WEICHAI WD615 Parts list manual

WD615欧Ⅱ系列柴油机维修保养手册
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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 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
X X X
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
1.2 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).

WD615欧Ⅱ系列柴油机维修保养手册
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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.
· 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.
1.3 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

WD615欧Ⅱ系列柴油机维修保养手册
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Maintenance Manual for WD615 Series EuroⅡDiesel Engine
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５－１５０
d[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．
1.4 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．
1.5 柴油机的起动
Starting
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

WD615欧Ⅱ系列柴油机维修保养手册
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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
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 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。

WD615欧Ⅱ系列柴油机维修保养手册
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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，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℃ .
1.6 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
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．

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WD615欧Ⅱ系列柴油机维修保养手册
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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；
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.

WD615欧Ⅱ系列柴油机维修保养手册
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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．
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
或酷热，含尘量高，短距离运
输，在工地使用以及公共汽
车，市政工程车，扫雪车，消
防车）或汽车年行驶里程不足
2×104km 或年工作时间不足
600h
U n d e r s e v e r e o p e r a t i n g
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.
年行驶里程不足6×
104km，短中距离运输（用于
送货）
Annual running mileage of the
vehicle less than 6×104km,,
for short- or medium-distance
transportation (for goods).
年行驶里程超过6×
104km 的远距离运输汽车
Annual running mileage of the
vehicle more than 6×104km for
long distance transportation.

WD615欧Ⅱ系列柴油机维修保养手册
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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
项目
Item
(WGⅠ) (WGⅡ) (WGⅢ)
第1次检查
The first inspection
行使1000～1500km时
行使30～50h
Running
1,000~1,500km or
30~50h
行使1500～2000km时
Running
1,500~2,000km
行使1500～2000km时
Running
1,500~2,000km
例行检查
Routine inspection
每隔5000km
每隔150h
Every 5,000km or
150h
每隔1x104km
Every 1×104 km
每隔1.5x104km
Every 1.5×104 km
1级保养
Level 1 maintenance
每隔1x104km
每隔300h
Every 1×104 km or
300h
每隔2x104km
Every 2×104 km
每隔3x104km
Every 3×104 km
2级保养
Level 2 maintenance
每隔2x104km
每隔600h
Every 2×104 km or
600h
每隔4x104km
Every 4×104 km
每隔6x104km
Every 6×104 km
3级保养
Level 3 maintenance
每隔4x104km
每隔1200h
Every 4×104 km or
1,200h
每隔8x104km
Every 8×104 km
每隔12x104km
Every 12×104 km
4级保养
Level 4 maintenance
每隔8x104km
每隔2400h
Every 8×104 km or
2,400h
每隔16x104km
Every 16×104 km
每隔24x104km
Every 24×104 km

WD615欧Ⅱ系列柴油机维修保养手册
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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
使用条件
Operating
condition
项目
Item
(WGⅠ) (WGⅡ) (WGⅢ)
年行使里程
不到2x104km
Annual running mileage
<2×104 km
年行使里程
不到6x104km
Annual running mileage
< 6×104 km
年行使里程
超过2x104km
Annual running mileage
> 6×104 km
第1次检查
The first inspection
行使1000～1500km时
Running 1000~1500km
行使1500～2000km时
Running 1500~2000km
行使1500～2000km时
Running 1500~2000km
例行检查
Periodical inspection
每隔5000km
Every 500km
每隔1x104km
Every 1×104 km
每隔1.5x104km
Every 1.5×104 km
1级保养
Level 1 maintenance
每隔1x104km
Every 1×104 km
Every 2400h
每隔2x104km
Every 2×104 km
每隔3x104km
Every 3×104 km
2级保养
Level 2 maintenance
每隔2x104km
Every 2×104 km
Every 2400h
每隔4x104km
Every 4×104 km
每隔6x104km
Every 6×104 km
3级保养
Level 3 maintenance
每隔4x104km
Every 4×104 km
Every 2400h
每隔8x104km
Every 8×104 km
每隔12x104km
Every 12×104 km
4级保养
Level 4 maintenance
每隔8x104km
Every 8×104 km
Every 2400h
每隔16x104km
Every 16×104 km
每隔24x104km
Every 24×104 km

WD615欧Ⅱ系列柴油机维修保养手册
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Maintenance Manual for WD615 Series EuroⅡDiesel Engine
2.2.2 保养项目
Maintenance Items
保养项目
Items
更 换
Replacement
调 整
Adjustment
检 查
Inspection
第1次检查
The 1st
inspection
机油
Oil
机油滤清器
Oil filter
气门间隙
Valve clearance
紧固管路管夹
Tighten pipe clamps
紧固三角皮带
Tighten V-belts
例行检查
Periodical inspection
机油
Oil
机油滤清器
Oil filter
紧固三角皮带
Tighten V-belts
1级保养
WD1
机油
Oil
机油滤清器
Oil filter
燃油滤清器
Fuel filter
气门间隙
Valve clearance
空气滤清器
Air filter
进气系统
Air intake system
紧固管路管夹
Tighten pipe clamps
紧固三角皮带
Tighten V-behs
2级保养
WD2
机油
Oil
机油滤清器
Oil filter
燃油滤清器
Fuel filter
气门间隙
Valve clearance
空气滤清器
Air filter
进气系统
Air intake system
紧固管路管夹
Tighten pipe clamps
紧固三角皮带
Tighten V-belts

WD615欧Ⅱ系列柴油机维修保养手册
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Maintenance Manual for WD615 Series EuroⅡDiesel Engine
保养项目
Items
更 换
Replacement
调 整
Adjustment
检 查
Inspection
3级保养
WD 3
机油
Oil
机油滤清器
Oil filter
燃油滤清器
Fuel filter
冷却液
Coolant
空气滤清器
Air filter
气门间隙
Valve clearance
空气滤清器
Air filter
进气系统
Air intake system
紧固管路管夹
Tighten pipe clamps
紧固三角皮带
Tighten V-belts
在试验台上检查调整
喷油泵
Inspect and adjust the
injection
fuel pump on test
bench
4级保养
WD 4
机油
Oil
机油滤清器
Oil filter
燃油滤清器
Fuel filter
冷却液
Coolant
空气滤清器
Air filter
气门间隙
Valve clearance
空气滤清器
Air filter
进气系统
Air intake system
紧固管路管夹
Tighten pipe clamps
紧固三角皮带
Tighten V-belt
检查增压器轴承间隙
Check the 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

WD615欧Ⅱ系列柴油机维修保养手册
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Maintenance Manual for WD615 Series EuroⅡDiesel Engine
2.3 维护保养记录
Maintenance Record
柴油机编号
Engine number
柴油机型号
Engine model
用户名称
User name
设备名称
Equipment name
日期
Date
公里小时
或间隔时间
Running
Kilometers／hours
or interval hours
实际里程
Actual
Kilometers
保养内容
Maintenance
contents
保养者
Operator
备注
Remark

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WD615欧Ⅱ系列柴油机维修保养手册
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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.
检查：
Inspect：
·泄漏
Leakage
·易损件
Fast wearing parts
·柴油机上出现的任何异常
Any unconventionality

WD615欧Ⅱ系列柴油机维修保养手册
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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．
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．

WD615欧Ⅱ系列柴油机维修保养手册
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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
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

WD615欧Ⅱ系列柴油机维修保养手册
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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
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．

WD615欧Ⅱ系列柴油机维修保养手册
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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，
then re-install the cup again

WD615欧Ⅱ系列柴油机维修保养手册
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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
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)