WEICHAI WD615 Series Usage Instructions
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WEICHAI WD615 Series Usage Instructions

WEICHAI WD615 Series Usage Instructions

Euro ii diesel engine
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Table of Contents

WD615欧Ⅱ系列柴油机维修保养手册
Maintenance Manual for WD615 Series EuroⅡDiesel Engine
1.1 WD615系列客车柴油机代号的含义
The signification of the code of WD615 Series Diesel Engines
W D 6 15
1.2 新柴油机使用须知
Operating notice for new diesel engine
·汽车用柴油机，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).
1.柴油机使用说明
Usage Instructions
X X
X
X X
基本产品代号
Basic product code
柴油机单缸排量
Single cylinder displacement
缸数
Number of Cylinder
柴油机
Diesel engine
水冷
Water cooled
变型产品设计编号
Design code for developed
diversity model
用途代号
Application code:
C––船用柴油机
Marine diesel
engine
D––发电用柴油机
Diesel engine for
generating set
G––工程机械用柴油机
diesel engine for
construction
machinery
T––推土机用柴油机
Diesel engine for
bulldogets
Q––汽车用柴油机
Diesel engine for
trucks
K––客 车 用柴油机
N––水泥搅拌机
-1-

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Summary of Contents for WEICHAI WD615 Series

  • Page 1: Description Of Illustration Marks 1. 柴油机使用说明

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 1.柴油机使用说明 Usage Instructions 1.1 WD615系列客车柴油机代号的含义 The signification of the code of WD615 Series Diesel Engines W D 6 15 变型产品设计编号 Design code for developed diversity model 用途代号 Application code: C––船用柴油机 Marine diesel engine 基本产品代号...
  • Page 2 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine · 工程机械用柴油机， 在最初使用的 60h 内， 柴油机应在部分负荷 ( 油门在 3 ／ 4 位置以下 ) 工作。 For construction machinery application，the engine sho．uld be running under part load(the accelerograph should be controlled under 3 ／ 4 full load)during its initial 60h running.
  • Page 3 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，...
  • Page 4 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 ，...
  • Page 5 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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，...

  • Page 7: 柴油机维护保养指南

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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；...
  • Page 8 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 operating condition is heavy dust content or the engine running on started-stopped frequently，the regular maintenance period should be shortened accordingly．...
  • Page 9 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Operating condition (WGⅠ) (WGⅡ) (WGⅢ) 项目 Item 行使1000～1500km时 行使30～50h 行使1500～2000km时 行使1500～2000km时 第1次检查 Running Running Running The first inspection 1,000~1,500km or...
  • Page 10 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 表2-3 斯太尔汽车保养制度的机油换油期 Table 2-3 Oil Replacement Period in SteyrVehicle Maintenance System (WGⅠ) (WGⅡ) (WGⅢ) 使用条件 Operating 年行使里程 年行使里程 年行使里程 condition 不到2x10 不到6x10 超过2x10 项目 Annual running mileage Annual running mileage Annual running mileage Item <2×10...
  • Page 11 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 2.2.2 保养项目 Maintenance Items 保养项目 更 换 调 整 检 查 Items Replacement Adjustment Inspection 机油 紧固管路管夹 第1次检查 气门间隙 Tighten pipe clamps The 1 机油滤清器 Valve clearance 紧固三角皮带 inspection Oil filter Tighten V-belts 机油...
  • Page 12 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 保养项目 更 换 调 整 检 查 Items Replacement Adjustment Inspection 空气滤清器 Air filter 机油 进气系统 Air intake system 机油滤清器 紧固管路管夹 Oil filter Tighten pipe clamps 3级保养 燃油滤清器 气门间隙 紧固三角皮带 WD 3...
  • Page 13 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 公里小时 或间隔时间 实际里程 保养内容 日期 保养者 备注 Running Actual Maintenance Date Operator Remark Kilometers／hours Kilometers contents...

  • Page 15: 柴油机保养内容

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 be done 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.
  • Page 16 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 17 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 18 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 检查三角皮带 Inspect the V-belts 用肉眼检查三角皮带，有无...
  • Page 19 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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，...
  • Page 20 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 21 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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，...
  • Page 22 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 23 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 24 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 25 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 26 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 T h e C l e a r a n c e o f W E V B systerm is 0.25mm...
  • Page 27 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 28 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 29 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 步骤 A 位置。 Step A The piston of 1 cylinder is at　TDC of the compression　stroke． 如步骤 A 所示检查或调整气门 间隙 (I 表示进气， E 表示排气 )。...
  • Page 30 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 用 盘 车 扳 手 再 转 动 曲 轴 。 ；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 。 after marking on the vibration damper.
  • Page 31 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 32 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 33 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 34 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 35 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 36 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 1、 纸质滤芯 7kpa，it should be checked while Paper foltering element the engine running at rated speed　...
  • Page 37 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 从空滤器中拆下空滤芯，轻 拍端面使灰尘落下，也可用压缩 空气反吹 ( 由内向外吹 )。 Remove the filter core from the 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　...
  • Page 38 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.

  • Page 39: 柴油机几大系统示意图

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 40 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 41 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 42 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 43 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 --...
  • Page 44 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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)
  • Page 45 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 4.4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...

  • Page 47: Schematic Diagram Of Main Systems 5. 柴油机强力螺栓的扭紧力矩和扭紧方法

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 分两次拧紧...
  • Page 48 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 49 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 50 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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． 。...
  • Page 51 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 一次拧紧到60 N·m Tighten the bolt with a torque of 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．...
  • Page 52 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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150 N·m Tighten the boh with a torque of 150 N·m...
  • Page 53 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool：13mm sleeve wrench 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 2 4 2 T H R E A D L O C K E R b e f o r e tightening．...
  • Page 54 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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45 N·m Tighten these bolts in sequence， and the torque is 45 N·m...

  • Page 55: 柴油机所用的燃料油、 润滑油、 冷却液和辅助材料

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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℃，...
  • Page 56 3 litr． According to the agreement between Weichai and customers，the engine could be supplied with or without the oil in the sump of the engine． If the engine was supplied with the oil in the sump，...
  • Page 57 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 细钼粉 涂在平滑的金属表面防止咬合 Fine 黑色 Apply to smooth surface of metal to prevent biting.
  • Page 58 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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． -5-...

  • Page 59: 电气部分

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 60 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 61 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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℃...

  • Page 63: 主要零部件的调整与更换

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 64 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool：16mm open-ended wrench 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．...
  • Page 65 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 13mm 开口扳手 Tool：13mm open-ended wrench 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。...
  • Page 66 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 拆下发电机 Remove generator． 16mm开口扳手 Tool：16mm open-ended 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． -66-...
  • Page 67 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool：13mm sleeve wrench 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．...
  • Page 68 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 13mm开口扳手 Tool：13mm open-ended 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． -6-...
  • Page 69 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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． -6-...
  • Page 70 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 a s s e m b l y ，t i g h t e n 6 h e x a g o n nuts.(There is a nut in the inner side...
  • Page 71 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 装上发电机 Install generator． 16mm开口扳手，铁棒 Tool：16mm open-ended 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。 I n s t a l l t h e V - b e l t a n d adjust the tensity, tighten M10 hexagon lock nuts of tightening pulley．...
  • Page 72 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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。 I n s t a l l t h e V - b e l t o f generator and adjust the tensity，...
  • Page 73 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool：13mm sleeve wrench 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...
  • Page 74 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 6mm套筒扳手 Tool：6mm sleeve wrench 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.
  • Page 75 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 更换机油冷却器芯密 封热圈。 Replace seal ring of oil cooler element. 13mm 套筒扳手 T o o l ： 1 3 m m s l e e v e 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．...
  • Page 76 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 77 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 拆下油底壳托块， 并拿下 油底壳。 Remove retainer，then remove 0il pan． 27mm 开口扳手 Tool：27mm open-ended 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.
  • Page 78 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 27mm 开口扳手 Tool：27mm open-ended 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...
  • Page 79 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 更换机油泵 Replace Oil Pump 13mm 套筒扳手 16mm 开口扳手 T o o l ： 1 3 m m s l e e v e wrench and 16mm open- ended wrench 拆下油底壳， 拆机油集 滤器。...
  • Page 80 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm 开口扳手 ( 双级机油 泵 ) Tool：16mm open-ended 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...
  • Page 81 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 d a m p e r a n d crankshaft is transition fit，the damper can be knocked slightly if it is necessary for removing．...
  • Page 82 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm 套筒扳手 Tool：16mm sleeve wrench 拆下机油泵中间齿轮轴螺栓。 R e m o v e t h e b o l t s o f 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．...
  • Page 83 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 拆下机油泵中间齿轮 Remove intermediate gear of oil pump ． 16mm 套筒扳手 Tool：16mm sleeve wrench 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． --...
  • Page 84 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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。 --...
  • Page 85 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm套筒扳手 Tool:16mm sleeve wrench 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)
  • Page 86 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 安装机油泵中间齿轮轴。 Install intermediate gear shaft of oil pump． 16mm套筒扳手 Tool：16mm sleeve wrench 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 Tightening torque：60。 N·m -6-...
  • Page 87 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 安装减振器和皮带轮。 Install damper and pulley． 16mm套筒扳手 Tool：16mm sleeve wrench 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 Tightening torque：60。 N·m --...
  • Page 88 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm 开口扳手 Tool：16mm open-ended 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． --...
  • Page 89 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 8． 3 供油系统 Fuel Supplying System 更换喷油泵 Replace injection pump 16mm 开口扳手 T o o l ： 1 6 m m o p e n - e n d e d wrench 拆下高压油管与喷油泵连接...
  • Page 90 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm 套筒扳手 Tool：16mm sleeve wrench 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 T o o l ： 1 6 m m o p e n - e n d e d...
  • Page 91 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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． -1-...
  • Page 92 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 T o o l ： 1 9 m m o p e n - e n d e d wrench 拆下喷油泵连接油管。...
  • Page 93 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool：8mm sleeve wrench 拧 紧 喷 油 泵 内 六 角 头 螺 栓， 并连接好管路。...
  • Page 94 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 16mm 开口扳手， 16mm 梅花 扳手 T o o l ： 1 6 m m o p e n - e n d e d wrench and 10mm(double offset ring wrench． 安 装 喷 油 泵 与 连 轴 器 连 接...
  • Page 95 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 96 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 Tool:16mm sleeve wrench 装 上 连 轴 器 与 驱 动 轴 连 接...
  • Page 97 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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， r e m o v e b o l t s a t t a c h i n g s h a f t coupling and driving shaft for readjustment if necessary．...
  • Page 98 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 拆下喷油器回油管。 Remove fuel return pipe of the injector． 13mm 开口扳手 Tool：13mm open-ended wrench 松开紧固压板螺栓，拿下紧 固压板。 Loosen bolts of mounting plate， then remove mounting plate． --...
  • Page 99 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 拆下喷油器。 Remove injectors． 清洁喷油器座孔。 Clean seat hole of injector． --...
  • Page 100 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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． -100-...
  • Page 101 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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。 I n s t a l l t h e m o u n t i n g p l a t e o f injector.
  • Page 102 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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。...
  • Page 103 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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．...
  • Page 104 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 6mm 内六角扳手 Tool：6mm inner hexagon wrench 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 Tool：16mm open-ended wrench 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．...
  • Page 105 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...

  • Page 107: 柴油机典型故障及处理

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 or hose Clear away the dirt and check if the fuel is clean clogged 排除空气，检查接头密封性，修复之...
  • Page 108 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 9.2起动不久就停车 Stop soon after starting 拆卸滤清器体，清除内部污染物及水份，必 1.燃油滤清器堵塞 要时更换滤芯 Fuel filter clogged Dismantle and clean away dirt and water, replace the filter element if necessary 检 查 油 管 及 接 头 密 封 性 ， 放 气 螺 钉 是 否 拧...
  • Page 109 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 9.3 功率不足 Insufficient output 检查空滤器，进气管、清理或更换滤芯 1.进气堵塞(空滤器堵塞) Check the air cleaner and air intake pipe,clean or replace filter Air intake clogged (air cleaner choked) element 2.排气背压过高 检查气门定时，排气管道有否堵塞，调整及修理之 Exhaust back pressure is too high Check the valve-timing and exhaust pipe, adjust and repair 3.增压系统压力不足...
  • Page 110 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 9.4燃油消耗过大 Fuel consumption is too high 检查空滤器、进气管路，清理之 1.进气堵管 Check air cleaner and air intake pipe, then Air intake clogged (air cleaner choked) clean them 检查排气管道及制动阀，清理之 2.排气背压过高 Check exhaust pipe and brake valve, then clean...
  • Page 111 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 pressure is Clean 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 supply Adjust according to requirements 4.喷油嘴物化不良...
  • Page 112 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 检查节温器工作温度，必要时更换 2.冷却水温过低 Check working temperature of thermostat, replace Temperature of cooling water is too low if necessary 3.配气或供油定时不对...
  • Page 113 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 effect Repair or replace turbocharger 2.油气分离器失效 调换 The gas-oil separator cease to be in effect Replace 检查放出适量机油符合规定...
  • Page 114 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 9.9既有压力过低 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 main oil Check valve, clean and repair passage 3.集滤器、机油管路、接头垫片等，有否堵塞...
  • Page 115 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 116 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 9.11零件磨损过快 Parts wore quickly 1.空滤器滤芯不合格，或破损1. Filter element 检查，更换合格滤芯Check and replace filter of air cleaner is unquali- element fied or damaged 2.进气系统短路2. Air leakage in air intake system 检查进气管、垫片、连接管套，修复或更换 Check air intake pipe, gasket and connect- ing sleeve, repair or replace 3.油底壳油面过低或缺油...
  • Page 117 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 118 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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...
  • Page 119 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 检查发电机及电流表接线，修复 Wire connecting broken, short circuit, joint Check the connecting wire of generator or loosened galvanometer repair 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, broken Repair or replace 3.
  • Page 120 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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, terminal loosened Repair 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 broken partially Repair or replace 3.
  • Page 121 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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.
  • Page 122 WD615欧Ⅱ系列柴油机维修保养手册 编校：魏红珍 2007年7月版...
  • Page 123 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 特 别 提 示 Special Attention · 柴油机的操作人员在操作之前， 必须认真阅读柴油机的使用保养说 明书， 严格遵守使用保养说明书规定的操作与保养规程； Prior to the operation, the operator shall read the Diesel Engine Operation and Maintenance Manual carefully, and comply with the operation and maintenance procedure thereof strictly.
  • Page 124 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine Weichai is entitled to dismantle the rotator assembly; · 柴油机主轴承螺栓和连杆螺栓有严格的扭矩和转角要求， 用户不得 松动和拆卸， 否则公司保证失效。 There are strict demands on torque and turned angle for main bearing bolts and connecting rod， loosening and dismantling is forbidden， or the guarantee cease to be in effect．...
  • Page 125 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.
  • Page 126 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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 avoiding the air from entering into the cylinder directly without filtering.
  • Page 127 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 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：...
  • Page 129 The new model engines developed by our company have reached over hundreds to meet the market needs and thus we have goaen a big market share tm now In order to help customers understand WD615 series diesel engines well and operate correctly， we especially provide this maintenance manual.

  • Page 131: Table Of Contents

    WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 目 录 CONTENTS 标记说明 Description of Illustration Marks 1. 柴油机使用说明 -------------------------------------1 Operation Description 2. 柴油机维护保养指南 ---------------------------------7 Guide for Maintenance 3. 柴油机保养内容 -------------------------------------15 Maintenance Contents 4. 柴油机几大系统示意图 -------------------------------39 Schematic Diagram of Main Systems 5.
  • Page 133 WD615欧Ⅱ系列柴油机维修保养手册 Maintenance Manual for WD615 Series EuroⅡDiesel Engine 图 示 标 记 说 明 Description Of The Illustration Marks 拆卸(组合件) 涂润滑油 Dismounting (assembly Oil coating parts) 专用工具，如S K……， 装配(组合件) KUKKO,……，TS……W Fitting (assembly parts) Special tools, such as K--- ---, KUKKO, --- ---, TS--- ---W 打记号（分解前打上，重新...

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