm 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 the
fuel filter，unloosen the upper bolt
and disassemble the fuel filter.
装上新的燃油粗滤芯和精滤
芯。
Install the new fuel pre-fiher
element and filter element．
3‐17
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 the
bracket 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 fuel
delivery pipe and fuel tilter
拧开喷油泵进油口放油螺钉。
Open the fuel draining bolt at the
inlet of injection pump.
3‐18
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 plug
till the fuel drained off from the
draining bolt outlet does not contain
air，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 rubber
pipes are aging or cracked，the
steel wire hoop is loosening．If
it is necessary tighten or replace
the parts to ensure good sealing
performance．
3‐19
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。
The maximum air intake resistance
of the engine should be less than
7kpa，it should be checked while
the engine running at rated speed 1、纸质滤芯
Paper foltering element
2、毛毡安全滤芯
Blanketry sofety futering
Element and full load When the resistance
reaches the maximum limit or the
indicator light glows，the air
filter element should be cleaned
or replaced as per the maintenance
guide from the manufacture.
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.
3‐20
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 air
filter element and beat the side of
the element lightly to make dust fall
down,or blow the element backward
(blow back from inside to utside)
by compressed air．
注意：
Nole：
·不得吹破滤纸
·Don't blow off the air filtering
Paper
不得用水和油清洗滤纸
·Don't clean the air filtering
paper by water and oil
·不得用力拍打或敲打滤芯
·Don't beat the core forcibly．
3‐21
3.3 柴油机长期存效时的维护保养
Maintenance of Diesel Engine during Long-term Storage
为防止锈蚀，柴油机出公司时进行油封，一般柴油机的油封期为一年，凡
超过一年的
应进行检查并采取必要的补充措施。
In order to prevent rust and corrosion, the diesel engine is oil sealed before
ex-work.
Usually, the oil seal period for the diesel engine is one year. Whenever the oil seal
period
exceeds one year, check and take necessary supplementary measures.
油封：首先向柴油机加入机油和带防锈剂的冷却液，开机并空转达 15-25
分钟，在
停机前 2 分钟向空气压缩机进口喷油封油，停车拆除中冷器与发动机的连接
管路，以起
动机带动发动机转动，向发动机进气管、涡轮增压器等内腔喷油封油。向所有
的裸露表面
和轴伸出端涂油封油。
Preservation: First fill the diesel engine with sealing oil and coolant with
anti-rust agent,
start the engine and run at idling speed for 15~25min. Spray sealing oil to air
compressor intake
2min before stopping of the engine. After stop, remove the pipeline connecting
intercooler and
engine, so that the starter drives the engine to rotate. The sealing oil is sprayed into
the cavities
of intake pipe, turbo-supercharger, etc. Apply sealing oil on all the exposed
surfaces and the
extended shaft ends.
存放期间的防护：用盖子或塑料布捆扎封墙各油、气、水的进出口；用气
象防锈膜
封存整台发动机。
Protection in storage period: Use covers or plastic cloth to tie and block all the
intake and
outlet ports. Use weather anti-rust film to seal the whole engine.
如果需要运输则应该外加包装。
Pack the engine if transportation is necessary.
3‐22
3‐23
3‐24
4．柴油机几大系统示意图
The Main System Flow Chart of Engine
·润滑系统
Lubricating system
·冷却系统
Cooling system
进排气系统
Intake and exhaust system
·燃油系统
Fuel supplying system
了解斯太尔柴油机的各大系统流程，将为您使用维护保养及故障排除提供帮助。
To understand the main system flow chart of the engine will give help to you for operating
and maintaining the engine．
4.1润滑系统
Lubricating system
1．集滤器
Strainer
2．机油泵
Oil pump
3．机油滤清器
Oil filter
4．机油冷却器
Oil cooler
5．主油道
Main oil passage
6．机油泵安全阀
Safety valve of oil pump
7．安全阀
Safety valve
8．主油道限压阀
Oil release valve for main oil passage
9．机油滤清器旁通阀
Bypass valve of oil filter
4‐1
各大运动零件的润滑
Lubricating for main moving parts
1．机油冷却器来油
The oil flowing from the oil
cooler
2．主油道
Main oil passage
3．通往主轴颈
Oil to the main crankshaft joumal
4．连杆轴颈
Connecting rod joumal
5．曲轴主轴颈处
The main journal of crankshaft
6．通往连杆轴承
Oil to connecting rod beating
7．主油道通向主轴承的斜油道
The branch oil passage passing
to main Dearing
8．付油道
Sub-passage of oil
9．冷却活塞喷油
Oil injection nozzle to cool piston
10．凸轮轴轴承
Camshaft beating
11．付油道来油润滑空压机
Lubricating air compressor
through the oil from sub-passage
12．付油道来油润滑喷油泵
Lubricating fuel injection pump
through the oil from sub-passage
4‐2
摇臂机构的润滑
Lubricating for rocker arm
system
1．主油道斜油孔来油
Oil flowing from the oil
branch passage
2．挺柱油孔
Tappet oil hole
3．挺杆油孔
Push rod oil hole
4．摇臂螺钉油孔
Oil hole of rocker arm bolt
5．摇臂油孔
Oil hole of rocker arm
增压器的润滑
Lubricating
turbocharger
1．主油道来油
Oil from the main oil
passage
2．增压器进油口
Oil inlet of turbocharger
3．增压器回油口
The oil outlet of turbocharger
4‐3
4.2冷却系统
Cooling system
1．水泵进水口
Water pump inlet
2．水泵
Water pump
3．机油冷却器水腔
Water channel of oil cooler
4．气缸体水套
Water jacket of cylinder block
1．气缸体水套
Water jacket of cylinder block
2．来自缸体水套之水
Cooling water flowing from
water jacket of cylinder block
3．气缸垫
Cylinder head gasket
4．流经气缸盖水腔
Cooling water passing through
the water passage of cylinder
head
5．出水口
Cooling water outlet
4‐4
1．机体流出冷却液
Coolant flowing from
cylinder block
2．调节器
Thermostat
3．旁通阀
Bypass valve
4．流入水泵的冷却液
Coolant flowing into water
pump
5．旁通阀关闭
Bypass valve closed
6．冷却液流入散热器
Coolant flowing into the radiator
4‐5
4.3进排气系统
Intake and exhaust system
1．经过滤清器滤清的空气进入增压器
The fresh air passing through the
air filter flows into turbocharger
2．流经中冷器的增压空气(增压
非中冷机无中冷器)
The turbocharged air passing
through intercooler There is no
intercooler for turbocharged but
not inter-cooled engine)
3．中冷器(我厂不配带中冷器)
Intercooler(The engine supplied
without intercooler when
delivering out of our company)
4．进气管
Intake manifold
5．进气门
Intake valve
1．排气门
Exhaust Valve
2．排气管
Exhaust manifold
3．排气进入增压器涡轮
Exhausting gas flowing into the
turbo of turbocharger
4．增压器排气出口
Exhaust outlet of turbocharger
4‐6
4.4燃油系统
Fuel supplying system
1．来自油箱的燃油
Fuel from the fuel tank
2．输油泵
Fuel delivery pump
3．燃油滤清器
Fuel filter
4．低压油管
Fuel delivery pipe
5．冒烟限制器空气接管
Air connecting pipe for smoke
controlling device
6．喷油泵
Fuel injection pump
7．高压油管
High pressure fuel pipe
8．喷油器
Injector
9．喷油器回油管
Fuel returning pipe of
injector
10．回油箱燃油管
Fuel pipe back to the fuel tank
4‐7
4‐8
5．柴油机强力螺栓的拧紧力矩和拧紧方法
Tightening Torque And Tightening Method
of High Strength Bolts
1．主轴承螺栓：
Main-Bearing Bolt
14 根 M 1 8 22 套筒扳手
T0tal nos．：14 pcs M 1 8 bolts，Tool：22mm sleeve wrench
+25
分两次拧紧 ( 拧紧顺序按上图所示 ) 第一次：80N·m 第二次：250 N·m
Tighten bolts in twice(tightening sequence see the figure above) The first time：
+25
80N·m The second time：250 N·m
2．气缸盖螺栓：
Cylinder Head Bolt：
24根M1 6的主螺栓，22套筒扳手
Total nos：24 pcs M16 main bolts，Tool：22mm sleeve wrench
7根M 12副螺栓的螺母，17套筒扳手
Total nos：7 pcs nuts of M 1 2 auxiliary bolt，Tool：17mm sleeve wrench
5‐1
按下列顺序拧紧：
Following such tightening sequence：
第一步：气缸盖安装好后须找正，即排气口侧应在一个平面内：所有螺栓按
30N·m预紧。
Step 1：Align cylinder head after assembly，i．e．the exhaust port side of cylinder
heads should be in the same plane．All the bolts should be tightened beforehand，and
the torque is 30N·m．
第二步：24 根主螺栓用 200N·m 力矩按上图所示主螺栓次序拧紧。
Step 2：Tighten 24 pcs main bolts as the sequence in above figure，and the torque is
200N·m
第三步：7 根副螺栓螺母用 100N·m 力矩按上图所示副螺栓次序拧紧。
Step 3：Tighten 7 pcs auxiliary bolts as the sequence in above figure，and the torque
is 100N·m
第四步：主螺栓按上图次序旋转 90。
Step 4：Turn the main bolts 90。as the sequence in above figure。
第五步：副螺栓螺母按上图次序旋转 90。
Step 5：Turn the auxiliary bolts 90。 as the sequence in above figure．
第六步：主螺栓按上图次序再次旋转，扭矩达到 240-340 N·m。
Step 6：Turn the main bolts 90。as the sequence in above figure again，and the
torque range is 240—340 N·m．
第七步：将副螺栓螺母按上图次序再次旋转 90。，扭矩同时达到 120~160N·m。
Step 7：Turn the auxiliary bolts 90。as the sequence in above figure again．the
torque range is 120 ～ 160 N·m．
对达不到最终扭矩要求的螺栓应更换，主螺栓允许重复使用 3 次，副螺栓允
许重复使用 2 次。
Replace those bolts that cannot reach required torque range．The main bolt is
allowed to be reused for 3 times．and the auxiliary bolt is allowed to be reused for 2
times．
3．连杆螺栓：
Connecting rod Bolt：
两根 M14x1.5 19mm 套筒扳手
Total nos．：2 pcs M14x1.5 for each connecting rod Tool：19mm sleeve wrench
第一步：先拧靠，再用120N·m的力矩对称扭紧。
Step 1：Tighten tightly，then tighten these bolts symmetrically with a torque of 120N
第二步：旋扭 90。±5。，扭矩须在 170~250 N·m 范围内
Step 2：Turn these bolts 90。±50。 and the torque range is 170~250 N·m．
对达不到扭矩要求的螺栓应更换
Replace those bolts that can not reach required torque range．
5‐2
注意：经过拆卸后的连杆螺栓不得再使用。
Note：The connecting rod bolts that have been used should not be reused．
4．飞轮螺栓：
Flywheel Bolt：
9根M14x1.5 22套筒扳手
Total nos．：9 pcs M14x1.5 Tool：22mm sleeve wrench
第一步：60N·m力矩对称扭紧
Step 1：Tighten these bolts symmetrically with a torque of 60N·m．
第二步：转180。±50。，扭矩同时达到230~280 N·m
Step 2：Turn these bolts 1 80。±5。，and the torque range is 230~280 N·m．
对达不到扭矩要求的螺栓应更换
注意：飞轮螺栓只许使用2次。
Note：The flywheel bolt is only allowed to be reused for 2 times．
5．飞轮壳螺栓：
Bolt for Flywheel Housing
13根M12螺栓套筒扳手
Total nos．：1 3 pcs M 12 bolts Tool：box wrench
第一步：40N·m力矩拧紧
Step 1：Tighten these bolts with a torque of 40N·m．
第二步：分别旋转120。±50。，同时达到110~140N·m
Step 2：Turn these bolts 1 20。±5。respectively，and the torque range is 110~140 N·m．
不在扭矩范围内的螺栓应更换
飞轮壳螺栓允许重复使用2次。
The flywheel housing bolt is allowed to be reused for 2 times．
注意：以上几种强力螺栓拧入前均要在螺纹及支撑面上涂润滑油。
Note：Smear thread and bearing surface of high strength bolts described
above with lubricating oil before tightening．
5‐3
6．中间齿轮轴螺栓：
Bolt for Intermediate Gear Shaft
4 根 M10 套筒扳手
Total nos．：4 pcs M10 bolts Tool:sleeve wrench
第一步：60N·m 力矩对称拧紧
Step 1：Tighten these bolts symmetrically with a torque of 60N·m．
第二步：分别旋转90，扭矩达到100-125 N·m。
Step 2：Turn these bolts 90。，and the torque range is 100~125 N·m．
达不到扭矩要求螺栓应更换
螺栓拧入前螺纹部位涂乐泰密封胶 242。
Smear the thread with LOCTITE 242 THREADLOCKER before tightening．
中间齿轮轴螺栓允许重复使用 3 次。
The bolt for intermediate gear shaft can only be used three times.
5‐4
7．机油泵惰轮轴螺栓：
Bolt／Oil Pump Idler Gear Shaft
M10 16mm套筒扳手
T0tal nos．：1 piece M10 bolt
Tool：16mm sleeve wrench
+5
一次拧紧到60 N·m
+5
Tighten the bolt with a torque of 60 N·m．
拧人前螺纹部位涂乐泰密封胶242。
Coat the thread with LOCTITE 242
THREADLOCKER before tightening．
8．摇臂座螺栓：
Bolt／Rocker-Arm Support
12根M12
Total nos．：12 pcs M12 bolts
18mm套筒扳手
一次拧紧到100N·m
Tighten these bolts with a torque
of 100N·m．
5‐5
9．喷油泵连轴器与喷油泵紧固的六
角头螺栓：
Hex head Bolt ／ Binding Coupling
and Injection Pump：
M14x1．5
Total nos．：1 piece M14x1．5 bolt．
18mm套筒扳手
Tool：18mm box wrench
一次拧紧到1500+15N·m
Tighten the boh with a torque of 1500+15N·m
Coat the thread with LOCTITE 242
THREADLOCKER before tightening
10．喷油泵驱动齿轮紧固螺母：
Tight Nut／Injection Pump Driving Gear
M24x1.5．
Total nos．:1 piece M24x1.5 nut
36mm套筒扳手
一次拧紧到450~500N·m
Tighten the nut with a torque
0 f 450~500N·m．
Coat the thread with LOCTlTE 242
THREADLOCKER beforetightening
5‐6
l 1．凸轮轴齿轮螺栓：
Bohs|Camshaft Gear
4根M8
Total nos．：4 pcs M8 bolts
13mm套筒扳手
对称拧紧到35N·m
Tighten these bohs aymmetrically
with a torque of 35N·m．
拧入前螺纹部位涂乐泰密封胶242。
Coat the thread with LOCTITE
242 THREADLOCKER before
tightening．
12．减振器皮带轮与曲轴连接螺栓：
Bolt／Attaching Damper Pulley and
Crankshaft
8根M10
Total nos：8 pcs M10 bolts
16mm套筒扳手
Tool：16ram sleeve wrench
+5
对称拧紧到60 N·m
Tighten these bolts symmetrically with
+5
a torque 0f 60 N·m．
5‐7
1 3．喷油泵与托架紧固螺栓：
Tight bolts／Attaching
Injection Pump and Bracket
4根M10内六角螺栓
Total nos.：4 pcs M10 socket head
bolts
6mm内六方扳手
Tool：6mm inner hexagon wrench
按次序拧紧到450+5N·m
Tighten these bolts in sequence，
and the torque is 450+5N·m
14．排气管螺栓：
Bolts／Exhaust manifold
12根M10
Total nos．：12 pcs M 10 bolts
对称拧紧到(65-80)N·m
Tighten these bolts symmetrically
with fl torque of (65-80)N·m.
注意：螺栓拧入前在螺纹部位及螺纹
支撑面上涂二硫化钼油剂。
Note:Coat the thread and bearing
surface with Molybdenum disulfide Lube
before tightenin．
排气管螺栓允许重复使用2次
The bolt for exhaust manifold can
only be used two times
5‐8
5‐9
6．柴油机所用的燃料油、润滑油、冷却液和辅助材料
Fuel，lubricant，coolant and Auxiliary Materials
6.1 燃料油
Fuel：
夏季 0号柴油 GB252 冬季 -10号柴油 GB252
In Summer No.0 Diesel Fuel GB252 In Winter No.-10 Diesel Fuel GB252
当冬季温度为-15℃，选用-20号柴油。冬季温度低于-30℃，采用-35号柴油。
In winter，when the temperature is-15 ℃，you should use No.-20 Diesel Fuel．If the
temperature is below-30℃，you should use No.-35 Diesel Fuel．
6.2 润滑油：
Lubricant：
6.2.1 300PS以下机型推荐选用CD级机油，300PS以上机型推荐选用CF-4级
For engines with power of lower and higher than 300PS,grade CD and CF-4
oil are recommende respectively.
6.2.2 允许以高品位的机油代替较低品位的。
It is allowed to replace low-grade oil with high-grade oil．
6.2.3环境温度-15℃以上用CD15W/40，-15℃以下用5W/20级机油
CD15W/40 oil showld be used when the ambient temperature is higher than
-15℃,and 5W/20 oil when the temperature is lower than -15℃.
6.2.4 发动机润滑油的粘度可参照下图选用。
Please reference the following chart to choose viscosity of lubricant．
6‐1
6.2.5 油面处于油标尺上限位置时，机油容量约20升，油标尺上下刻度问的落差
约3升；根据用户协约，出厂时油底壳内，可以是充油，也可以是不充油的。当
充油时，该油内含有特种磨合(防蚀)剂，用户可在运行2000公里(或50小时)时将
机油全部放出，更换新机油。
The approximate volume of the oil sump is 20 litres when the oil level stays at the
upperlimit of oil dipstick．The fall between upper and lower limit of oil dipstick is
about 3 litr．According to the agreement between Weichai and customers，the engine
could be suppliedwith or without the oil in the sump of the engine．If the engine was
supplied with the oil in the sump，some special anticorrosive agent was
contained．The customer can replace it with new oil after running 2000km or 50hs)．
6.3 润滑脂：水泵油杯注入锂基脂，符合GB/T5671的要求。
Grease：Fill GB/T5671 lithium grease into the grease cup of the water pump.
6.4 冷却液：冷却系统加入防冻液约40升，此液体具有防锈防冻的能力。(配比
请参阅防冻液使用说明)
Coolant：Fill the cooling system with 40 litres anti-freeze coolant which can prevent
rust and frostbite．(Please reference the Operating Instruction Manual of Coolant for
mixture ratio)
6.5 辅助材料：
Auxiliary Materials：
6.5.1 本机在装修过程中，可使用乐泰510、242、271、277,262等规格的密封胶
和粘接剂。
LOCTITE 510、242、271、277、262 sealing glue and cohesive material can be used
during tne process of mounting and repalnng．
6.5.2 细钼粉
Fine molybdenum powder．
6.5.3 各种辅助材料的使用部位见下表。
Please reference the following table for detailed application of auxiliary
materials．
6‐2
WD615系列柴油机所用的辅助材料表
Auxiliary Materials List of WD615 Series Diesel Engine
序号名称颜色用途与应用
Serial No Name Color Purpose and Application
1 细钼粉涂在平滑的金属表面防止咬合
黑色
Fine Apply to smooth surface of metal to prevent
Black
Molybdenum biting.
Powder 例如：涂在气缸套外表面
eg，Apply to exterior surface of cylinder
liner.
2 二硫化钼膏剂深灰色零件处在较高温度下防粘着
Molybdenum disulphide ointment Deep To prevent adhesion of parts under
Lube gray higher temperature．
例：增压器排气口螺栓等
eg，Apply to the bolts of exhaust
outlet of turbocharger
3 乐泰242 兰色涂在螺纹部位固持、密封
LOCTITE 242 glue Blue Apply to thread to seal．
例：各种螺栓、螺纹部位
eg，Apply to bolts and thread
4 乐泰262 红色涂在螺纹部位锁紧密封、高力度
LOCTITE 262 glue Red Apply to thread to lock and seal．
例：气缸盖副螺栓
eg，Apply to auxiliary bolts of
cylinder head
5 乐泰510 红色涂在金属表面起密封作用
LOCTITE 510 glue Red
Apply to surface of metal to seal．
例：气缸体与曲轴箱结合面
eg，Apply to bond surface
of"cylinder block and crankcase
6 乐泰271 红色涂在金属表面起密封作用
LOCTITE 271 glue Red Apply to surface of metal to seal．
例：油道碗形塞
eg，Apply to oil channel plug
7 乐泰962 红色芯子与孔之间的密封
LOCTITE 962 Red Sealing of plug and hole．
例：机身水腔碗形塞
eg，Apply to the water reservoir plug
of cylinder block
8 锂基脂红色水泵润滑脂
Lithium grease glue Red Grease for Water Pump
6‐3
本章注意：为确保您所购的柴油机的正常使用，必须按本说明中规定，使用正
确牌号的燃油、机油。
Note：To ensure the proper operation of our diesel engines，please
use the correct brand fueI and oil as this manuaI described．
6‐4
7．电气部分
Electrical Appliance
电机部分包括发电机、起动机、水温表传感器、机油压力感应塞等。
This section consists of generator，starter，sensor of water temperature
indicator，induction plug of oil pressure，etc．
发电机
Generator
发电机为三相交流发电机，经硅整流为直流。
The generator is three-phase alternator，after silicon rectification the current change into
direct current．
输出电压28V电流27A(根据用户需要也可配有35A、55A)旋转方向右旋。
Output Voltage：28V DC，Current：27A(In order to meet customer's demand，the
currents of 35A and 55A are available for option)，Rotation Direction：clockwise
最大允许转速11000转／分
Maximum Allowable Speed：11000 r ／ min
额定负荷转速6000转／分
Rated Load Speed：6000 r ／ min
电路图：
Circuit Diagram：
1
接线柱
Connection Pole
D+接充电指示灯螺纹规格M4
D+connect to Charging(electri6cation)Indicating Lamp，the screw specification：M4
W接测速电机螺纹规格M5
Wconnect to Speed Measuring Motor，the screw specification：M5
B+接蓄电池正极负载，电机外壳接地螺纹规格M6
B+connect to the positive electrode of battery，generator shell is grounded，the screw
specification：M6
起动机
Starter
直流起动机电压24V,功率5.4kW,7.5kW或8.1kW旋转方向右旋(面向柴油机输端
看)
The starter is DC starter，Voltage：24V,Power：5.4kW,7.5kW or 8.1 kW，Rotation
Direction：
clockwise(View direction：face to the output end of the engine)
模数为3的起动机齿数为9齿(用于SAE II飞轮壳)和11齿(用于SAE1和6I 35飞轮壳)
两种(目前7。5kW和8．1kW无9齿的起动机)模式数为3.5的起动机分10齿和11齿
两种，11齿为Bosch预齿合起动机。模数为3.5的起动机分10齿和11齿两种，11齿
为Bosch预齿合起动机
There are two types of starter with modulus is 3：9 teeth(apply to SAE II flywheel
housing)；11 teeth(apply to SAEI and 6I 35 flywheel housing)．7．5kW and 8.l kW
starters with 9 teeth are not available currently．
电路图：
Circuit Diagram：
外部接线柱：
Extemal Connection Pole：
30接蓄电池正极螺纹规格M10
30 connect to the positive electrode of battery，the screw specification：M10
3 1接地螺纹规格M10
3 1 grounding the screw specification：M10
50接电磁开关螺纹规格M6
50 connect to the electromagnetic switch the screw specification：M6
2
机油压力感应塞：
Induction plug of oil pressure
工作温度 -25~100℃
Operating Temperature：-25~100℃
测量范围 0~500kPa
Measurement Range：0~500kPa
报警压力 45~75kPa
Alarm Pressure：45~75kPa
额定电压 6~24V
Rated Voltage：6~24V
水温表传感器
Sensor of water temperature meter
工作温度 -25~120℃
Operating Temperature：-25 ～ 120℃
额定电压 6~24V
Rated Voltage：6~24V
蓄电池
Battery
2x12V 135Ah 可选用 165Ah 或 195Ah
2×12V 135Ah or 165Ah or 195Ah
3
4
8．主要零部件的调整与更换
Adjustment and Replacement of Main Components
8.1 冷却系统
Cooling System
更换三角皮带
Replace the V-belts
16mm开口扳手
Tool：16mm open-ended
wrench
松开发电机拉紧螺栓螺
母，拿下发电机皮带。
Loosen the tightening nut of
the generator to remove
generator belt．
16mm开口扳手
wrench
松开涨紧轮M10的2
型全金属六角锁紧螺母，就
可拆下水泵三角皮带。
Loosen the M10 self-lock nut
(2)of tension pulley，remove
the V-beh of water pump．
8‐1
换上三角皮带，涨紧合
适后重新拧紧2型六角螺母
和拉紧螺栓螺母。
Replace the V-belts，tighten
self-lock nuts (2)and the nuts
of tension bolts again．
更换水泵
Replace Water Pump
16mm开口扳手
松开发电机拉紧螺栓，拆下三
角皮带。
Loosen the tightening bolts of
generator to remove the V— beIt
8‐2
13mm 开口扳手
松开发电机固定板处螺栓。
Loosen the bolt from the generator
mounting plate．
13mm 开口扳手
Tool：13mm open cnded wrench
拆下拉紧螺栓和齿轮室连接
的六角螺母。
Remove the tightening bolts and
hexagon nuts attaching gear case。
8‐3
拆下发电机
Remove generator．
16mm开口扳手
wrench
松开涨紧轮六角锁紧螺
母，拆下水泵三角皮带。
Loosen the hexagon lock nuts of
tension pulley to remove the V-belt of
water pump．
8‐4
6# 螺丝刀
Tool：6# Screwdriver
松开水管接头处橡胶软管
卡箍。
Loosen the rubber hose clamp
of water pipe joint．
13mm 套筒扳手
松开水管接头螺栓，并
拆下水管接头。
Loosen the bolt of water pipe
joint to remove water pipe joint．
8‐5
13mm开口扳手
wrench
拆下水泵与齿轮室连接
的6个六角螺母。
Loosen the 6 hexagon nuts
attaching water pump and gear
case。
拆下水泵。
Remove water pump．
8‐6
擦净水泵密封平面。
Clean the seal surface of
water pump．
更换水泵密封垫片。
Replace the seal gasket of
water pump．
8‐7
13mm开口扳手
Tool：13 mm open-ended
wrench
换上新的水泵总成，拧紧 6
个六角螺母 ( 注意水管接头内侧
有一螺母 )。
Install the new water pump
assembly，tighten 6 hexagon
nuts.(There is a nut in the inner side
of water pipe joint)
注意：水泵内腔内装入约
3
120cm 汽车通用锂基润滑脂。需
定期从小油杯处补充。
Note：Fill the Iumen of water
3
pump with 120cm general
Iithium grease．Refill lithium
grease with grease cup
periodically．
13mm开口扳手
安装水管接头，并拧紧水管
接头上两M8螺栓，并安装好橡胶
软管。
Install the water pipe joint，tighten
two M8 bolts of water pipe joint，
then i nstall the rubber hose．
8‐8
装上发电机
Install generator．
16mm开口扳手，铁棒
wrench and pontil
安装三角皮带，调好涨
紧度拧紧涨紧轮上M10六角
锁紧螺母。
Install the V-belt and
adjust the tensity, tighten M10
hexagon lock nuts of tightening
pulley．
8‐9
13mm开口扳手，16mm
开口扳手
Tool：13mm and 16mm
open-ended wrench
安装发电机三角皮带，
涨紧适度后拧紧拉紧螺栓上
螺母和固定板处螺母。
Install the V-belt of
generator and adjust the tensity，
tighten top nuts of tightening
bolts and nuts of mounting
plate.
8‐10
8.2 润滑系统
Lubricating System
更换机油冷却器芯
Replace the oil cooler core
13mm套筒扳手
松开机油冷却器盖上的一圈
M8螺栓，并拆下机油冷却器盖。
(拆卸前要放掉发动机内的冷却液)
Loosen all of the M8 bolts on
the oil cooler cover to remove oil
cooler cover．(Discharge coolant
before demounting the oil cooler
cover)
清理机油冷却器盖和机身密
封结合面并更换新的机油冷却器
盖垫片。
Clean the oil cooler cover
and seal surface of the cylinder
block,replace with new gasket of oil
cooler cover.
8‐11
6mm套筒扳手
松开机油冷却器芯4根M8
螺栓。
Loosen the 4pcs M8 bolts
of oil cooler element.
拆下机油冷却器芯，并清
理干净机身上机油冷却器芯
法兰结合面。
Remove element of oil
cooler and clean the bonding
surface of flange of oil cooler
element.
8‐12
更换机油冷却器芯密
封热圈。
Replace seal ring of oil
cooler element.
13mm 套筒扳手
Tool ： 13mm sleeve
wrench
安装新的机油冷却器芯，
并拧紧 M8 六角螺栓。
Install the new oil cooler
element and tighten the M8
hexagon bolts．
注：螺栓拧紧前须在螺纹部
位涂乐泰 242 密封胶。
Note：Coat the thread with
LOCTITE 242
THREADLOCKER before
tightening．
8‐13
13mm 套筒扳手
Tool：13mm sleeve
wrench
安装机油冷却器盖 ,
并拧紧外围所有 M8 六角
头螺栓。
Install the oil cooler
cover and tighten all the
peripheral M8 hex head
bolts.
更换主油道限压阀
Replace the release
valve of main oil channel
13mm 套筒扳手
Tool：13mm sleeve
wrench
松开油底壳外围 M8
六角头螺栓。
Loosen all peripheral
M8 hex head bolts of oil
pan.
8‐14
拆下油底壳托块，并拿下
油底壳。
Remove retainer，then
remove 0il pan．
27mm 开口扳手
wrench
拆下主油道限压阀。
Remove the release valve
of main oil channel．
拆下主油道限压阀时应
搬动阀体六方的外螺纹端部
分。
When removing the release
valve of oil channel,move the
male end of hexagonal part on
valve body.
8‐15
27mm 开口扳手
wrench
安装新的限压阀，拧入
前需在螺纹部位涂乐泰242
密封胶。
Install new release valve，
coat the thread with LOCTITE
242 THREADLOCKER before
tightening．
安装新的限压阀时应搬
动阀体六方的外螺纹端部
分。
When installing new
release valve，move the male
end of hexagonal part on valve
body．
13mm开口扳手
Tool:13mm open-ended
wrench
安装油底壳，拧紧M8六
角头螺栓。
Install oil pan and tighten
the M8 hex head bolts．
注意：压好油底壳密封
垫圈
Note ： Make sure
packing washer of oil pan
was pressed well．
8‐16
更换机油泵
Replace Oil Pump
13mm 套筒扳手 16mm
开口扳手
Tool ： 13mm sleeve
wrench and 16mm open-
ended wrench
拆下油底壳，拆机油集滤器。
Remove oil pan and
suction pipe.
l0mm 开口扳手
Tool：l0mm open-ended
wrench
松开吸油管固定压板
( 双级机油泵 )。
Loosen the mounting
plate of oil suction pipe(two-
stage oil pump)
8‐17
16mm 开口扳手 ( 双级机油

泵 )
wrench(two-stage oil pump)
松开吸油管 M10 六角螺栓，
并拆下吸油管。
Loosen the M10 hex head
bolts of oil suction pipe to remove
oil suction pipe．
16mm 开口扳手，16mm 套
筒扳手
wrench and 16mm sleeve wrench
松开涨紧轮六角螺母和曲
轴皮带轮螺栓。
Loosen the hex head bolts
of tension pulley and the bolts of
crankshaft pulley．
8‐18
拆下皮带轮和减振器，减
振器和曲轴为过渡配合，必要
时可以轻击减震器。
Remove the pulley and
d a m p e r ，t h e damper and
crankshaft is transition fit，the
damper can be knocked slightly
if it is necessary for removing．
22mm 开口扳手
wrench
拆下齿轮室处六角螺塞。
Remove the hex head plug
screws of gear case．
8‐19
16mm 套筒扳手
拆下机油泵中间齿轮轴螺栓。
Remove the bolts of
intermediate gear shaft of oil
pump.
用专用工具拆下机油泵中
间齿轮轴。
Remove intermediate gear
shaft of oil pump with special
tool．
8‐20
拆下机油泵中间齿轮
Remove intermediate gear of
oil pump ．
16mm 套筒扳手
拆下六角螺塞处六角头
螺栓和另外一个六角头螺栓。
Remove the hex head bolts
from the hex plug and another hex
head bolt．
8‐21
拆下机油泵。
Remove oil pump．
清理曲轴箱与机油泵结合面
处。
Clean the seal Surface between
crankcase and 0il pump。
8‐22
16mm套筒扳手
安装新的机油泵和机油
泵垫片，并拧紧六角螺栓(一
个在六角螺塞处)。
Install new oil pump and
gasket，tighten the hex head
bolts.(one of them is in the
hex head plug)
安装机油泵中间齿轮
(注：凸面朝里)。
Install intermediate gear of
oil pump
(Note：convex towards inside)
8‐23
安装机油泵中间齿轮轴。
Install intermediate gear shaft
of oil pump．
16mm套筒扳手
安装中间齿轮轴螺栓，并
拧紧。
Install the bolts of intermediate
gear shaft and tighten them．
拧紧力矩：60。 N·m +5
Tightening torque：60。 N·m +5
8‐24
安装减振器和皮带轮。
Install damper and pulley．
16mm套筒扳手
安装皮带轮螺栓,并拧紧。
Install the bolts of pulley and
tighten them．
拧紧力矩：60。 N·m +5
Tightening torque：60。 N·m 5
8‐25
16mm 开口扳手
wrench
装好三角皮带涨紧适度
后拧紧涨紧六角锁紧螺母。
Install the V—belt pulley
and adjust the tensity，then
tighten the hex head lock nuts．
8‐26
8．3 供油系统
Fuel Supplying System
更换喷油泵
Replace injection pump
16mm 开口扳手
wrench
拆下高压油管与喷油泵连接
接头。
Remove the joint between the
high pressure pipe and injection
pump．
缓慢盘车，使飞轮壳上的刻
线对准飞轮上“OT”刻线，确定第
一缸活塞压缩行程上止点位置。
Rotate flywheel slowly，align
the calibrating line of flywheel
housing to“OT”calibrating line，
to fix the position of TDC of
compression stroke of the first
cylinder．
8‐27
16mm 套筒扳手
拆下连轴器与驱动轴紧固螺
钉。
Remove the screws attaching
shaft coupling and driving shaft．
16mm 开口扳手 16mm 梅花
扳手
wrench and 16mm double offset
ring wrench
拆下连轴器与喷油泵法兰连
接螺栓。
8‐28
6# 螺丝刀 0.5kg
Tool：6# screwdriver O.5 kg
撑开连轴器与驱动轴连接角
度调节板上的缺口。
Open the gap on the angle
regulating plate connecting the
coupler and the driving shaft.
后推连轴器。
Push shaft coupling backward．
8‐29
8mm 内六角套筒扳手
Tool：8mm inner hexagon
wrench
拆下喷油泵与托架连接的 4
个内六角头螺栓。
Remove the 4 pcs socket head
bolts attaching injection pump and
bracket
19mm 开口扳手
wrench
拆下喷油泵连接油管。
Remove all the connecting
pipes from the injection pump.
8‐30
拆下喷油泵并安装新的喷油
泵和喷油泵内六角头螺栓。
Remove the injection pump
and install new injection pump and
socket head bolts．
8mm 套筒扳手
拧紧喷油泵内六角头螺栓，
并连接好管路。
Tighten socket hexagon bolts
of injection pump，connect pipeline.
拧紧力矩 45。 N·m +5
Tightening torque：45。 N·m

+5
8‐31
16mm 开口扳手，16mm 梅花
扳手
wrench and 10mm(double offset
ring wrench．
安装喷油泵与连轴器连接
螺栓，螺栓拧入前在螺纹部位涂
乐泰 242 密封胶，拧紧力矩为
110N·m。
Install bolts attaching injection
pump and shaft coupling，coat
the thread with LOCTITE 242
THRERADLOCKER before
tightening．Tightening torque：
110 N·m．
8‐32
转动连轴器至一缸出油口油
面微动时止。
Rotate shaft coupling to watch
the fuel oil jiggle at the outlet of any
cylinder of the injection pump,then
stop rotation.
盘车使飞轮刻线至上死点前
供油始点位置。（各缸供油提前角
见燃油系统配套表）
Rotate flywheel to align the
indicated needle of flywheel to
fuel supply advance angle.(Please
reference fuel system mating list for
fuel supply advance angle of each
cylinder)
8‐33
此时喷油泵上的刻线和喷油
提前器（或法兰）上的刻线基本对
齐。
The calibration tails of injection
pump is aligned with calibration tails
of tining adwance unit(or flange).
16mm 套筒扳手
装上连轴器与驱动轴连接
螺栓。螺栓旋入前螺纹部位涂
乐太胶 242 密封胶，拧紧力矩
1500+5N·m。
Install bolts attaching shaft
coupling and driving shaft.
Coat the thread with LOCTITE
242 THREADLOCKER
before tightening.Tightening
torque:1500+5N·m.
8‐34
盘车复查供油提前角，必要
时拆开连轴器与驱动轴紧固螺栓
重新调整。
Rotate flywheel to recheck
the advance angle of fuel supply，
remove bolts attaching
s h a f t coupling and driving shaft
for readjustment if necessary．
更换喷油器
Replace Injection Pump
17mm 开口扳手
Tool：17mm open-ended 具
wrench
清理喷油器四周并拆下高压
油管与喷油器连接接头。
Clean all round of the injector，
remove the joint attaching high
pressure fuel pipe and injector
8‐35
拆下喷油器回油管。
Remove fuel return pipe of the
injector．
13mm 开口扳手
松开紧固压板螺栓，拿下紧
固压板。
Loosen bolts of mounting plate，
then remove mounting plate．
8‐36
拆下喷油器。
Remove injectors．
清洁喷油器座孔。
Clean seat hole of injector．
8‐37
更换新的铜质密封垫圈。
Replace with new copper washer．
更换新的喷油器然后装上新
的橡胶密封圈。
Replace with new injector and
install new rubber seal ring．
8‐38
将新的喷油器装入喷油器座
孔。
Install new injector into the seat
hole.
注意：装好喷油器后胶圈不
得有压挤现象。
Note：It is not allowed to appear
any mark of pressing rubber
cushion after mounting injector．
安装喷油器固定板。
Install the mounting plate of
injector.
8‐39
13mm 套筒扳手
Tool：l3mm sleeve wrench
安装喷油器压板螺栓或六角
螺母，拧紧力矩 25N·m。
Install bolts or hex head nuts
of mounting plate．Tightening
torque：25N·m
13mm 开口扳手 17mm 开口

扳手
Tool：13mm and 17mm open ended
wrench
拧紧喷油器与高压油管连接
接头及安装好回油管。
Tighten the joint attaching injector
and high pressure fuel pipe，install
fuel return pipe．
8‐40
8.4 进气系统
Air Intake System
更换涡轮增压器
Replace Turbocharger
6mm螺丝刀
Tool：6mm screwdriver
松开压气进气管处的橡胶软
管卡箍和压气机出气管软管卡箍。
Loosen rubber hose clamps from the
inlet and outlet of compressor。
6mm 螺丝刀
Tool：6mm screwdriver
松开增压器回油管软管卡箍。
Loosen hose clamp from
turbocharger oil retum pipe．
8‐41
6mm 内六角扳手
拆下增压器进油管内六角螺
栓，抬起进油管法兰。
Remove inner head bolts from
turbocharger oil inlet sucker, raise
flange of sucker．
16mm 开口扳手
拆开排气管和增压器连接法
兰自锁螺母，拿下增压器。
Remove the self-locking nuts
from exhaust manifold to remove
turbocharger．
8‐42
更换新的增压器
Replace with new tu rbocharger
注意：如果涡轮增压器不是
立即更换．则应盖好各进出气口。
以防止任何物品掉入气缸里。
Note：If the turbocharger is not
replaced immediately，the intake
and exhaust manifolds should
be cove red to prevent anything
falling into cylinder．
6mm 内六角扳手
更换新的进油管垫片，并拧
紧进油管螺栓。
Replace with new gasket for
inlet pipe,fighten bolts of oil inlet
pipe.
注意：安装进油管垫片时，
一定对正垫片油孔和增压器法兰
处油孔 , 且加入干净的机油并转
动涡轮叶轮．使机油流入轴承室。
Note：Make sure to adjust the
gasket oil hole and tu rbocharger
flange oil hole，add some clean
oil and rotate turbo impeller to Iet
oil flow into bearing Case．
8‐43
8‐44
9. 柴油机典型故障及处理
Common Troubles and Remedy
9.1 柴油机不能起动
Diesel engine can not start
故障原因排除方法
Cause Remedy
1.输油泵进油滤网或软管等油路堵塞检查清除污物，检查燃油的清洁度
Fuel intake filter screen of supply pump Clear away the dirt and check if the fuel
or hose is clean
clogged
2.燃油系统内有空气排除空气，检查接头密封性，修复之
Air entered into the fuel system Drain off the air, check the
sealing of the connector and repair
it
3.喷油泵有故障
检查柱塞、出油阀修理或更换损件
Injection pump damaged
Check plunger, fuel outlet valve and
repair or
replace the broken parts
4.喷油器有故障检查喷油器物化情况
Injector damaged Check the atomization of injector, and
repair it
5.配气或供油管损坏及漏油检查并调整之
Initial angles of valve gear or fuel Cheek and adjust it
delivery
is wrong
6.高压油管损坏及漏油修复与更换
High pressure line damaged or leaked Repair or replace
7.气缸压缩压力不足检查气门密封性，缸垫的密封性，活塞
Insufficient pressure in cylinder
坏的
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
replace
them
8.气温过低增加起动辅助设备措施
The temperature is too low
With the addition of start-assist device
1
9.2起动不久就停车
Stop soon after starting
1.燃油滤清器堵塞拆卸滤清器体，清除内部污染物及水
Fuel filter clogged 份，必要时更换滤芯
Dismantle and clean away dirt and water,
replace
the filter element if necessary
2.燃油系统内进入空气检查油管及接头密封性，
Air entered into fuel system
放气螺钉是否拧紧，排斥贮留空
气
Check fuel pipe and s
ealing o f t h e connector,tighten
air venting bolt, and drain offthe air
3.输油泵不工作
检查输油泵活塞、阀门，清理及修复
Supply pump doesn't work Check piston and valve of supply pump,
clean
and repair
4.燃油质量差，含水过多清洗滤清器，更换燃油
Poor quality of fuel
Clean fuel filter and renew fuel
5.怠速调速过低重新调整
Idling speed is too low Readjust it
2
9.3 功率不足
Insufficient output
1.进气堵塞(空滤器堵塞) 检查空滤器，进气管、清理或更换滤芯
Air intake clogged (air cleaner choked) Check the air cleaner and air intake
pipe,clean or replace filter
element
2.排气背压过高检查气门定时，排气管道有否堵塞，调
Exhaust back pressure is too high 整及修理之
Check the valve-timing and exhaust pipe,
adjust and repair
3.增压系统压力不足检查，排除管路连接处泄漏
Insufficient pressure in supercharging Check
pipeline
and block up the leakage of
syste
4.增压器工作失常更换总成
Faults in turbocharger Replace the turbocharger assembly
4.1压气机，涡轮流道污塞清洗或更换
Compressor and turbine streets choked up Clean or replace
4.2浮动轴承失效更换
Floating bearing cease to be in effect Replace
4.3涡轮，压力机背面间隙处积炭，油泥清洗
Carbon deposit or greasy filth in Clean
clearance of turbine and compressor
bac
5.中冷器损坏，漏气更换或修补
Intercooler damaged Replace or repair
6.燃油管路漏油或堵塞检查油管及接头密封性，滤清器的污染
Leakage or choke of fuel line 度及燃油管道修复
或清除污塞，更换滤芯
Check the sealing of fuel pipe and
connector, fuel filter and fuel
line, repair, clean or replace the filter
element
7.燃油质量差清洗油箱，滤清零件及油管，更换燃油
Poor quality of fuel Clean the fuel tank, filter parts and fuel
pipe. Renew the fuel
8.喷油泵或调速器磨损过大修理或更换
Excessive wear for injection pump or Repair or replace
gover- nor
9.喷油泵冒烟限制器膜片破损更换修理
Smoke -limiter diaphragm of injection
pump damaged Repair or replace
10.冒烟限制器空气管损坏漏气更换Replace
Air pipe of smoke-limiter damaged
11.喷油嘴物化不良检查喷油压力，喷油嘴积炭，调整及修
Poor atomizing 理之
Check the injecting pressure, clean away
the carbon deposit in nozzle, adjust and
repair in-jector
12.配气或供油定时不对检查并调整之
Incorrect timing of valve gear or fuel
deliv-ery Check and adjust it
3
13.调速器高速调整过低检查调速特性，调整之
High-speed of governor is adjusted too
low Check the speed-governing and adjust
14.油底壳机油面过高检查油尺，放出多余机油
Oil level in the oil sump is too high
Check the oil-dipstick, and drain off
unnecessary oil
15.气缸垫漏气热车时检查压缩压力，更换损坏气缸垫
Check the compressed pressure at hot
Leakage in cylinder gaskets state, replace cylinder
gaskets
16.活塞环磨损断裂，轴瓦间隙过大更换磨损零件，或大修发动机
Replace worn parts or overhaul the
Piston ring broken, the clearance of main engine
bearing is too large
17.缸套或活塞磨损或拉缸大修发动机
Cylinder liner or piston worn, or piston Overhaul the engine
scuffing
4
9.4燃油消耗过大
Fuel consumption is too high
1．.进气堵管检查空滤器、进气管路，清理之
Air intake clogged (air cleaner Check
then
air cleaner and air intake pipe,
choked)
clean them
2.排气背压过高
Exhaust back pressure is too high 检查排气管道及制动阀，清理之
Check exhaust pipe and brake valve, then
clean
them
3.燃油质量差按规定更换燃油
Poor quality of fuel Renew the fuel according to requirements
4.燃油管路堵塞检查并修复之
Fuel line choked Check and repair
5.燃油管路漏油检查并修复之
Fuel line leaked Check and repair
6.喷油器物化不良检查并调整或修复之
Poor atomizing Check, adjust and repair
7.配气或供油定时不对按规定调整气门间隙及供油提前角
Incorrect timing of valve gear or fuel Adjust valve clearance and injection
delivery ad-vance
angle according to requirements
8.缸垫漏气检查压缩压力
Leakage in cylinder gasket Check compressed pressure
9.轴瓦间隙过大，发动机需大修检查及大修
The clearance of main bearing shell is too Check and overhaul
large
Engine need to overhaul
10.活塞涨缸更换气缸套、活塞及活塞环
Piston scuffing Replace cylinder liner, piston and piston
ring
11.增压系统压力不足检查排除管路和连接处泄漏
Insufficient pressure in supercharging Check and block up the leakage of
system
pipeline
12.增压器工作失常检查并更换
Faults in turbocharger Check and replace
13.中冷器损坏或漏气更换或修补
Intercooler damaged or leaked Replace or repair
5
9.5排气冒黑烟
Black smoke exhaust
1.进气堵管或排气背压高清理之
Air intake isn't free or exhaust back Clean
pressure is
too high
2.燃油质量差清洗及更换
Poor quality of fuel Clean and renew
3.配气或供油定时不对按规定调整
Incorrect timing of valve gear or fuel Adjust according to requirements
supply
4.喷油嘴物化不良检查，修复或更换
Poor atomizing Check, repair or replace injector
5.喷油泵油量过多检查并调整(由专业厂进行)
Excessive injection quantity Check and adjust (by manufacturer)
6.增压系统压力不足检查排除管路和连接处漏
Insufficient pressure in supercharging Check and block up the leakage of
system pipeline and
connector
7.增压器工作失常检查更换总成
Faults in turbocharger Check and replace
8.中冷器损坏，漏气更换或修补
Intercooler damaged or leaked Replace or repair
9.冒烟限制器起作用点不对重新调整(由专业厂进行)
Incorrect working point of smoke-limiter Readjust ( by manufacturer)
6
9.6排气冒白烟、蓝烟
White, blue smoke exhaust
1.燃油质量差，含水份多更换燃油
Poor quality of fuel, contains water Renew fuel
2.冷却水温过低检查节温器工作温度，必要时更换
Temperature of cooling water is too low Check working temperature of
thermostat, replace
if necessary
3.配气或供油定时不对检查并调整
Incorrect timing of valve gear or fuel
delivery Check and adjust
4.喷油嘴物化不良检查并修复
Poor atomizing Check and repair
5 . 压缩压力低，燃烧不完检查活塞环、气缸套、缸垫、修复之
Check piston ring,cylinder
全及活塞涨缸 liner,cylinder
Incomplete combustion, scuffing gasket,and repair them
and the
compressed pressure is too low
6.活塞环，缸套未磨合好继续磨合
Wear-in between the piston rings and Go on wearing-in
cylinder
liners is not good
7.活塞环开口未错开调整重新装配
The gaps of the piston rings are not Adjust, reassembly
staggered
8.活塞油环失效更换
Piston oil rings cease to be in effect Replace
9.活塞缸套配合间隙过大检查，更换
The fit clearance between piston and Check and replace
cylinder liner is too large
10.增压器密封环磨损检查，更换
The sealing ring of turbocharger worn Check and replace
11.增压器止推轴承磨损检查，更换
The thrust bearing of turbocharger worn Check and replace
12.增压器回油管路阻塞清洗或修理
The oil return pipe of turbocharger Clean or repair
choked.
7
9.7增压器进气口，进气管富集机油
Lub-oil gathered in air intake port and air intake pipe of
turbocharger
1.增压器密封失效修理或调换增压器
The sealing of turbocharger cease to be in Repair or replace turbocharger
effect
2.油气分离器失效调换
Replace
The gas-oil separator cease to be in effect
3.油底壳机油面过高，加入机油过多检查放出适量机油符合规定
Lub-oil level in oil sump is too high Drain off unnecessary oil
according to re-quirements
9.8转速不稳定
Uneven engine speed
1.燃油质量差，含水或蜡质更换燃油
Clean fuel system, and renew fuel
Poor quality of fuel, mingled with water
or wax
2.燃油吸油管漏入空气检查油管及接头密封性，排除空气
Air entered into fuel suction pipe Check the sealing of fuel pipe and
connector,
drain off air
3.调速器重锤、调速弹簧工作不正常检查并调整(由专业厂进行)
Faults in flyweight of governor
and speed governing spring Check and repair (by manufacturer)
4.供油不均匀检查并调整(由专业厂进行)
Uneven fuel delivery Check and adjust (by manufacturer)
5.喷油嘴物化不稳定检查并修复
Unstable atomizing Check and repair
6.增压器发生喷振
检查，清洗压气机流道，排除污塞，清
Surge in turbocharger
除废
气通道积炭
Check, Wash compressor streets, clean
a-way the
carbon deposit from exhaust passage
7.增压器轴承损坏
更换
Bearing of turbocharger damaged
Replace it
8
9.9 机油压力过低
Lub-oil pressure is too low
1.油底壳油面过低或缺油检查油面及有否漏油处，添加机油
Oil level in oil sump is too low Check oil leakage, add oil
2.主油道调压阀有故障检查阀门，清洗并修复
Faults in pressure regulating valve of Check valve, clean and repair
main oil
passage
3.集滤器、机油管路、接头垫片等，有检查，清洗压气机流道，排除污塞，清
除废
否堵塞气通道积炭
或破裂 Check strainer and connector , check
Strainer, oil pipes, connector gasket if there is any sponge in oil passage,
choked or broken repair
4.机油牌号不符合规定按规定更换机油，选用合适牌号机油
Lub-oil doesn't conform to specifica-tions Renew the lub-oil according to
requirements
5.机油泵进油管漏检查油管、接头，修复或更换
Intake pipe of oil pump leaked Check the oil pipe and
connector, repair or replace
6.冷却系统水温过高，机油温度过高检查冷却系统工作，纠正之
Water temperature in cooling Check cooling system, and correct it
system and oil
temperature are too high
7.机油滤清器阻力过大更换新滤芯
Excessive resistance of oil filter Renew the filter element
8.机油冷却器堵塞检查并清理
Oil cooler choked Check and clean
9.主油道堵塞检查并清理
Main oil passage choked Check and clean
10.轴瓦间隙过大,或轴瓦损坏检查并更换
The clearance of bearing is too large or Check and replace
bearing damaged
11.部件磨损过大,要大修11. Excessive 检查发动机工作实数,大修
wear of Check the working time of the engine,
parts, need to over-haul over haul
9
9.10 冷却水温过高
Cooling water temperature is too high
1.水箱水面过低检查有无漏水处，加水
Water level in water tank is too low Check water leakage, add water
2.水箱堵塞检查水箱，清理或修复
Water tank clogged Clean or repair
3.水泵皮带松弛按规定调整张紧力
The belt of water pump loosened Adjust tension according to requirements
4.水泵垫片损坏，水泵叶轮磨损检查并修复或更换
Water pump gasket damaged, Check and repair, or replace
water pump impeller worn
5.节温器故障更换
Faults in thermostat Replace it
6.水管损坏，漏入空气检查水管、接头、垫片等，更换损坏件
Water pipe damaged and air entered Check the water pipe, connector
and gasket. Renew the damaged parts
7.油底壳油面过低或缺油检查油面及漏油处，修复并加油
The oil level in oil sump is too low
Check oil leakage, repair and add oil
9.11 零件磨损过快
Parts wore quickly
1.空滤器滤芯不合格，或破损检查，更换合格滤芯 Check and
1. Filter element of air cleaner is unquali-
fied or damaged replace filter element
10
9.12 噪音过大
Noise is too high
1. 燃油质量差更换燃油
Poor quality of fuel Renew fuel
2. 冷却水温过低检查节温器，必要时更换
Temp of cooling water is too low Check thermostat, replace it if necessary
3. 配气或供油定时不对检查并修复调整
Incorrect timing of valve gear or fuel Check, repair and adjust
delivery
4. 喷油嘴物化不良检查并修复调整
Poor atomizing Check, repair and adjust
5. 喷油泵油量过大检查并调整(由专业厂进行)
Excessive injection quantity Check and adjust (by manufacturer)
6. 减震器磨损检查有否损坏，连接螺栓情况，更换损
Vibration damper damaged 坏件
Check connecting bolt and replace
damaged parts
7. 气门漏气或调整不当拆检气门，调整
Leakage in valve or adjusted unsuitably Dismantle and check valve, readjust it
8. 齿轮间隙过大或齿断裂检查并更换损坏件
Excessive gear clearance or tooth broken Check and replace damaged parts
9. 缸套或活塞磨损或拉缸检查并修复或更换
Cylinder liner or piston worn, or piston Check and repair, or replace
scuffing
10. 推杆弯曲或断裂更换
Push rod bended or broken Replace it
11. 活塞环断裂或磨损检查或更换损坏件
Piston rings broken or worn Check and replace damaged parts
11
9.13 起动电机不工作
Starting motor doesn't work
1. 蓄电池充电不足检查，充电或更换电池
Insufficient charging for battery Check, charge or replace
2. 连接线接触不良清理线路，旋紧接柱
Bad contact in connecting wire Check up circuit, tighten terminal
3. 熔断器熔断更换熔断器
Fuse broken Replace
4. 电刷接触不良清洁电刷表面或更换电刷
Bad contact in brush Clean brush surface or replace brush
5. 起动电机本身短路修检电机或更换总成
Short circuit in starting motor Check and repair it, or replace
the motor assembly
9.14 起动电机无力
Starting motor is powerless
充电或更换电池
1. 蓄电池充电不足
Charge or replace
Insufficient voltage of battery
2. 轴承衬套磨损更换总成
Bearing bush worn Replace bearing assembly
3. 电刷接触不良清洁电刷表面或更换电刷
Bad contact in brush Clean brush surface or replace brush
4. 换向器不洁或烧毛清除油污并用砂纸磨光或更换总成
Commutator unclean or sintered Clean away the dirt and furbished using
sandpaper, or replace commutator
assembly
5. 线端脱焊重新焊接
Sealing off at wire end Reweld
6. 开关接触不良检查开关并修复
Bad contact for switch Check and repair
7. 磨损离合器打滑调整离合器工作力矩或更换总成
wore clutch slipped Adjust working moment of clutch or
replace
12
9.15 发电机完全不发电
Generator doesn't work
1. 接线断路、短路、接头松动修复
Connecting wire broken or shorted, Repair
terminal loosened
2. 转子、定子线圈断路、短路或搭铁修复或更换总成
Coil of rotator and stator shorted or Repair or replace
broken partially
3. 发电机皮带松弛检查并调整皮带张紧力
Belt of generator loosened Check and adjust tension
4. 发电机整流管损坏，电池接触不良修复
Rectifier tube damaged,bad contact in Repair
brush
5. 调节器电压调整过低调整
Insufficient voltage of regulator Regulate
6. 调节器磁场线圈或电阻接线断开修复或更换
Field coil or resistance connecting wire Repair or replace
broken
7. 蓄电池电解液太少，或电池陈旧加注电解液，或更换电池
Insufficient electrolyte of battery or
battery is too old Add electrolyte or renew battery
9.16 发电机充电不足
Insufficient charging of generator
1. 接线断路、短路、接头松动修复
Connecting wire broken or shorted, Repair
terminal loosened
2. 转子、定子线圈断路、短路或搭铁修复或更换总成
Coil of rotator and stator shorted or Repair or replace
broken partially
3. 发电机皮带松弛检查并调整皮带张紧力
Belt of generator loosened Check and adjust tension
4. 发电机整流管损坏，电池接触不良修复
Rectifier tube damaged,bad contact in Repair
brush
5. 调节器电压调整过低调整
Insufficient voltage of regulator Regulate
6. 调节器磁场线圈或电阻接线断开修复或更换
Field coil or resistance connecting wire
broken Repair or replace
7. 蓄电池电解液太少，或电池陈旧加注电解液，或更换电池
Insufficient electrolyte of battery or
battery is too old Add electrolyte or renew batter
13
9.17 充电电流不稳定
Uneven charging current
1. 定子或转子线圈即将断路、短路修复或更换
Coil of rotator or stator will short or Repair or replace
break
2. 电刷接触不良修复
Bad contact in brush Repair
3. 接线柱头松动，接触不良修复
Terminal loosened and bad contact Repair
4. 电压调节器损坏修复
Voltage regulator damaged Repair
5. 电压调整不当检查并调整
Incorrect regulated voltage Check and regulate
9.18 发电机充电过多
Generator over-charged
1. 蓄电池内部短路修复或更换
Shorted in battery Repair or replace
2. 调节器电压过高修复并调整
Voltage of regulator is too high
Repair and regulate
3. 调节器搭铁不良修复
Bad contact in regulator Repair
4. 调节器触头失灵, 污染, 电压线圈或修复或更换
电阻接线断开 Repair or replace
Faults in regulator contact, voltage coil or
resistance connecting wire broken
9.19 发电机有不正常声音
Abnormal sound in generator
1. 发电机安装不当修复
Incorrect mounting for generator Repai
2. 轴承损坏更换轴承
Bearing damaged Replace
3. 转动部分已触及固定部分修复或更换
Moving parts bumping to fixed parts Repair or replace
4. 整流器短路更换
Rectifier shorted Replace
5. 定子线圈短路修复或更换
Stator coil shorted Repair or replace
14
15

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WD615欧Ⅱ系列柴油机维修保养手册

Maintenance Manual for WD615 Series EuroⅡDiesel Engine

catalogue and specifications of maintenance manual. Purchased parts

operating condition is heavy dust content or the engine running on

(WGⅠ) (WGⅡ) (WGⅢ)

使用条件 (WGⅠ) (WGⅡ) (WGⅢ)

Operating 年行使里程不到 年行使里程不到 年行使里程超过

使用条件 (WGⅠ) (WGⅡ) (WGⅢ)

例行检查 每隔5000km 每隔1x104km 每隔1.5x104km

1级保养 每隔1x104km每隔300h 每隔2x104km 每隔3x104km

2级保养 每隔2x104km每隔600h 每隔4x104km 每隔6x104km

3级保养 每隔4x104km每1200h 每隔8x104km 每隔12x104km

4级保养 每隔8x104km每2400h 每隔16x104km 每隔24x104km

1级保养 机油 气门间隙 空气滤清器

2级保养 气门间隙 空气滤清器

3级保养 机油 气门间隙 空气滤清器

4级保养 机油 气门间隙 空气滤清器

日期 公里小时或间 实际里程 保养内容 保养者 备注

停车后约 5min 让机油自上部

采用 WEVB 系统后，排气门间隙的调整方法 ( 零件序号参见图 1)：

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.

The piston of 1 cylinder is at TDC of Step A

16mm 开口扳手 ( 双级机油

Tightening torque：60。 N·m +5

Tightening torque：60。 N·m 5

Tightening torque：45。 N·m

13mm 开口扳手 17mm 开口

The sealing ring of turbocharger worn Check and replace

Uneven fuel delivery Check and adjust (by manufacturer)

Excessive resistance of oil filter Renew the filter element

parts, need to over-haul over haul

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Operating 年行使里程不到年行使里程不到年行使里程超过

例行检查每隔5000km 每隔1x104km 每隔1.5x104km

1级保养每隔1x104km每隔300h 每隔2x104km 每隔3x104km

2级保养每隔2x104km每隔600h 每隔4x104km 每隔6x104km

3级保养每隔4x104km每1200h 每隔8x104km 每隔12x104km

4级保养每隔8x104km每2400h 每隔16x104km 每隔24x104km

1级保养机油气门间隙空气滤清器

2级保养气门间隙空气滤清器

3级保养机油气门间隙空气滤清器

4级保养机油气门间隙空气滤清器

日期公里小时或间实际里程保养内容保养者备注