WP12 国四系列柴油机培训

Training of WP12 Series diesel engine of Ⅳ

潍柴国际服务部
7/7/22
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图 0-1 WP12 国四车机典型结构产品示意图
Shape structure diagram of WP12 Series diesel engine of Ⅳ

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 目 录
Contents
第一篇 内燃机基础知识
5
The first chapter combustion engine basics
  第一章 内燃机基础知识
6
Chapter 1 combustion engine basics
第二章 WP12 系列柴油机基本参数
12
Chapter 2WP12 Series diesel engine basic parameters
第二篇 WP12 柴油机介绍
15
The second chapter WP12 diesel engine introduced
第一章 机体组
16
Chapter 1 of the body set
第二章 曲柄连杆机构
35
 Chapter 2 Crank Mechanism
第三章 配气机构 3
第五章 燃油供给系统
69
Chapter 5 fuel supply system
第六章 进排气系统
90
Chapter 6 intake and exhaust system
第七章 冷却系统
153
Chapter 7 The cooling system
第八章 润滑系统
172
Chapter 8 The lubrication system
第九章 起动系统
190
Chapter 9 starting system
第三篇 WP12 柴油机的维护保养
212
Third WP12 diesel engine maintenance
第一章 柴油机维护保养 4
第一篇 内燃机基础知识
Chapter 1 Internal combustion engine basics

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第一章 内燃机基础知识
Chapter 1 Internal combustion engine basics

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1.1 柴油机的四个工作过程
1.1 Four stroke cycle of Diesel Engine

四冲程内燃机工作循环，由进气冲程、压缩冲程、做功冲程和排气冲程组成一个工
作循环。 Work cycles of a four-stroke engine are terms: Intake stroke, Compression stroke,
Combustion stroke, Exhaust stroke, four strokes forms a working cycle.

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1.2 内燃机基本组成
1.2 The basic composition of the internal combustion engine
内燃机是一种复杂的能量转换机器。
随着技术水平的不断提高，各种类型内燃机的构造及其布置也就各有差异。但是为
了保证内燃机能够正常地连续运转和更好地实现能量转换，往复活塞式内燃机的基本构
造，都由下列二个机构：曲柄连杆结构、配气机构（包含齿轮传动系统）和五个系统：
机体组、供给系统（包含燃油系统、进排气系统、后处理系统）、润滑系统、冷却系统、
起动系统所组成。
The internal combustion engine is a complex energy conversion machines.
As technology continues to improve, construction and arrangement of the engine types has
differences. However, in order to ensure the continuous operation of the internal combustion
engine to be normally and achieve better energy conversion, the basic structure of a
reciprocating piston internal combustion engine, by the following two bodies: crank rod
structure, valve (containing gear transmission) and five system : body group supply system
(including the fuel system, intake and exhaust systems, after-treatment system), lubrication
system, cooling system, starting system formed.

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1.3 内燃机的性能指标
1.3 Performance of internal combustion engine
内燃机的性能包括动力性能（功率、转矩、转速）、经济性能（燃油消耗率等）和
使用性能（起动性、可靠性）等。
Performance of the engine, including power performance (power, torque, speed), economic
performance (fuel consumption rate, etc.) and service performance (starting, reliability) , etc.

a ）柴油机与汽油机对比之柴油机 b ）柴油机与汽油
机对比之汽油机
Comparison of diesel Comparison of gasoline

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 柴油机与汽油机比较，各有特点。汽油机具有转速高、质量轻、工作噪音小、起动容

易、制造和维修费用低等特点，故在轿车和轻型货车及越野车上得到了广泛应用；其不足

之处是燃油消耗率高，燃油经济性差。

Diesel and gasoline engine compared to its own characteristics. Gasoline has a high speed,

light weight, low noise, easy to start, manufacturing and maintenance costs low, so gasoline have

been widely used in cars, light trucks and sport utility vehicles ; their deficiency is the high fuel

consumption rate and poor fuel economy.

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 a ）柴油机与汽油机对比之柴油机 b ）柴油机与汽油
机对比之汽油机
Comparison of diesel Comparison of gasoline
柴油机因压缩比高，燃油消耗率平均比汽油机低 20%~30% 左右，所以燃油经济性好。一般装
载质量为 3.5t 以上的货车大都采用柴油机；其缺点是转速较汽油机低、质量大、制造和维修费用高。
Due to high compression ratio, Diesel fuel consumption is about 20% to 30% lower than the average rate
of gasoline, so the fuel economy is good. Usually the quality of 3.5t or more loader were powered by diesel
engine; their deficiencies are low speed compared with gasoline, massive, high manufacturing and
maintenance costs.

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第二章 WP12 系列柴油机基本参数

Chapter 2 WP12 Series diesel engine basic parameters

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2.1 WP12 系列柴油机技术参数
2.1 WP12 Series diesel engine basic parameters

WP12 X XXX E4 XX

变型代号 Variant code

排放阶段 Discharging stage

功率代号 Power Code
用途代号 Use code
产品系列代号 Products Code

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 表 2-2 WP12 系列柴油机基本参数
Tab-2 WP12 Series diesel engine basic parameters
参数 Parameters 数值 Numerical
四冲程、水冷、直列、直喷、干式缸套
型式 Type
Four-stroke, water-cooled, in-line, Direct Injection, Dry Liner
缸数 \ 缸径 \ 行程（ mmNumber of
6/126/155
cylinders \ Bore \ stroke (mm) ）
排量 （ L ） Displacement (L) 11.596
点火顺序 / 旋转方向
1-5-3-6-2-4 / 顺时针（从风扇端看）
Firing order / direction of rotation
冷态气门间隙 valve
进气 0.4 排气 0.6
clearance （ mm ）
起动方式 Starting 电启动 Electric start
润滑方式 Lubrication 压力润滑 Pressure lubrication
冷却方式 Cooling 水冷强制循环 water forced circulation
机油压力 Oil pressure （ kPa ） 350~550 ，怠速时机油压力为 idle oil pressure from130~250
28 （实际加注量以油尺为准） (actual fill quantity dipstick,
润滑油容量 Oil Capacity L
whichever)
允许倾斜角度 Allowed tilt angle
前后 30/30 / 左右 45/30
（°）
涡轮后排温 Turbine rear 增压及中冷机型≤ 600supercharged and intercooled models ≤600
temperature (℃) （℃）
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第二篇 机体缸盖组

Chapter 2 The body head group

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第一章 机体缸盖组
The first chapter The body head group

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1.1 机体组
1.1 The engine body

机体缸盖组是发动机的支架，是曲柄连杆机构、配气机构和发动机各系统主要零部件的装配基础。气缸盖用来

封闭气缸顶部，与活塞顶和气缸壁一起形成燃烧室，另外气缸盖和机体内的水套和油道以及油底壳又分别是冷却系统

和润滑系统的组成部分。

The body head group is bracket of the engine, It is the assembly basis of crank linkage, valve

mechanism and all kind of major components. Cylinder head for closing the top of the cylinder, the piston

and cylinder wall together form the top of the combustion chamber. In addition ,the cylinder head and the

body of water jacket and oil passages and the oil pan and are an integral part of the cooling system and

lubrication system.
发动机机体缸盖组主要由机体、气缸盖、气缸盖罩、气缸衬垫、主轴承螺栓、气缸盖螺栓、飞轮壳及油底壳等

组成。

The engine body and cylinder head consists of body, cylinder head, cylinder head cover, cylinder liner,

main bearing bolts, cylinder head bolts, flywheel housing and oil pan and other components

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 WP12 系列降重柴油机机体缸

盖组采取直列六缸、一缸一盖的四

气门结构、机体采取一般式（框架

式）结构，齿轮室后置，与气缸体

集成为一体，结构如图 1-1 所示。

WP12 series of lower heavy

diesel engine block and cylinder head

take inline six-cylinder, a cylinder

head of a four-valve structure, the

body taken by the general formula

(frame) configuration, the set gear

housing, and the cylinder body are

integrated, structure as shown in 图 1-1 WP12 系列柴油机机体组结构图

Figure 1-1 WP12 Series diesel engine body chart group
Figure 1-1.

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1.1.1 机体缸盖组主要部件
1.1.1 The main parts of body group head

机体 The engine body

机体是发动机核心的零部件，许多零部件和系统都安装在机体上，另外，机体上
的水套和油道也是冷却系统和润滑系统的组成部分。
The body is the core of the engine parts, many components and systems are installed on
the body. In addition, the water jacket and oil passages on the body are also part of the cooling
system and lubrication system

图 1-2 WP12 系列降重柴油机机体结构图

Figure 1-2 WP12 Series diesel drop weight body structure diagram

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 WP12 系列柴油机机体结构特点如下：
WP12 Series diesel engine body structure features are as follows:
①WP12 系列降重柴油机机体气缸排列形式为直列六缸，采用一般式（亦称框架式） WP12

series drop weight arranged in the form of a cylinder engine block inline six-cylinder, using the general

formula (also known as frame)

②机体采用了干式气缸套结构，缸心距仅 150mm ，使机体结构紧凑、体积小，大大减轻了整

机质量。 The engine body with a dry cylinder liner structure, only the cylinder center distance 150mm, so

that the body compact, small size, greatly reducing the overall quality.

③合理降重，优化结构布置，去除多余凸台，减小部分壁厚，使机体在保证强度的前提下，重

量 更 轻 ， 降 低 整 机 重 量 ， 从 而 降 低 整 机 能 耗 。 Reasonable drop weight, optimizing the structure is

arranged to remove more than the boss, reduced part wall thickness, so that the body under the premise of

ensuring the strength, lighter weight, lower total weight, thereby reducing the overall energy consumption

④机体与曲轴箱之间结合面采取涂胶密封。 The joint surface between the body and the headstock

take adhesive to seal,

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 ⑤机体上有七道主轴承，止推片置于第六主轴承孔座两侧。 There is a bearing on the main body,

thrust washer placed on both sides of sixth main bearing housing hole.

⑥ 曲轴后油封安装在飞轮壳上，前油封安装在前端盖上。 The crankshaft rear oil seal is mounted

on the flywheel housing, front oil seal installed on the front cover.

⑦ 机体前后端分别与前端盖、飞轮壳连接，与前端盖的结合面采取涂胶密封方式，其密封效果

可靠，不渗漏。 The body front and rear ends with the front cover and flywheel shell connection

respectively, take glue sealing manner with the front cover of the joint surface, reliable sealing effect, no

leakage.

⑧机体与油底壳结合面处以倒 U 型橡胶密封垫密封，油底壳托块紧固，密封良好并具有吸振作用。

The body surface in combination with the oil pan impose inverted U-shaped rubber seals, oil pan holder block

fastening, sealing well and having vibration absorbing effect.

⑨在机体两侧分别加工有前后贯通的 φ27 主油道孔（右侧）以及 φ14 副油道（左侧），副油道为

六个活塞冷却喷嘴供油以保证活塞有效地冷却。 On both sides of the body are formed with φ27 main oil

through the hole before and after (right) and Vice-φ14 oil channel (left), Vice-six piston cooling oil passage

fueling nozzle to ensure effective piston cooling.

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 ⑩机体右侧与机油冷却器盖一起构成水腔，内装有机油冷却器，相邻两缸之间的水套间铸有横
隔板，隔板两侧有两个通道。这样既加强了机体的刚性，又有利于冷却水的流动，确保了良好的刚度
和冷却效果。 On the right side of the body and the oil cooler lid together constitute a water chamber, built
with oil cooler, two adjacent water jacket between cylinders cast with the crossbeam, there are two channels
on both sides of the separator. This will not only enhance the rigidity of the body, and it helps the flow of
cooling water to ensure good stiffness and cooling effect.
⑪机体右侧缸盖回水铸在机体上，相当于回水管，结构紧凑并且减少零件之间的连接，减小三
漏的风险。 The right of the head body cast backwater in the body, the equivalent of the return pipe, compact
and reduce the connection between the parts, reduce the risk of leakage of water.
⑫机体上相邻两缸之间安装 2 件 M12 的双头螺柱，起到气缸盖副螺栓的作用，有助于气缸盖紧
固。 Arranged between the two cylinder studs 2 M12, played the role of the cylinder head bolts deputy to
help tighten the cylinder head adjacent to the upper body.
⑬采用转子式机油泵结构，机油泵安装于曲轴箱底部，缩短了前端尺寸。 Uses a rotor-type oil
pump structure, pump attached to the bottom of the crank case, reducing the size of the tip

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1.1.2 机体组工作及注意事项
1.1.2 Body work group and precautions
主轴承螺栓的安装规范
The main bearing bolt and installation specification

主轴承螺栓装配时必须保证按规范要求进行紧固，装配前螺纹及承压面涂润滑油。
As the main bearing bolt assembly , it must be guaranteed according to specifications fastening,
Before mounting screw and bearing lubricant topcoat.

图 1-3 螺栓拧紧顺序
Figure 1-3 Bolt tightening sequence

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1.2 气缸盖
1.2 Cylinder Head
序号 中文名称 Denomination
WP12 柴油机气缸盖结构如图 1-2 及 Pos.
1 吊环螺钉 Screw rings
图 1-3 所示。 WP12 diesel engine cylinder 2 吊环夹紧块 Rings clamp block
head structure as shown in Figures 1-3 and 3 气门杆密封套 Valve stem seal sets
4 气门导管 Valve Guide
12 3 4 5 6 7 8 9 10 11
1-2 5 气缸盖 Cylinder Head
6   带肩螺母 Shoulder nut
7 夹紧块 Clamp block
8 喷油器衬套 Injector bush
9   密封圈 Seals
10 气缸盖主螺栓 Master cylinder head bolts
11   碗形塞 Bowl-type plug
12   碗形塞片 Bowl blocking piece
13 堵塞 Block
14 密封圈 Seals
20 19 1817 161514 13 12 15 气门推杆衬套 Valve push rod bushing
16 拉铆钉 Rivet
17   碗形塞片 Bowl blocking piece
图 1-4 气缸盖结合
组示意图 18 气缸盖衬垫总成 Cylinder head gasket assembly
Figure 1-4 cylinder head binding set of 19 排气门座 Exhaust valve seat
schematic diagrams 20 进气门座 Intake valve seat

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 WP12 柴油机气缸盖结构主要特点如下：
WP12 diesel engine cylinder head structure of the main features are as follows:
①气缸盖采用合金铸铁材料制成，以适应高温、高强度强化柴油机的要求。 Cylinder head

made of alloy cast iron material to adapt to high temperature, high strength hardening requirements for

diesel engines.

②一缸一盖结构型式，工艺性好，便于搬运、拆装，防止变形，用主、副螺栓固定，增加了

发动机的刚度，降低了铸造废品率和市场上更换维修缸盖的成本。 A cylinder cover a structure type,

technology, and ease of handling, assembly and disassembly, to prevent deformation, with the primary and

secondary bolts to increase rigidity of the engine, reducing maintenance replace the cylinder head casting

scrap and marketing costs .

③每个气缸盖上均布置有 2 个进气门和 2 个排气门，进、排气道分布于两侧。进气道采用螺

旋气道 + 切向气道结构，保证产生一定的涡流，以有利于混合气的形成，满足直喷式燃烧系统对进

气的要求。 Each cylinder head are decorated with two intake and two exhaust valves, intake and exhaust

channels distributed on both sides. Inlet spiral airway + tangential airway structure to ensure a certain

vortex to facilitate mixture formation, direct injection combustion system to meet the intake requirements

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 ④气缸盖喷油器安装孔采用镶入喷油器衬套结构。喷油器衬套是由紫铜管经过挤碾收口制成，
位于燃烧室中心位置，直接与冷却水接触，这对改善喷油嘴的散热，提高喷油嘴工作可靠性十分有
利。 Cylinder head injector mounting hole injector using the insert bushing structure. Injector liner is
made of copper through the squeeze shut grind, the center position of a combustion chamber, in direct
contact with the cooling water, which is to improve the cooling of the nozzle, nozzle improve reliability
very favorable.
⑤气缸盖上冷却水道采用双层水套结构，布置合理。冷却水由缸盖下水套流入气缸盖后，全部
通过气缸盖鼻梁热区的水腔，然后经过喷油器衬套进入上水套，冷却效果好，可经受冷热冲击，避
免了该处的热裂现象，保证安全可靠。 The cylinder head water jacket cooling water with double
structure, reasonable layout. Cooling water from flowing into the cylinder head water jacket cover, cover all
the water chamber through the cylinder nose of the hot zone, then enter the liner through injector water
jacket, cooling effect is good, can withstand thermal shock, to avoid the department's hot cracking
phenomenon, to ensure safe and reliable
⑥气缸盖进排气门座圈采用粉末冶金材料，耐磨性、导热性优异。 Of the cylinder head intake
and exhaust valve seat material by powder metallurgy, wear resistance, excellent thermal conductivity. 气缸
盖总高度 125mm 。 The total height of the cylinder head 125mm.

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 ⑦每个气缸盖上有 4 根 M14 的气缸盖主螺栓及 4 个 M12 的与邻缸共用的双头螺栓，通过带
轴肩螺母和具有 V 型压紧面的夹紧块压紧，当被压紧的两缸高度略有差异时，会自动调整，保证
螺母压紧面垂直于螺栓轴线；在两端处则采用悬挂式压紧块。气缸盖主螺栓及螺母均用转角法拧紧。
Each cylinder has a cylinder head cover main four M14 bolts and four M12 studs shared with adjacent
cylinder through the shoulder belt clamping nut and clamping block has a V-shaped clamping surface,
when pressing the two-cylinder slight difference in height, it will be automatically adjusted to ensure that
the nut clamping surface is perpendicular to the axis of the bolt; is used at both ends hanging a shoe.
Master cylinder head bolts and nuts are tightened with the angle method.
⑧进、排气门导管均采用粉末冶金材料，具有自润滑性能。为了防止机油从导管间隙中进入
气 道 ， 在 气 门 导 管 上 方 安 装 了 气 门 杆 密 封 套 。 Intake and exhaust valves are made of powder
metallurgy catheter material, self-lubricating properties. In order to prevent the oil from the catheter into
the airway gap at the top of the valve catheter valve stem seal sets installed.
⑨气缸盖上有三种碗形塞： 25/8 、 22/8 、 17/8 ，采用不锈钢材料，分布在缸盖两侧和缸盖
上平 面 。 There are three bowl-shaped plug cylinder head: 25 / 8,22 / 8,17 / 8, made of stainless steel,
located in the cylinder head and cylinder head on both sides of the plane.

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1.3 气缸盖垫 Cylinder head pad

⑩WP12 系列柴油机气缸垫亦采用了一缸一垫结构，这种结构避免了因运输、放置不当而产

生变形，安装方便，密封性好。 WP12 Series diesel engine cylinder head gasket also uses a cylinder a pad
structure which avoids resulting from transportation, improper placement of deformed, easy installation, good sealing.

⑪气缸垫有单层结构和多层结构两种。 Cylinder head gasket has two single-layer structure

and a multilayer structure. 单层缸垫，本体采用镀锌钢板，在缸口部位压筋用来封气；通过金属骨

架将橡胶圈铆接到本体上，用来密封油和水。垫片在螺栓把紧时缸口部位厚度为 1.2mm 。 Single

cylinder head gasket, the body made of galvanized steel, the brim portion beading to seal gas; by metal skeleton rubber ring

riveted to the body for sealing the oil and water. Shim thickness at the brim portion of the bolt tightening is 1.2mm.

⑫多层缸垫分上板、调整板、下板三层，在缸口部位调整板上压筋来封气；橡胶圈用来密

封 油 和 水 ， 垫 片 在 螺 栓 把 紧 时 缸 口 部 位 厚 度 为 1.2mm 。 单 层 缸 垫 与 多 层 缸 垫 可 以 互 换 。

Multilayer cylinder head gasket on the score board, adjustment plate, a lower plate three in the brim

portion adjustment panel beading to seal gas; rubber ring for sealing oil and   water-tight gasket bolt the

brim portion thickness 1.2mm. Single and multi-cylinder head gasket cylinder head gasket can be

interchanged.

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1.4 气缸盖罩
1.4 Cylinder head cover

气缸盖罩根据缸盖的形式也采用一缸一罩的结构，其示意图如图 1-4 所示。 WP12

系列柴油机的气缸盖罩采用铸铝材料，在降低重量的同时，起到很好的保护、密封和降
噪的作用。气缸盖罩和气缸盖之间采用垫片密封。

According to the form of a cylinder

head ,The cylinder head cover is also used
a shield structure diagram shown in
Figure 1-4. WP12 Series diesel engine
cylinder head cover using cast aluminum,
reducing weight at the same time, play the
role of good protection, sealing and noise
reduction. Cylinder head cover using the
seal between the cylinder head gasket. 图 1-5 WP12 柴油机气缸盖罩
Figure 1-5 WP12 diesel engine cylinder head cover

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 图 1-6 气缸盖主螺栓拧紧次序图
Figure 1-6 master cylinder head bolt tightening sequence
Fig.

30
1.6 油底壳
1.6 Oil pan
WP12 系列发动机油底壳采用薄钢板冲压而成，带有翻边，以便安装油底壳和
增加其刚度，其优点为重量轻，工艺简单，适宜于大批量生产，其结构如图 1-6 所示。
WP12 series engine oil pan using a thin steel plate stamping, with a flange for mounting the
oil pan and increase its rigidity, the advantage of light weight, simple process suitable for
mass production, the structure shown in Figure 1-6 FIG.
油底壳与机体间有 U 型橡胶密封垫，起密封和吸振作用，
油底壳密封垫与机体、齿轮室之间通过 12 个 M8 六角法兰面螺栓和
油底壳托块进行紧固，油底壳托块为铸钢件。油底壳底部装有磁性
螺塞，能吸住摩擦副磨下来的铁屑。 Between the oil
pan and the body has a U-shaped rubber gasket for sealing and vibration
图 1-7 WP12 油底壳
absorbing effect between the oil pan gasket and the body, through the Figure 1-7 WP12
Series diesel engine oil
gear chamber 12 M8 hex flange bolts and oil pan holder block fastening,
pan
sump tray block castings. Equipped with a magnetic drain plug at the
bottom of the oil pan, you can suck iron friction wear down.

31
1.7 飞轮壳
1.7 Flywheel housing
WP12 系列发动机飞轮壳为集成齿轮室结构，与机体之间用飞轮壳连接板连接，共
同形成齿轮室，安装时涂装密封胶，其结构如图 1-7 所示。
WP12 series engine flywheel housing integrates a gear chamber structure, with the
flywheel housing webs connection between the body and together form the gear room, paint
sealant installation, the structure shown in Figure 1-7.

图 1-8 WP12 系列柴油机飞轮壳

Figure 1-8 WP12 Series diesel engine flywheel housing

32
 飞轮壳材料选用铸铝材料，左右侧铸有四个耳形平台，用于与发动机包装箱支架连接，便于
发动机的运输，另外部分主机厂在此处连接发动机支架，将发动机支撑在整车上。 Cast aluminum is
selected on flywheel housing ， Left and right side cast four ear-shaped platform for box bracket
connected to the engine for easy transport 。 Also part of the OEMs in here to connect the engine bracket,
the engine is supported on the vehicle.
飞轮壳与发动机机体用两件 φ12 的圆柱销定位，通过 12 件 M12 螺栓把紧，扭紧力矩为（ 110
～ 140 ） N·m 。 可 重 复 使 用 两 次 。 Flywheel housing and engine block with two cylindrical pin
positioning φ12 through 12 M12 bolts tight, tightening torque (110 ~ 140) N · m. Reusable twice.
飞轮壳的左下侧（发动机前端视向）加工有起动机安装座面和安装孔，用 3 件 M10 的双头螺
柱及螺母将起动机固定其上。
The lower left side of the flywheel housing (depending on the front of the engine) is formed with the
starter surface mount and mounting holes, with three of the M10 studs and nuts starter fixed thereto.
飞轮壳与变速器连接面处加工有止口及 12 个 M10 螺孔，用 12 根 M10×35 的双头螺柱与变速
箱连接。底部或右侧中部有一观察孔，观察孔上加工有正时刻线，平时用两件 M10 螺栓及观察窗
盖将观察窗孔进行遮挡，以防尘土进入。
Flywheel housing face of the processing and the transmission connection and a mouth stopper 12
M10 screw connection M10 × 35 with 12 stud in the gearbox. Bottom or right side of a central observation
hole, the hole machining observed a positive time line, usually with two M10 bolts and observation
window cover will be observed aperture shutter to prevent dust from entering.

33
第二章 曲柄连杆机构
Chapter 2 Crank Mechanism

34
2.1 曲柄连杆机构概述
2.1 Crank Mechanism Overview
曲柄连杆机构是发动机的主要运动机构，其功用是将燃料燃烧时产生的热量转变为
活塞往复运动的机械能，再通过连杆将活塞往复运动变为曲轴的旋转运动而对外输出动
力。 Crank Mechanism is the main movement mechanism of the engine, its purpose is to
generated heat by the fuel combustion into mechanical energy of the piston reciprocating
motion, the piston rod then export power. through the reciprocating motion into rotational
motion of the crankshaft.
曲柄连杆机构的主要零部件可以分为两组：活塞连杆组、曲轴飞轮组。 The main
Crank Mechanism can be divided into two components groups: the piston connecting rod,
crankshaft flywheel group.
在发动机做功时，气缸内温度、压力较高；部分部件与可燃混合气和燃
烧废气接触。因此，曲柄连杆机构工作条件的特点是高温、高压、高速和化学腐
蚀。 When engine acting , the cylinder has high temperature and pressure; some parts of the
combustible mixture and the combustion exhaust gas into contact. Thus, the characteristics of
Crank Mechanism working conditions of high temperature, high pressure, high speed, and
chemical corrosion.

35
2.2 曲柄连杆机构主要部件 Crank Mechanism main components
2.2.1 活塞连杆组 Piston and connecting rod set

 活塞连杆组概述
Piston and connecting rod set overview
活塞连杆组将活塞的往复运动转变为曲轴的旋转运动，同时将作用于活塞上的力转
变为曲轴对外输出的转矩，以驱动车轮转动。
The piston connecting rod reciprocation of the pistons into rotary motion of the
crankshaft, while the force acting on the piston into the crankshaft torque external output to
drive the wheels turning.
活塞连杆组由活塞、活塞环、活塞销、活塞销挡圈、连杆、连杆轴瓦等部件组成，
如图 2-1 所示。
Piston pin from the piston connecting rod, piston ring, piston, piston pin retainer,
connecting rod, connecting rod bearing and other components, shown in Figure 2-1.

36
 图序 零件名称 Part name
号 No.
1 活塞 Piston
2 活塞销 Piston pin
3 梯形桶面环（一环）
Trapezoidal ring(1st)
4 扭曲锥面环（二环）
cone ring(2nd ring)
5 螺旋撑簧油环
Oil ring
6 活塞销挡圈
retaining ring
7 连杆
Connecting rod
图 2-1 活塞连杆组
Piston and connecting rod set 8 连杆螺栓
Connecting rod bolt
9 连杆下瓦
Shell down
10 连杆上瓦
Shell up

37
 活塞
Piston
活塞的主要作用是承受气缸中的气体压力，并将此力通过活塞销传给连杆，以推动
曲轴旋转。活塞顶部还与气缸盖、气缸壁共同组成燃烧室。 The main piston is subjected to
the gas pressure in the cylinders, and this force is transmitted to the connecting rod by a piston
pin, to facilitate rotation of the crankshaft. Also piston top and the cylinder head, cylinder wall
composed chamber.
活塞材料为铸造铝合金。
Piston material cast aluminum alloy.
活塞的基本构造可分为顶部、头部和裙部三部分。
The basic configuration of the piston can be divided into three parts, top side, the head and
the skirt.

38
 火力岸 气门坑
Firepower 一环 1st Valve pit
ring
二环 2nd ring
活塞头部
油环 oil ring 燃烧室
Piston head
Combustor

图 2-3 活塞顶面 top surface of

piston

活塞裙部
Piston skirt

图 2-2 活塞与活塞环
Piston and piston ring 图 2-4 活塞底面 bottom surface of
piston

39
 连杆 Connecting rod
连杆的功用是连接活塞和曲轴，把活塞的往复运动转变为曲轴的旋转运动，并将活
塞承受的力传给曲轴。连杆由连杆小头、杆身、连杆大头、连杆盖组成。如图 2-6 所示。
Connecting rod function is to transfer the piston and connecting rod reciprocation movements
into rotary movement of the crankshaft, The components combined by connecting rod bushing,
connecting rod small head, connecting rod body, connecting rod cap. As shown in Figure 2-6.
连杆大头 rod 连杆下瓦
杆身 big side Shell down
连杆小头
Rod small head rod body 连杆盖
Rod cap

连杆螺栓
连杆衬套 连杆上瓦 Rod bold
bushing Shell up

图 2-5 连杆总成
Fig2-5 connecting rod set

40
 连杆螺栓 Connecting rod bolt
连杆螺栓连接连杆体和连杆大头盖（如图 2-5 所示），为了保证连接的可靠性，必
须对其施加相当高的预紧力。 Rod bolt connecting rod body and the connecting rod head
cover (shown in Figure 2-5), in order to ensure the reliability of the connection, it must be
applied fairly high preload.
WP12 系列发动机连杆螺栓制造工艺复杂，要求高。采购时必须高度重视，必须选
用原机配件。 连杆螺栓只允许使用一次。
WP12 series engine connecting rod bolt manufacturing process is complicated and
demanding. Procurement must gave great attention, you must use the original accessories.
Connecting rod bolt is allowed to use onlyonce.
手动拧紧工艺：先拧靠，再用 115N.m 的力矩对称拧紧，最后各转 90°±5° 。 Hand-
tighten process: first by screwing, then tightening torque symmetry 115N.m Finally, each turn
90 ° ± 5 °.

41
2.2.2 曲轴飞轮组 Crankshaft flywheel group

曲轴飞轮组概述 Crankshaft flywheel group overview

曲轴飞轮组主要由曲轴和飞轮以及其他具有不同作用的零件和附件组成。其零件和附件的种类和
数量取决于发动机的结构和性能要求。如图 2-6 。
Crankshaft flywheel set mainly combined by the crankshaft and flywheel and other parts . The
accessories have different effects composition. Type and quantity of its parts and accessories depend on the
structure and performance requirements of the engine. Figure 2-6.

曲轴 Crankshaft
曲轴的功用是把活塞、连杆传来的气体力转变为转矩，用以驱动汽车的传动系统和配气机构、
机油泵、燃油泵、水泵、发电机以及其他辅助装置。后端正时齿轮驱动齿轮系统，同时驱动飞轮向后
传动力矩；前端驱动机油泵，前端轮系，带动水泵、发电机等。
The crank function is to transmit coming gas into the torque force of piston rod in order to drive the
car's transmission and gas distribution mechanism, oil pump, fuel pump, water pumps, generators and other
auxiliary equipment. End timing drive gear system while driving backwards flywheel transmission torque;
front-end driven oil pump, the front end of the train wheels, drive the pumps, generators, etc.

42
 曲轴主要由三部分组成：曲轴的前端轴；若干个由曲柄销、曲柄销左右两个曲柄
臂、前后两个主轴颈组成的曲拐；曲轴的后端法兰。 Crankshaft mainly consists of three
parts: the front end of the crankshaft axis; a plurality of the crank pin, crank pin left and right
crank arms, consisting of crank both before and after the main journal ; crankshaft rear flange.

图 2-6 曲轴结合组
Fig 2-6 Crankshaft

43
 名称
图序号
Name
No.
曲轴
1 Crankshaft
塞堵
2 Plug
机油泵齿轮
3 oil pump gear
定位销
4 location pin

5 曲轴正时齿轮

crankshaft timing gear

44
 （ 1 ）采用全支承、整体式曲轴结构，抗弯曲强度高，有利于减轻主轴承的载荷，
便于加工制造。 With full support, the overall structure of the crankshaft, high flexural
strength, will help reduce the main bearing loads, ease of processing and manufacturing.
（ 2 ）该曲轴采用 8 块平衡块结构，在平衡块上加工去重孔以保证曲轴动平衡，重
叠度大，减振性好。 The balance of the crankshaft using 8 block structure, processing the
block to re-balance hole to ensure the balancing of the crankshaft, a large degree of overlap, and
good damping.
（ 3 ）曲轴经仿形机床自动完成车削加工，具有较高的精度。 Crankshaft has high
precision after copying machine automatically crank turning,
（ 4 ）曲轴正时齿轮后置，噪音低，振动小，提高了整机的 NVH 性。 After the
crankshaft timing gear set, low noise, small vibration, improving the overall NVH properties.

45
 飞轮 Flywheel
飞轮是一个转动惯量很大的圆盘，其主要作用是将在做功行程中传输给曲轴的一部
分功储存起来，用以在其他行程中克服阻力，带动曲柄连杆机构越过上、下止点，保证
曲轴的旋转角速度和输出转矩尽可能均匀，并使发动机有可能克服短时间的超载荷；此
外，在结构上飞轮又往往用作汽车传动系统中摩擦离合器的驱动件。
Moment of inertia of the flywheel is a great disc, and its main role is to transport during
the power stroke portion of the work to the crankshaft of the store, to overcome resistance in
other stroke, driving Crank Mechanism across the top and bottom dead center, ensure the output
torque and the rotational angular velocity of the crankshaft as uniform as possible, and make it
possible to overcome the engine load over a short time; in addition, the structure of the flywheel
is often used as a vehicle driveline clutch friction drive member.

46
 图 2-7 飞轮结合组
Fig 2-7 Flywheel combined group

47
 扭振减振器 Supporting plate of muffler
扭转减振器工作原理是曲轴扭转振动能量逐渐消耗于减振器内的摩擦，从而使振
幅逐渐减小。曲轴扭振减振器常安装在扭振振幅最大的曲轴自由端。
Supporting plate of muffler works crankshaft tensional vibration energy is gradually
consumed in the friction damper, so that the amplitude decreases. Crankshaft tensional vibration
damper tensional vibration often installed in the maximum amplitude of the crankshaft free end.

图 2-8 减振器皮带轮安装关系
Fig 2-8 Installation Relations of muffler

48
 轴瓦 Main bearing bush
连杆瓦：由钢背、合金层、减磨层三部分组成。 Connecting rod bearing: steel back,
alloy layer, anti-friction layer consists of three parts.
主轴瓦：更好的耐疲劳性和耐腐蚀性、减摩性能，并有很好的抗咬合性和嵌藏性。
主 轴 瓦 安 装 如 图 2-10 所 示 。 Main bearing: better resistance to fatigue and corrosion
resistance, friction properties and good seizure resistance and inlays of possession. Main bearing
is installed as shown in Figure 2-10
轴瓦的使用特点是：在正常使用和充分润滑条件下，有极好的减摩性能，但在负荷
极高和边界润滑条件下，抗损坏的程度不及铜铅合金，应注意这个特点，若使用不当，
易产生早期损坏。
Bush used features are: under normal use and adequate lubrication conditions, has an
excellent anti-friction performance, but at high loads and boundary lubrication conditions, the
extent of damage is not as anti-copper-lead alloy, should pay attention to this feature, if used
improper, easy to produce early damage.

49
 安装轴瓦位置
Location of
bush

图 2-10 安装轴瓦位置
main bearing bush 图 2-11 止推片安装
installation location Install thrust washer

止推片：分为上、下止推片，由钢背和合金层组成，合金层侧加工有油槽，安装时
油槽应向外侧，与曲轴接触，保证工作室止推片的良好润滑，如图 2-11 所示。 Thrust
washer: divided into upper and lower thrust sheet, the steel back and alloy layer, an alloy layer is
formed with the side tank, when the fuel tank should be installed outside and in contact with the
crankshaft, to ensure good lubrication studio thrust sheet, such as Figure 2-11.

50
2.3 曲柄连杆机构工作及注意事项
2.3 Crank Mechanism work and precautions
2.3.1 选购活塞注意事项 Optional piston Caution

WP12 系列发动机活塞均采用“ ω” 型燃烧室，顶部有避阀坑 , 在活塞顶面打印重

量分组标记、零件号等标识。在选购活塞时请注意：同一机型必须用同一产品图号的活
塞，同一台发动机所用活塞的产品图号必须一致，购买活塞需将机型或旧活塞顶部的产
品图号记下，以便购买相同产品图号的活塞。否则，会引起发动机燃烧不良、振动和爆
震、油耗高、无力等故障。
WP12 series engine pistons are made of "ω" combustion chamber, the top valve to avoid
the pit, the weight of the print packet marking, part number and logo of the piston A top surface.
In the purchase of the piston Please note: the same model with the same product must figure
number of pistons, the same engine piston products figure number must be the same need to
purchase the model number or product image in mind of the old lower piston top of the piston, in
order to FIG buy the same product number of pistons. Otherwise, it will cause poor combustion
engine, vibration and knocking, high fuel consumption, weakness and other failures.

51
2.3.2 连杆使用与维修注意事项
2.3.2 Connecting rod use and maintenance considerations

WP12 系列发动机的连杆分为多个级别，分别以 C 、 D 、 E 等大写英方字母来表示，

各级别间连杆不能互换。
WP12 series engine connecting rod is divided into multiple levels, respectively, C, D, E
and other capital letters to represent the British side, the link between the various levels are not
interchangeable.
连杆螺栓是一次性的，绝对不能使用第二次，请广大用户切记。
Connecting rod bolt is disposable, should never be used a second time, please keep in
mind the majority of users.

52
第三章 配气机构
Chapter 3 Valve

53
3.1 配气机构概述
3.1 Valve Overview
摇臂轴 EVB 支架
WP12 柴 油 机配气 机构为 气门 Rocker shaft EVB bracket
气门弹簧座
顶置、凸轮轴侧置布置、凸轮轴传 Valve spring retainer 摇臂 Rocker
气门弹簧
动方式为齿轮传动。 Valve spring
摇臂支架 Rocker
WP12 Diesel Engine Valve as EVB 气门桥 bracket
EVB valve bridge
OHV, arranged side-mounted
camshaft, camshaft drive by gear.
排气门
WP12 配气机构主要由凸轮轴、 Exhaust valve
进气门
挺柱、推杆、摇臂、摇臂轴、摇臂 Intake valve
支架、气门弹簧、气门桥、 EVB 支
架、 EVB 气门桥、进气门、排气门 推杆
Putter
等零件组成。
WP12 Valve consists of
camshaft, tappet, push rod, rocker arm, 凸轮轴止推片
Camshaft Thrust
rocker shaft, the rocker arm bracket, 挺柱 Washer
凸轮轴 Camshaft
valve springs, valve bridge, EVB Tappet
bracket, EVB valve bridge, intake
valve, exhaust valve and other parts. 图 3-1 WP12 柴油机配气机构组成
Fig 3-1 WP12 Diesel Engine Valve Structure

54
3.2 配气机构主要部件
3.2 Valve main parts
3.2.1 气门组 Valve Group
气门组包括气门、气门弹簧、弹簧座、气门锁夹等零件。
Valve group includes valves, valve springs, spring seat, valve lock folder and other parts

进气门 Intake valve 排气门 Exhaust valve

图 3-2 气门及气门弹簧结构
Fig 3-2 Valve and valve spring structure

55
3.2.2 气门传动组 Valve Train Set

气门传动组包括凸轮轴、挺柱、推杆、摇臂和摇臂轴等零件。
Valve train set includes camshaft tappet, push rod, rocker arm and rocker shaft and other
parts.

图 3-3-9 凸轮轴等
Fig 3-3-9 camshaft

56
3.2.3 气门间隙
3.2.3 Valve Clearance
为补偿配气机构受热后的膨胀量，
防止气门及传动件的受热膨胀引起的气门
关闭不严，通常发动机在冷态装配时，在
气门及其传动机构中留有适当的间隙，以
表 3-1 WP12 气门间隙控制值
补偿气门受热后的膨胀量。这一间隙被称
Table 3-1 WP12 valve clearance volume
为气门间隙。
The amount of compensation for the 冷态气门 总装时控制 试车后控制
expansion valve mechanism after heating, 间隙 要求 要求
thermal expansion valve to prevent the valve （ mm ） （ mm ）
and transmission parts caused by closed lax,
usually when the engine is cold assembly, 进气 0.38±0.03 0.4±0.06
proper clearance in the valve and actuator,
the valve to compensate the amount of 排气 0.58±0.03 0.6±0.06
expansion after heating. This gap is called
the valve clearance EVB 系统 0.38±0.03 0.4±0.06
WP12 柴油机冷态气门间隙按表 3-1
控制
WP12 diesel cold valve clearance as
table3-1 .

57
3.2.4 配气相位
3.2.4 Valve Timing
进、排气冲程有较大的曲轴转角，充
分保证排气干净、进气充足。进、排气门
在排气冲程结束和进气冲程开始有较大的
表 3-2 WP12 配气相位
气门重叠（叠开）角，更有利于发动机换
Table 3-2 WP12 Valve Timing
气，使废气排出完全，提高充气效率 .
Intake and exhaust stroke of a larger 冷态配气相位（进气 曲轴转角 °CA
门间隙 0.4mm ，排气
crank angle, to make exhaust clean, adequate
门间隙 0.6mm ）
intake. Intake and exhaust valves at the end of 进气门开（上止点
20±5
the exhaust stroke and the intake stroke starts 前）
greater valve overlap angle, the engine is 进气门关（下止点 34±5
后）
more conducive to ventilation, the exhaust gas
排气门开（下止点 49±5
is discharged completely, improving 前）
volumetric efficiency. 排气门关（上止点 21±5
后）

58
 凸轮轴轴向间隙的测量
Measure the camshaft axial clearance
用千分表测量。其轴向间隙标准允许值为
0.1 ～ 0.4mm 。若不在上述范围，应选配或修理
凸轮轴止推板，使其符合技术要求。
By micrometer. Its standard allows axial
clearance is 0.1 ~ 0.4mm. If the above this range,
should be repaired or matching camshaft thrust plate
so that it meets the technical requirements.

图 3-10 轴向间隙测量
Figure 3-10 axial clearance measurement

59
3.3 摇臂、摇臂轴使用与维护
3.3 Rocker, rocker shaft use and maintenance

WP12 中 摇 臂 轴 孔 的 标 准 尺 寸 为 D=29.972 ～ 29.993mm ， 摇 臂 轴 轴 颈

b=29.927 ～ 29.960mm ，间隙 D-b=0.012 ～ 0.066mm
Standard size with WP12 of rocker shaft hole is D = 29.972 ~ 29.993mm, rocker
shaft journal is b = 29.927 ~ 29.960mm, the clearance is D-b = 0.012 ~ 0.066mm.
修理要求：应保证技术要求的配合间隙值；摇臂轴颈经氮化处理，有极高
的耐磨性，一般不易损坏，如轴颈尚好，则只更换或修理摇臂即可，应选购原
厂配件。
Repair requirements: the clearance value should ensure that they meet the
technical requirements; rocker journal by nitrogen treatment, with high wear
resistance, is generally difficult to damage, such as the journal is still good, only to
replace or repair the arm, to be elected purchase Genuine parts.

60
3.4 EVB 排气制动原理及过程 EVB exhaust brake principle and process

3.4.1WP12EVB 制动原理 EVB exhaust brake

principle
WP12 采用泄气式排气制动，它需要排
气蝶阀进行辅助。当排气蝶阀关闭后，柴油
机压缩行程形成使得排气通道中的废气压力
急剧上升，相邻处于吸气冲程下止点附近气
缸的排气门会被压力顶开一个小缝隙，再通
过增加一套控制排气门行程的执行机构，实
现排气门在发动机制动过程中保持打开一个
空隙。
WP12 using frustrating exhaust brake, it
needs to be assisted exhaust valve. When the
exhaust valve is closed, the compression stroke
diesel engine exhaust passage is formed so that
the exhaust gas pressure risen sharply in the near 图 3-11 泄气式排气制动的四冲程
adjacent cylinder under the intake stroke of the Figure 3-11 frustrating four-stroke exhaust brake
exhaust valve is only the top of the pressure to
open a small gap, and then by adding a loop
control of the exhaust valve actuator stroke, the
exhaust valve in the engine braking to achieve
during a gap remains open

61
3.4.2 WP12EVB 制动过程
3.4.2 EVB exhaust brake process

排气制动起作用时，排气蝶阀关闭，柴油机压缩行程使得排气通道中的废气压力急
剧上升，相邻处于吸气冲程下止点附近气缸的排气门会被压力顶开一个小缝隙。
When the exhaust brake function, the exhaust valve is closed, the compression stroke so
that diesel exhaust passage of the exhaust gas pressure rises sharply, the adjacent point in the
exhaust valve near the cylinder at the intake stroke top dead will be pressure to open a small
gap .
由于排气门的下移， EVB 气门桥中与排气门接触的小活塞在油压的作用下下移，
EVB 气门桥的机油通道充满机油且在 EVB 支架的作用下密闭，由于机油的不可压缩性，
使得小活塞无法复位，一直保证排气门一定的开度。
Because down the exhaust valve, the valve EVB bridge in contact with the exhaust valve
under the action of small piston down oil pressure, valve bridge EVB oil passage full of oil
and closed under the effect of EVB bracket, since oil is not available compression, so that the
smaller piston can not be reset, has been guaranteed a certain degree of opening of the exhaust
valve.
压缩行程结束时，开始排气行程，由于 EVB 气门桥与 EVB 支架脱离，气门桥中的
油腔泄油，小活塞复位。
At the end of the compression stroke, exhaust stroke began, since the valve bridge and
EVB EVB bracket disengage the valve bridge of the oil drain chamber, the smaller piston
reset.

62
 图 3-12 EVB 系统具体结构
Figure 3-12 EVB system configuration

63
第四章 齿轮传动
Chapter 4 gear drive

64
4.1 齿轮传动系统概述 Gear Transmission Overview

齿轮传动系统主要作用是传递动力，保证柴油机的配气相位及高压油泵的喷油时刻。
齿轮系结构如图 4-1 。 Gear transmission main role is to transfer power to ensure the injection
timing of the diesel engine valve timing and high-pressure pump. Gear train structure shown in
Figure 4-1. 后取力齿轮轴 After
the PTO gear shaft
液压泵齿轮
Gear pumps 中间齿轮总成
Intermediate gear

凸轮轴正时齿轮
Camshaft timing gear

喷油泵齿轮
Injection pump gear

空压机齿轮
Air compressor gear

曲轴正时齿轮
Crankshaft timing gear

图 4-1 齿轮传动系统
Figure4-1 Gear Transmission
65
4.2 齿轮传动系统的主要部件
The main part of the gear transmission system
曲轴正时齿轮 Crankshaft timing gear

图 4-2 曲轴正时齿轮
Figure4-2 Crankshaft timing gear

66
 （二）凸轮轴正时齿轮 Camshaft timing gear
安装时，注意凸轮轴正时齿轮上工艺销孔须与齿轮室连接板上的工艺销孔对齐，同
时 凸 轮 轴 齿 轮 上 的 刻 线 之 一 指 向 销 孔 。 When installing, pay attention to the camshaft
timing pin hole on gear required to align the pin hole on the gear chamber webs, while the
camshaft gear on one reticle pointing pin hole.

图 4-2 曲轴正时齿轮装配
Figure4-2 Assembly of Crankshaft timing gear

67
 （三）中间齿轮总成 Intermediate gear assembly
转动中间齿轮总成，使中间齿轮总成标记与曲轴正时齿轮标记对应，如图 4-5 ，同
时凸轮轴正时齿轮标记与中间齿轮总成标记对应，如图 4-6 。 Rotate the intermediate
gear , to make the intermediate gear assembly mark correspond with the mark of
crankshaft timing gear, as Figure 4-5, while the camshaft timing gear and the
intermediate gear assembly marking tag corresponds to Figure 4-6.

图 4-4 中间齿轮 图 4-5 标记 图 4-6 对标记

Figure4-4Intermediate gear Figure4-5 Mark1 Figure4-6mark2

68
第五章 燃油供给系统
Chapter 5 fuel supply system

69
5.1 燃油系统介绍
5.1 Fuel System Introduction

5.1.1 国四燃油系统配置
Emission four-Fuel System Configuration
采用博世电控高压共轨：
Bosch High Pressure Common Rail:
高压油泵 High pressure pump:
CPN2.2+ （同国三）
共轨管 Common rail:
HFRN-16 （同国三）
喷油器 Injector CRIN2-16 （外形同
国三，流量不同）
图 5-1 国四燃油系统配置
ECU ： EDC17-CV44 Pag5-1Emission four-Fuel System Configuration

70
国四燃油系统配置与国三相比 Emission four fuel system compared with Emission three
主要区别 difference ：
燃油系统最高使用轨压由 1400bar 变为 1600bar
Maximum operating rail pressure of fuel system from 1600bar to 1400bar
ECU 硬件由 EDC7 变为 EDC17; 增加部分软件功能 ECU
hardware change from EDC7 into EDC17; increase some software features
发动机端线束由两根变为一根
Engine wiring harness change from two into one

图 5-2 博世电控高压共轨
Pag5-2 Bosch High Pressure Common Rail
71
5.1.2. 高压油泵 High pressure pump

图 5-3 高压油泵
Pag5-3 High pressure pump

72
 喷油泵与发动机的速比为 1:2 ，喷油泵带有凸轮轴转速传感器，为保证同步信
号的正确性，喷油泵安装有要求。 Fuel injection pump and engine speed ratio is 1: 2,
with a camshaft speed sensor in fuel injection pump, in order to ensure the accuracy of the
synchronization signal.Fuel pump installation required.

图 5-4 喷油泵装配
Fig5-4 Assembly of high pressure pump
73
 喷油泵装配注意事项
Fuel Pump Installation Considerations ：
柴油机至第一缸压缩上止点时，转动喷油泵齿轮，当喷油泵齿轮刻线与喷油泵法
兰之间刻线对齐时，安装喷油泵组件。从齿轮室前端的观察窗看，喷油泵齿轮上的刻线
应与齿轮室上的刻线对齐 .
When the diesel engine comes to the first cylinder compression top dead center, turn the
fuel pump gears, when the engraved lines between the fuel pump and fuel pump gear reticle
alignment flange, install the fuel pump assembly. From the front of the gear chamber
observation window, the line engraved on the injection pump gear should be aligned with the
groove on the gear chamber.
安装喷油泵与齿轮室之间的六角螺母。
Install fuel injection pump and gear chamber between the hex nut.

图 5-5 安装油泵与齿轮时间螺母
Fig5-5 Install the hex nut.

74
5.1.3 燃油计量阀 Fuel metering valve

图 5-6 燃油计量阀
Fig 5-6 Fuel metering valve

75
 5.1.4 喷油器 Injector

喷油器的功用是将喷油泵输送来的高压柴油，以一定
的压力成雾状形式喷入燃烧室，并合理分布，以便和空气混
合形成最有利于燃烧的可燃混合气。喷油器还能迅速地切断
燃油供给，不发生滴漏现象。喷油器结构参见图 5-8 。
Function of injector is to make the high-pressure diesel into
a mist sprayed to the combustion chamber with a certain
pressure, and rational distribution, in order to mix with air and
most conducive to the formation of the combustion of the
combustible mixture. Injectors can quickly cut off the fuel 图 5-7 喷油器
supply, drip phenomenon does not occur. Injector Refer to Figure Pag5-7 Injector

5-8.

76
WP12 柴油机喷油器结构 WP12Diesel Injector Structure

图 5-8WP12 柴油机喷油器结构
Fig5-8 WP12Diesel Injector Structure

77
WP12 柴油机喷油器工作过程

图 5-9 WP12 柴油机喷油器工作过程

Fig5-9 Process of WP12Diesel Injector

78
WP12 柴油机喷油器的控制 WP12 diesel injector control

图 5-10WP12 柴油机喷油器的控制
Fig5-10 WP12 diesel injector control

79
 从发动机上拆卸喷油器总成 Removing the fuel injector on the engine
在取出喷油器前将喷油器周围清理干净，以防抽出后油污尘土落入气缸中。同时为了不损伤紫
铜套，应轻轻晃动将喷油器拉出来。如果拉不出来，则利用喷油器上端零件的螺纹，用拉力器将其拉
出。决不允许用锤或撬杠乱敲、乱撬。在拆卸过程中，必然有一些碳粒落进喷油器安装孔底部，维护
过程中，在装喷油器总成之前，应选用合适的工具进行清理。喷油器拆出后，应用于净擦布或塞子将
喷油器安装孔堵住，以防落入尘土或异物掉入。同时，对拆出的喷油器进行外观检查，根据喷嘴头部
的积碳多少和喷油嘴护帽颜色可以了解缸中燃烧情况和喷油器的工作质量。
Before removing the injector, clean up around the injector, to prevent dust falling into the
cylinder. Meanwhile, in order not to damage the copper sleeve, gently shake and pull the
injector out. If you can not do it, use the upper part of the injector thread, pull it out with a chest.
Never allow knocking with a hammer or crowbar. In the process, there are some carbon powder
fall into the bottom of the injector installation hole, maintenance, prior to loading fuel injector
assembly, appropriate tools should be used to clean up. After the demolition of the injector, used
in cloth or net plug the injector mounting holes plugged to prevent dirt or foreign objects fall
into the fall. Meanwhile, the demolition of the injector visual inspection, according to the head
of the nozzle and nozzle protection cap how much carbon can understand color cylinder
combustion conditions and injectors quality of work.

80
 喷油器检测
Injector detection
目前，电控喷油器需在专用试验台上进行试验（ EFS 试验台或博世 EPS200 ）。检
测项目包括气密性测试，全负荷工况点测试、排放工况点测试、预喷工况点测试、低怠
速工况点测试。
Currently, the electronically controlled fuel injection device for an experiment in a special
test stand. Test items include air tightness test, full-load operating point test, emission test
operating point, pre-spray test operating point, low idle operating point test.
喷油器铭牌刻印 Injector engraved nameplate ：
刻印位置 Engraving position ：喷油器顶部电磁阀处 Injector valve at the top
注意 Caution ：不同件号的喷油器不能互换 Different part numbers are not
interchangeable injector
喷油嘴更换 Injector replacement
喷油器油嘴更换须在博世专门维修服务站进行 Injector replacement must be in Bosch
specialized service station

81
 5.1.5 共轨管 Common rail
共轨管是一个压力存储器，将喷油泵输送来的高压油贮存起来。共轨管内不同位置
的压力基本一致，这就能保证从共轨管输送到 6 支喷油器的燃油压力一致。共轨管一端
有轨压传感器，将压力信号转换成电信号传达给 ECU 。
common rail is for storing pressure, to store the high-pressure oil from fuel injection
pump. Common rail pressure at different locations basically is the same, so it can ensure from
the common rail to six injector fuel pressure is the same . One end of the common rail rail
pressure sensor converts the pressure signal into an electrical signal communicated to the ECU.

图 5-11 共轨管
Fig5-11 Common rail

82
 5.1.6 燃油滤清器 Fuel Filter
功用 Function ：
燃油通过进油孔进入滤清器，经过滤芯过滤，
将过滤后干净的燃油从出油孔送入油泵，具体参
见 图 4-8 。 Fuel enters the filter, through the
cartridge filter, and make the clean fuel from the filter
omto fuel pump by the hole ,as Figure 4-8.

滤后的燃油 the fuel after filter

图 5-12 燃油滤清器滤清图
滤前的燃油 the fuel before filter Fig5-12 Fuel Filter

83
燃油滤清器匹配参数
Fuel filter matching parameters
流 量 Flow rate (ISO4020) 454L/h 时，原始阻力≤ 10kPa
过滤效率 Filtration efficiency (ISO19438) 10μm 粒子≥ 95% 、 4μm 粒子≥ 58%
水分离效率 Fuel/Water separation
efficiency (ISO16332) ≥93%

许用工作压力 Work pressure(Rel.) 9bar （相对压力）

静压爆破压力 Burst pressure (Rel.) 18bar （绝对压力）
燃
油 许用工作温度 Work temperature （ -40~120 ）℃
粗
滤 保养寿命 Filter change life 最高 30000km （根据使用条件）
器
结构形式 Form of structure 悬装式
进出油口螺纹 Threads of inlet/outlet M16×1.5

配置要求 Selected mating 放水阀；水位传感器；放气塞；

流 量 Flow rate (ISO4020) 454L/h 时，原始阻力≤ 10kPa

图 5-13 燃油滤清器
过滤效率 Filtration efficiency (ISO19438) 4μm 粒子≥ 96% ； 6μm 粒子≥ 98.5%
Fig5-13 Fuel filter
许用工作压力 Work pressure(Rel.) 7bar （相对压力）
燃
油 静压爆破压力 Burst pressure (Rel.) 18bar （绝对压力）
精
滤 许用工作温度 Work temperature （ -40~120 ）℃
器
保养寿命 Filter change life 最高 30000km （根据使用条件）
结构形式 Form of structure 悬装式
进出油口螺纹 Threads of inlet/outlet M16×1.5

84
 ECU 是电控发动机的大脑，收集发
动机的信息并向各执行器发布命
令。 ECU is the brain of electronically
controlled engine, to collect information
and issue the command for each actuator.
ECU 有两个接口，分别通过发动机
线束和整车线束连接发动机与整
车。 ECU has two interfaces, respectively,
through the engine wiring harness and
vehicle wiring harness connector of the
engine and vehicle. 图 5-14 ECU
Fig5-14 ECU

85
 ECU 通过 4 个螺栓固定在专用的支架上，并有 4 个减震块衰减震动，防
止发动机的震动影响 ECU 的正常工作。
ECU through four bolts in a special holder, and four vibration damping block
to prevent engine vibration affect the normal operation of the ECU.

图 5-15 ECU 安装位置

Fig 5-15 Position of ECU assembly

86
5.2 低压油路匹配参数要求
Low oil matching parameters require

图 5-16 低压油路匹配参数要求
Fig5-16 Low oil matching parameters require

87
5.5 低压油路排气路径 Low oil exhaust path

图 5-17 低压油路排气路径
Fig5-17 Low oil exhaust path

88
第六章 进排气系统
Chapter 6 engine intake and exhaust system

89
 6.1 进排气系统概述
WP12 发动机进排气系统示意图，如图 6-1 所示。
进气：

增压器压气机 中冷器 发动机

空气滤清器 气缸
（增压、中冷机型） （中冷机型） 进气管

排气：

缸盖 增压器 发动机 废气制动装置 后处理

气缸 涡轮 （可选）
排气道 排气管
装置
图 6-1 WP12 发动机进排气系统示意图

90
 6.1 Overview of intake and exhaust systems
WP12 engine intake and exhaust system diagram shown in Figure 6-1
Intake ：

Turbocharger Engine
Air Cleaner Intercooler Cylinder
compressor intake pipe

exhaust ：
post-
Cylinder head Turbo Engine Exhaust
Cylinder processing
exhaust duct charger exhaust pipe brake device  device

Figure 6-1 WP12 engine intake and exhaust system diagram

91
 空气增压系统流程图如图 6-2
所示。

图 6-2 WP12 发动机空气增压系统

92
 Air pressurization system flow chart shown in
Figure 6-2

Figure 6-2 WP12 engine air pressurization system

93
 进排气系统工作原理：当环境温度为 20℃ 时，新鲜空气经过空气滤清器，进入增
压器压气机，经增压后，从压气机进入进气管道，空气密度增加，温度升高，压气机出
气口处气体温度约为 150℃ 左右。
经过压气机出气管，增压后的新鲜空气流至中冷器进气口时，空气温度为 120℃ 左
右；经过中冷器冷却后，空气从中冷器出气口出来，温度降为 50℃ ，进入发动机进气管；
当到达各缸缸盖进气道内，空气温度稍有升高，为 55℃ 左右。
新鲜空气经进气门吸入气缸，经过压缩，空气温度、密度骤增，在达到上止点前喷
油提前角所对应的曲轴转角时，喷入的柴油达到所需的自燃温度和压力，空气与燃油混
合燃烧后膨胀做功；进入排气冲程，排气门打开，废气经缸盖气道时的废气温度高达
600℃ 以上。
经过排气歧管（每两缸一根），进入增压器涡轮，高温废气推动涡轮高速旋转后从
涡轮出气口排出，温度降为 440℃ 左右；经过排气制动阀体通道进入后处理装置除氮氧、
除碳粒、降噪后排入大气。

94
 Working principle of intake and exhaust system: when the ambient temperature is 20
degrees centigrade, the fresh air after the air cleaner, into the turbocharger compressor, after
pressurization, from the compressor into the intake pipe, the air density increases, temperature,
compressor outlet gas temperature is about 150 the left and right; after the compressor outlet
pipe,ressurized fresh the flow of air to the intercooler inlet, the air temperature is 120 degrees
Celsius; after cooler, cooler air from the air outlet, the temperature dropped to 50 degrees
Celsius, enters the inlet pipe of the engine; when each cylinder head of the air inlet, the air
temperature rose slightly to about 55 DEG C; fresh the air inlet valve into the cylinder,
compressed air, temperature and density increased, reaching the peak on the crank angle before
the fuel injection advance angle, diesel combustion reach required Temperature and pressure,
the air and fuel mixture combustion expand acting; into the exhaust stroke, the exhaust valve
opens, exhaust gas through the exhaust gas temperature in the cylinder head airway up to more
than 600 DEG C; after the exhaust manifold (every two cylinders of a root), enter the
turbocharger, high temperature exhaust gas promote turbine high speed rotating turbine from
the air outlet, the temperature dropped to about 440 DEG C; after entering the exhaust brake
valve channel processing device in addition to oxygen and nitrogen, with the exception of
carbon particle, noise reduction and then is discharged into the air.

95
6.2 进排气系统主要部件

6.2.1 空滤器
车机的公路路况较好，
通常选用单级干式滤清器即
普通空滤器。该滤清器全寿
命滤清效率不低于 99.9% ，
进气阻力 2.5KPa.

图 6-3 空滤器结构图

96
6.2 Intake and exhaust system main components

6.2.1 Air cleaner

When the car engine road
traffic is better, generally use a
single-stage dry cleaner that is
ordinary Air cleaner. The whole
life of the filter filtration
efficiency of not less than 99.9%,
the intake resistance 2.5KPa.

Figure 6-3 Air cleaner Chart

97
 空滤器使用保养注意事项：
1 、使用正品空气滤芯，不得私自改装滤芯。
2 、每周定期检查进气系统（管路有无裂纹、卡箍有无松动）有无漏气。
3 、根据环境灰尘情况和进气阻力指示灯进行主滤芯保养，不要不清扫或频繁清扫
主滤芯，主滤芯清扫 3 至 5 次后应更换新的主滤芯
4 、清洁主滤芯时如发现主滤芯外表面比较干净，主滤芯内安全滤芯外表面有灰尘，
应引起高度注意，检查进气道有无灰尘、滤芯是否已损坏或安装不到位

图 6-4 空滤器使用保养注意事项

98
 Use Air cleaner maintenance Note:
1, the use of genuine air filter, the filter can not be modified without permission.
2, check the weekly intake system (pipes for cracks, loose clamps) for leaks.
3, according to the environmental dust and air resistance indicator light for the main filter
maintenance, do not clean or frequent cleaning the main filter, the main filter cleaning 3 to 5
times after the replacement of the main filter should be replaced
4, cleaning the main filter element such as the discovery of the main filter element outer
surface is clean, the main filter element within the safety element on the external surface of the
dust, should pay attention to, check inlet with no dust, filter is corrupted or installed in place

图 6-4Air cleaner maintenance Note

99
 5 、使用小于 0.5MPa 的干净空气从内向外吹扫外滤芯上的灰尘，气管头
尽可能远离主滤芯内壁；注意：禁止由外向内吹扫外滤芯，如果滤芯外表面存
灰较多，可用手拍打使灰尘脱落；内滤芯（安全滤芯）不得拆卸和清理，要确
保与主滤芯一同更换；

建议使用此方法

6 、装回主滤芯前应清洁滤清器内壳，以免灰尘进入主滤芯内。
注意：装上清理后的主滤芯，报警器仍报警，需要更换新的滤芯

100
 5, the use of less than 0.5MPa clean air from the inside to the outside,
blowing the dust filter, pipe head as far as possible away from the inner wall of
the main filter element; note: blow sweep outside filter out from the outside to
the inside to be banned. If the outer surface of the filter core store ash more,
usable hand pat the dust off; filter (filter) not removing and cleaning, to ensure
that replaced together with the main filter element;

Proposed using this method

6, back to the main filter before the cleaning of the filter shell, so the dust
into the main filter.Note: after cleaning up the main filter, alarm is still alarm,
need to replace the new filter

101
6.2.2 增压器
6.2.2 turbocharger
WP12 柴油机采用废气涡轮增压。利用废气带动涡轮对气体做功，有效提高发动

机进气量，提升发动机的功率，满足发动机的排放要求，此技术在现代发动机上已被

广泛应用。

WP12 diesel engine using exhaust gas turbo. Utilizing waste gas turbo driven by acting

on the gas, effectively improve the engine air intake, improve engine power, meet the

requirements of the emissions of the engine, the technology in the modern engine has been

widely used.

102
 增压器的润滑：采用压力润滑，润滑油从机身上主油道进入进油口，进入
润滑系统，然后通过回油管流回发动机的油底壳，具体参见图 6-5 。

图 6-5 增压器结构示意图

103
 Turbocharger lubrication by means of pressure lubrication, lubricating oil from
the fuselage main oil enters the oil inlet port into lubricating system, and then passed
back to oil flows back to the engine oil bottom shell, specific see Figure 6-5.

Figure 6-5 turbocharger structure schematic diagram

104
图 6-6 润滑油流动示意图

105
Figure 6-6 The lubricating oil flow diagram

106
 图 6-6 是润滑油流动的示意图，从图中看出从发动机润滑系统流出的润滑
油是如何通过油孔和油槽流入两个主轴承的。
润滑油流过轴承中的油孔去润滑和冷却轴承、轴承孔和轴颈。润滑油也从
进油孔直接进入推力轴承，或者通过在压气机壳后盖板的油道进入推力轴承。
润滑油靠重力从中间体排出。

107
 Figure 6-6 is a schematic diagram of the flow of lubricating oil, from the
diagram shows that the flow of lubricating oil from the engine lubricating system is
how to flow through the oil hole and oil groove into the two main bearing.
Lubricating oil flows through the oil hole in the bearing to lubricate and cool
the bearing, the bearing bore and the journal bearing. The lubricating oil from the oil
inlet hole directly into the thrust bearing in the compressor casing or through oil
passages into the thrust bearing cover. Oil is expelled from the intermediate by
gravity.

108
图 6-7 涡轮侧动态油封

109
Figure 6-7 turbine side dynamic oil seal

110
图 6-8 压气机侧碳面油封

111
Figure 6-8 compressor side carbon face seals

112
图 6-9 压气机侧动态油封

113
Figure 6-9 compressor side dynamic oil seal

114
 废气涡轮增压器的使用特点：
（一）废气涡轮增压滞后现象
由于废气涡轮的工作相对于发动机气缸内的工作有一定的迟后，同时，由
于涡轮、压气机叶轮高速旋转的惯性，使发动机变工况时，响应迟缓，排烟增
加，柴油机的加速性较自然吸气（非增压）的稍差。这就是废气涡轮增压器的
滞后现象。

115
 Exhaust gas turbocharger use features:
( 一 ) exhaust gas turbocharger lag
As a result of phase with respect to the exhaust gas turbine engine cylinder
work within a certain degree of lateness, and because the turbine, compressor
impeller speed rotating inertia of the engine operating conditions change, the
response is slow, smoke increase, compared with the diesel engine acceleration
naturally aspirated (non-pressurized) slightly worse. This is the exhaust gas
turbocharger hysteresis.

116
 6.2.3 发动机进、排气管
（一）进气管
采用铸铝合金压铸制造， WP12 系列进气管基本形式为增压中冷柴油机所用进气管，
气体一般从进气管一端进入。进气管进口处装有进气加热器对进入气缸的气体进行预
热，可以有效解决冬季冷启动过程中冒“白烟”的现象，并实现 -30℃ 环境下发动机
顺利工作。进气管结构如下图示

图 6-10 进气管 图 6-11 进气加热器

117
 6.2.3 The engine intake and exhaust pipe
（一） The intake pipe
The manufacturing aluminum alloy die-casting, WP12 series of intake pipe basic form
for turbocharged diesel engine with intake pipe, general gas from the air inlet at one end of
the tube into the. Inlet inlet of the intake pipe is equipped with an air inlet heater to preheat
the gas into the cylinder, which can effectively solve the phenomenon of "white smoke" in the
process of cold start of winter, and realize the engine works smoothly under the environment
of -30. The intake pipe structure is shown as follows

Figure 6-10 The intake pipe Figure 6-11 Intake air heater

118
（二）排气管
WP12 柴油机排气歧管采用硅钼球铁制造， WP12 车机排气管采用三段式结构，
两缸一根，中间排气，增压器中置；排气管之间连接处采用密封环来密封，与缸盖之
间采用两颗螺栓固定；排气管与缸盖、增压器之间均采用不锈钢垫片密封。排气管结
构如下图所示

图 6-12 排气管 图 6-13 排气管密封环

119
（二） The exhaust pipe
WP12 diesel engine exhaust manifold using silicon molybdenum ductile iron is made,
the WP12 car engine exhaust pipe of the three segment type structure, two cylinder root,
middle exhaust, turbocharger centrally placed; between the exhaust pipe at the junction of
the sealing ring to seal, between the cylinder head and the two bolts to fix; the exhaust pipe
and the cylinder head, supercharger adopts stainless steel gasket seal. The exhaust pipe
structure is shown in the figure below.

Figure 6-12 the exhaust pipe Figure 6-13 Exhaust pipe sealing ring

120
 （三）检查进排气系统

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。
检查排气管上是否有裂纹，各连接处螺栓是否松动，是否漏气现象，必要
时更换垫片，确保气密性。
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。

121
 （三） Check intake and exhaust system
Check whether the air inlet hose aging cracks, ring hoop is loose. Tighten or
replace parts as necessary to ensure the sealing performance of the intake system.
Check whether there are cracks on the exhaust pipe, the connecting bolts are
loose, if leakage phenomenon, replace the gasket when necessary, to ensure air
tightness.
Note: never allow the use of the engine in the absence of air filter, dust and
impurities into the diesel engine wear due to early opportunity.

122
6.2.4 后处理系统
（一）后处理系统概述

WP12 电控国四发动机 SCR 系统示意图 (6-14) 及工作原理图 (6-15) 。

图 6-14 SCR 系统示意图 图 6-15 SCR 系统工作原理

123
 6.2.4 Post processing system
（一） Post processing system overview

WP12 electronically controlled Euro IV engine SCR system diagram(6-14) and

working principle diagram(6-15) 。

图 6-14 Schematic diagram of SCR system 图 6-15 Working principle of SCR system

124
 （二） The main parts of the post processing system

SCR （ Selective Catalytic Reduction ）技术是消除柴油机排气中氮氧化物

的主要后处理技术之一。根据功能主要分为控制单元、尿素剂量单元和催化反
应 单 元 三 部 分 ， SCR 系 统 由 催 化 转 化 器 （ SCR 箱 ） 、 尿 素 供 给 单 元
（ Supply Module ）、尿素喷射单元（ Dosing Module ）、尿素箱、后处理控
制单元（ DCU ）及相应管路和线束组成。

125
 （二） The main parts of the post processing system

SCR （ Selective Catalytic Reduction ） technology is the elimination of

nitrogen oxides in diesel exhaust is one of the main postprocessing technique.
According to the main function is divided into three parts: control unit, urea dosage
unit and catalytic reaction unit, the SCR system by the catalytic converter (SCR)
box, supply module, Dosing module and urea box, DCU, and relevant piping and
wiring harness.

126
（三）尿素溶液
不合适的尿素溶液容易造成 SCR 催化剂中毒失效或还原效率不足（如
尿素溶液中所含的磷、钠、钾、钙元素等成分超标容易造成催化剂中毒；
尿素溶液浓度不符合要求，容易导致 NH3 泄露过量或 NOx 还原效率不足），
导致因排放超标而出现故障灯报警现象，因此，所使用尿素溶液的质量及
性能应满足 ISO 22241 标准中规定的内容，具体要求参见表 6-1 ，应通过正
规渠道或到指定单位添加尿素溶液。

127
 （三） urea Solution
Inappropriate urea solution easily lead to SCR catalyst poisoning failure or
reduction efficiency problems (such as urea solution containing phosphorus,
sodium, potassium, calcium and other components exceeded easily lead to
poisoning of the catalyst; urea solution concentration does not meet the
requirements, easily lead to NH3 leak excessive or NOx reduction efficiency of
insufficient), caused by excessive emissions and lamp fault alarm phenomenon.
Therefore, the use the quality and performance of the urea solution should meet
the specified in the ISO 22241 standard content, specific requirements see table
6-1, through formal channels or to designated units added urea solution.

128
 表 6-1 尿素成分（参照 ISO 22241 标准）
组分 单位 最小限值 最大限值
尿素质量百分比 % 31.8 33.2
20℃ 密度 kg/m3
1087 1093
20℃ 的折射率 - 1.3814 1.3843
氨碱质量百分比 % - 0.2
缩二脲质量百分比 % - 0.3
乙醛 mg/kg - 5
不溶物 mg/kg - 20
磷（四氧化磷） mg/kg - 0.5
钙 mg/kg - 0.5
铁 mg/kg - 0.5
铜 mg/kg - 0.2
锌 mg/kg - 0.2
铬 mg/kg - 0.2
镍 mg/kg - 0.2
铝 mg/kg - 0.5
镁 mg/kg - 0.5
钠 mg/kg - 0.5
钾 mg/kg - 0.5

129
 Table 6-1 urea composition (with reference to ISO 22241 standard)
Component unit Minimum limit Maximum limit
Percentage of urea % 31.8 33.2
20 ℃ Density kg/m3 1087 1093
The refractive index of 20 ℃ - 1.3814 1.3843
The percentage by mass of % - 0.2
ammonia base
Mass percentage of two urea % - 0.3
acetaldehyde mg/kg - 5
Insoluble matter mg/kg - 20
Phosphorus (phosphorus tetroxide) mg/kg - 0.5

calcium mg/kg - 0.5

iron mg/kg - 0.5
copper mg/kg - 0.2
Zinc mg/kg - 0.2
chromium mg/kg - 0.2
nickel mg/kg - 0.2
aluminum mg/kg - 0.5
magnesium mg/kg - 0.5
sodium mg/kg - 0.5
Potassium mg/kg - 0.5

130
（四）尿素箱

尿素箱用于盛装尿素溶液，整体材料为塑料，顶部安装有传感器和加热器的

集成部件，见图 5-16 。传感器包括液位传感器和温度传感器，可感应液面高度和

温度，加热器可利用发动机冷却水的热量进行解冻。

通气阀可用于平衡罐内外气体压力。罐内装有尿素粗滤器，以防大于 0.1mm

的大颗粒进入喷射系统。罐底设有残液放出螺塞孔。尿素箱加注口应符合欧洲标准

DIN70070 ，与油箱口不同，可防止加错。

131
 （四） Urea tank
Urea tank for containing urea solution, the overall material is plastic, top-mounted
integrated components of the sensor and a heater as shown in Figure 6-16. Sensor includes a
liquid level sensor and a temperature sensor for sensing the liquid level and temperature of the
heater using heat of the engine cooling water thawed.
Tank vent valve can be used to balance the internal and external gas pressure. Urea tank is
equipped with a strainer to prevent large particles larger than 0.1mm into the injection system.
Tank bottom has a weep hole plug. Urea tank filler should be in line with European standards
DIN70070, with the tank port different to prevent a mistake.

132
 传感器组件
加注口
通气装置 传感器
通气装置 组件
加注口

标识位置 尿素泵
液位标识

放尿素螺塞

（ a ）凯龙尿素箱 （ b ）银轮尿素箱

图 6-16 尿素箱

133
 传感器组件
加注口
通气装置 传感器
通气装置 组件
加注口

标识位置 尿素泵
液位标识

放尿素螺塞

（ a ） KAILONG urea tank （ b ） YINLUN Urea tank

Figure 6-16 Urea tank

134
 尿素箱液位温度传感器组件根据是否集成尿素加热器分为非加热型尿
素箱传感器组件和加热型尿素箱传感器组件。非加热型尿素箱传感器组件
上没有集成尿素加热器，适合于在非寒冷地区（最低温度不低于 -7℃ ）的
使用；加热型尿素箱传感器组件上集成了尿素加热器，根据加热效果又分
为普通加热型尿素箱传感器组件和强化加热型（加热器为螺旋结构）尿素
箱传感器组件，普通加热型尿素箱传感器组件适合于在最低温度不低于 -
25℃ 的寒冷地区的使用，强化加热型尿素箱传感器组件适合于在最低温度
低于 -25℃ 的寒冷地区的使用，加热型尿素箱传感器组件如图 5-17 所示。

135
 Urea tank liquid level temperature sensor assembly according to whether the
integrated urea heater is divided into a non heating type urea tank sensor assembly and a
heating type urea tank sensor assembly. The non heating type urea tank sensor assembly has
no integrated urea heater, and is suitable for use in the non cold area (the lowest temperature
is not less than -7 C); The heated urea tank heater sensor assembly incorporates urea,
according to the heating effect is divided into ordinary heated urea tank sensor assembly and
strengthen heated (heater helical structure) urea tank sensor assembly, Common heated urea
tank sensor assembly is adapted for use in the minimum temperature not lower than -25 ℃
cold regions, strengthen heated urea tank sensor assembly suitable for use in low
temperature below -25 ℃ cold areas, heated urea tank sensor assembly as shown in Figure
5-17 FIG.

136
（ a ）普通加热型 （ b ）强化加热型 （ c ）加热型尿素箱传感器接口

图 5-17 加热型尿素箱传感器组件

137
（ a ） Ordinary heating type （ b ） Enhanced heating type （ c ） Heating type urea
tank sensor interface

图 6-17 Heating type urea tank sensor assembly

138
 （五） catalytic converter
图 6-18 为柴油机 SCR 箱式和筒式结构示意图，封装材料为不锈钢，内装 SCR 催
化剂和消声管路，表层不锈钢板下部装有绝热材料，运行过程中表面平均温度低于
200℃ 。法兰面接口为入口，另一光管接口为出口。催化器前后设有温度传感器安装孔，
在催化器后设计有 NOx 传感器安装座。

图 6-18 柴油机 SCR 结构示意图

139
 （五） catalytic converter
Figure 6-18 for diesel SCR box and a barrel type structure schematic diagram, package
material is stainless steel, SCR catalyst and a silencing pipe, surface of stainless steel plate
arranged at the lower part of the insulating material, running average surface temperature below
200 DEG C. Flange interface for the entrance, the other light pipe interface for export. Before
and after the catalytic converter is provided with a temperature sensor mounting hole in the
catalytic converter after the design of NOx sensor mounting seat.

Figure 6-18 Schematic diagram of diesel engine SCR structure

140
 （六）尿素泵
尿素供给单元如图 6-19 所示。尿素供给单元（尿素泵）重量约为 2.6kg ，工作电压
24V 。尿素供给单元内部集成计量泵、加热器、控制器，尿素供给单元内装配有主过滤
器、入口过滤器和回流过滤器，主过滤器更换周期一般为 30,000km 里程，但如果进入
尿素剂量单元的尿素清洁程度不符合要求，则更换周期可能会缩短。

电气接口

压力补偿

至喷嘴

至尿素箱 自尿素箱

图 6-19 尿素供给单元

141
 （六） Urea pump
Urea supply unit as shown in figure 6-19. Urea supply unit (Niao Subeng)
weighs about 2.6kg, working voltage 24V. Urea supply unit internal integrated
metering pump, a heater, a controller, the urea supply unit assembly filter, inlet
filter and return filter, filter replacement cycle is generally about 30000km mileage,
but if you enter the urea unit dosage of urea clean degree does not meet the
requirements, replacement cycle may be shortened.
电气接
口
压力补偿

至喷嘴

至尿素箱 自尿素箱

Figure 6-19 Urea supply unit

142
 泵电机结构如图 6-21 所示。该机构通过无刷直流电机旋转，使同轴连接的偏心轮
带动膜片往复运动，从而控制管路内压力。
该机构为智能执行器（ Intelligent actuator ），其控制电路不仅可以接受 DCU
以 PWM 形式传来的转速信号，完成电机的驱动功能；还可以通过 PWM 信号向 DCU 传递温
度和故障信号。

图 6-21 泵电机结构

143
 Pump motor structure as shown in figure 6-21. 。 The agency through no brush
DC motor rotation, so that the coaxial connector eccentric wheel drives the
diaphragm reciprocating motion, so as to control the pressure in the pipeline.The
agency is smart actuators (Intelligent actuator), the control circuit which is not only
acceptable form of PWM speed signal DCU came to complete the motor drive
function; can also pass temperature and fault signal via PWM signal to the DCU.

Figure 6-21 Pump motor structure

144
 表 6-2 尿素供给单元针脚定义
Table 6-2 Pin Definition urea supply unit

压力传感器“ +” 极 泵电机地
2 8 Pump motor ground
Pressure Sensor

泵电机“ +” 极
压力传感器信号
3 9 Pump motor the "+"
Pressure sensor signal
压力传感器地 Pressure 泵电机 PWM 线
4 10
sensor ground Pump motor PWM line
换向阀
5 加热器 Heater 11 Valve

换向阀信号
加热器信号 Heater
6 12 Valve signal
signal

145
 （七）尿素喷嘴

尿素喷射单元（ Dosing Module ）也称喷嘴，结构见图 6-22 ，其作用是

在 DCU 的控制下将尿素按照所需要的量成雾状喷到排气管中（图 6-23 ）。喷
嘴的主体是一个电磁阀，周围包围着尿素流道，起到冷却作用，另外上端设有
尿素的进、回液口，侧面设有电器接口，外围设有隔热罩。喷嘴工作环境温度
范围 -40~80℃ ，重约 0.25kg 。因为尿素对普通钢材有一定的腐蚀性，所以喷
嘴安装位置上游 200mm 到催化转化器的管路要使用不锈钢材料。

146
 （七） Urea nozzle

Nozzle structure see Figure 6-22 ,It is under the control of DCU urea according
to the required amount of spray to the exhaust pipe (Fig. 6-23) .

冷却水管接头
尿素管接头

喷射阀电子接头

冷却器体 隔热板

Figure 6-22 Nozzle structure

Figure 6-23 Urea spray shape

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 （八）后处理系统工作及注意事项

1. 确保添加及使用的尿素合乎规格，禁止添加其他成分的溶液（如柴
油、水、自制尿素水溶液等），如果加入了以上不满足标准的尿素溶液，
将会导致尿素计量泵严重损坏，并会引起发动机排放超标，发动机限扭。
一旦误加以上溶液，请立即联系当地的发动机服务经销商，并进行修理。
2. 每日检查尿素液位、检查有无尿素液的泄漏，并保证尿素箱中液位
不低于 18% 。
3. 应保持尿素加注口、加注设备（漏斗等）及其相邻部位清洁，否则
加注尿素溶液时会使尘土等杂志进入尿素罐，造成滤清器堵塞、老化及污
染尿素溶液等问题。

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 （八） Post processing system and matters needing
attention
1. Ensure add and use of urea meets the specifications, prohibited to add other components
of the solution (such as diesel oil, water and homemade urea water solution), if you added
the above does not meet the standard of the urea solution, will lead to serious damage to the
urea dosing pump, and can cause excessive emissions of the engine, engine torque limiting.
Once you add the above solution, please immediately contact the local engine service dealer
and repair it.
2 daily check urea level, check whether the leakage of urea solution, and ensure that the
liquid level in the urea tank is not less than 18%.
3. Keep urea filling mouth, filling equipment (cone) and its adjacent areas clean, otherwise
add urea solution will enable dust and other magazines in the urea tank. As a result, the filter
blockage, aging and pollution urea solution and other issues.

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 4. T15 断电后， SCR 系统会进入 90s 的倒吸时间，此过程严禁切断整车电源，否则 SCR 系
统内残留的尿素溶液会存在堵塞计量泵阀门和尿素喷嘴的危险，温度过低的情况下会导致尿素泵损坏。

5. 避免 SCR 催化器受污染，应做到以下几点：
（ 1 ）检查有无下列发动机问题 / 故障：增压器内部漏油、气缸磨损导致窜机油、气门油封漏油；
（ 2 ）定期更换油气分离器：更换里程约为 60,000 公里；
（ 3 ）催化器一旦被污染，可以通过高温进行再生，恢复后处理催化剂性能。
4. AfterT15 power failure, the SCR system will enter 90s suck time, this process is strictly
prohibited vehicle off the power, otherwise remaining in the SCR system urea solution there will be risk
of clogging metering pump valves and urea nozzle temperature is low the case, lead to urea pump
damage.
5. Avoid SCR catalyst contaminated, you should do the following:
(1) Check for the following engine problems / fault: turbocharger internal leakage, abrasion
cylinder channeling oil valve seal leakage;
(2) regular replacement of oil and gas separator: Replace the mileage of about 60,000 km;
(3) Once the contaminated catalyst can be regenerated by a high temperature, the catalyst
performance after recovery processing.

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第七章 冷却系统
Chapter 7 of the cooling system

151
 7.1 冷却系统概述 Cooling System Overview
冷却系统的功用是使发动机在所有工况都保持在适当的温度范围内。冷却系统既要防止发动

机过热，又要防止冬季发动机过冷。当冷发动机起动后，冷却系统还要保证发动机迅速升温，尽快

达到正常的工作温度。

The function of the cooling system is making the engine at all operating conditions are maintained

within the proper temperature range. The cooling system is necessary to prevent overheating of the engine,

but also to prevent the engine cold winter. When cold engine start, the engine cooling system but also to

ensure rapid warming as soon as possible to reach normal operating temperature.

WP12 柴油机冷却方式为水冷强制循环系统。

WP12 diesel engine cooling method is water cooled forced circulation system.

强制水冷发动机冷却系一般由水泵、节温器、水箱散热器、风扇、膨胀水箱及管路、暖风系

统等部件组成，具体参见下图 7-1 。

Forced cooled engine cooling system generally consists of water pump, thermostat, radiator, fan,

expansion tank and piping, ventilation system and other components, in particular see the figure 7-1

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 图 7-1 冷却系统组成 Cooling system components

1- 散热器 Radiator 2- 散热器盖 Radiator cover 3- 补偿水桶 Compensation bucket 4- 散热器出水软

管 Radiator outlet hose 5- 风扇传动带 Fan belt 6- 暖风器出水软管 Air heater outlet hose 7- 管箍
Ferrule 8- 暖风机芯 Heater movement 9- 暖风机进水软管 Fan Heater inlet hose 10- 节温器
Thermostat 11- 水泵 Water pump 12- 冷却风扇 cooling fan 13- 护风圈 Wind protection ring 14- 散
热器进水软管 Radiator inlet hose

153
 工作原理：当发动机工作时，曲轴皮带轮通过风扇皮带带动风扇及水泵旋转。水泵将冷却水泵
入发动机，进入发动机右侧水室内，首先冷却机油冷却器，使机油得到冷却；之后，冷却水从机体
右下部进入缸体缸壁内冷却水道，对气缸体进行冷却；通过缸体与缸盖的冷却水孔进入气缸盖水腔，
对缸盖进行冷却；冷却缸盖后的冷却水汇流到发动机出水管中，出水管出水终端与节温器连接，节
温器的另外两端分别与水泵进水口和冷却水箱进水管相接。冷却水温度由节温器自动调节，将水温
控制在 80℃ ～ 93℃ （车用机）。
How it works: When the engine working,crankshaft pulley driven the fan and pump Rotating by fan
belt. Pump makes cooling water go to the water chamber on the right side of the engine, first cooled oil
cooler, so that the oil is cooled; Thereafter, the cooling water from the lower right portion body into the
cylinder block for cooling the cylinder block; By cooling water hole block and head into the water chamber
of the cylinder head for the cylinder head cooling; Cooling water to the engine cylinder head after the
confluence in the outlet pipe, water terminal outlet pipe connected to the Thermostat; Also both ends of the
thermostat connected with pump inlet and a cooling water tank inlet Respectively, Cooling water
temperature is automatically adjusted by the thermostat, the water temperature controlled at 80 ℃ ~ 93 ℃
(vehicle engine).

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 大循环时冷却水经过水箱散热器进行冷却；小循环时冷却水直接进入水泵进水口，
使柴油机迅速升温，达到正常运行所要求的热状态。汽车行驶的迎面风和风扇吸入的风
冷却散热水箱，带走散热水箱的热量，以保持发动机正常的工作温度 85℃ ～ 93℃ ，此

时，水温表指针应在绿区的水平位置，具体参见图 7-2 。

Large cooling water circulating through the Radiator for cooling; cooling water
directly into the pump inlet when small cycles, so that the diesel engine to heat up
quickly, reaching the normal operation of the thermal state requires.cars with the
head wind and the fan intake to take away the radiator heat maintain normal engine
operating temperature 85 ℃ ~ 93 ℃, At this time, water temperature table pointer
should be in a horizontal position Green Zone For details, see Figure 7-2.

155
 heater

Expansion tank

Outlet pipe
Intercoole
r
Fa Thermostat
n cylinder
head

图 6-1 冷却系统 The cylinder block

heat
sink 组成
Direction of Oil
Pum Cooler
travel p
图 7-2 WP12 柴油机冷却路线图 WP12 diesel engine cooling roadmap

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 7.2 冷却系统主要部件 The main cooling system components
7.2.1 冷却液 Coolant
潍柴动力专用冷却液的冰点有 -25 ℃ 、 -35 ℃ 、 -40 ℃ 等规格，如图 6-3 所示。
请根据当地环境温度选择不同冰点的潍柴专用冷却液，选择原则是冰点比当地最低气温
低 10 度左右，具体请参见表 7-1 。

Weichai Power has a dedicated coolant freezing point -25 ℃, -35 ℃, -40 ℃
and other specifications, shown in Figure 6-3. Please select a different freezing
temperature according to the local environment,the selection principle is the freezing
point lower than the local minimum temperature of about 10 degrees details, see
Table 7-1.

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 表 7-1 潍柴动力专用重负荷发动机冷却液
Weichai Power special heavy-duty engine coolant

注意： Cautions:
1. 必须定期检查冷却液； Coolant must be checked regularly
2. 禁止使用水及劣质冷却液作为发动机的冷却液。 Prohibit the use of
poor quality water and coolant as the engine coolant

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 4kg 装

-25℃ -35℃ -40℃

10kg 装

图 7-3 WP12 柴油机冷却液示意图

WP12 diesel engine coolant schematic diagram

159
 7.2.2 电磁离合器风扇 Electromagnetic clutch fan

电磁离合器 线束 温控开关
（防转托架） （防水防松脱） （防水）
Electromagnetic clutch Harness thermal control
(anti-rotation bracket) (waterproof anti-loose) (waterproof)
燃油消耗
装载生产能力（ t/h ） （ mL/t ）
生产能力
提升率
砝码重量 不使用电磁风 使用电磁风 Enhance 不使用电磁风扇 使用 省油率
（t） 扇 Do not use 扇 use the rate of Do not use 电磁风扇 use Fuel ratio
electromagnetic electromagn production electromagnetic electromagnet
fan etic fan capacity fan ic fan

3.44 342.34 343.67 0.39% 77.64 76.83 -1.04%

4.25 413.63 406.11 -1.82% 65.74 64.75 -1.51%
5.01 482.12 492.45 2.14% 57.52 56.09 -2.49%
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 上述试验环境温度 23℃ ，装载机使用电磁风扇与不使用电磁风扇相比，装电磁风
扇后整机生产效率略有提升，同时燃油消耗量有所减低，平均节油 1.7% ，最高节油
2.5% 。如果环境温度进一步降低，省油效果会更加明显。
The above test the ambient temperature 23 ℃, loaders do not use electromagnetic
solenoid and the fan compared to a fan after fan mounted electromagnetic machine production
efficiency improved slightly, while fuel consumption has been reduced, the average fuel
economy of 1.7%, the highest fuel economy 2.5 %. If the ambient temperature is further
reduced, fuel efficiency will be more apparent.
电磁离合风扇和普通风扇的区别：低温季节使用电磁离合风扇后发动机水温上升快：
高温季节使用电磁离合风扇水温会短暂冲高，对发动机热平衡水温没影响。
The difference between electromagnetic clutch fans and ordinary fan: low season after
using an electromagnetic clutch fan engine temperature rises rapidly: the hot season
electromagnetic fan clutch temperature shot up briefly, no effect on engine thermal equilibrium
temperature.

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 7.2.3 节温器 Thermostat

节温器是控制冷却液流动路径的阀门。它根据冷却液温度的高低，打开或
关闭冷却液通向散热器的通道。
Thermostat control valve coolant flow path. It is based on the level of coolant
temperature, turn on or off the coolant channel leading to the radiator.
WP12 系列柴油机采用蜡式节温器。
WP12 series diesel engine using a wax-type Thermostat
蜡式节温器结构主要分为阀座、阀门、中心杆和旁通阀等，具体参见下图
7-4 。
Wax-type Thermostat structure is divided into the seat, valves, center rod and the
bypass valve, and other details, see the following figure 7-4.

162
 Central rod
Seat

The main valve

paraffin Bypass valve

图 7-4 蜡式节温器结构图 Wax-type Thermostat Chart

163
 节温器工作原理： Thermostat works:
1. 小循环 Small cycles
当发动机水温低于 83℃ （节温器开启温度）时，石蜡
呈固态，主阀门完全关闭，旁通阀完全开启，由出水管出来
的水经旁通管直接进入水泵，故称为小循环。由于水只是在
水泵和水套之间流动，不经过水箱散热器，所以冷却强度弱。
可以使得发动机快速升温至适宜的发动机工作温度，如右图
7-5 所示。 When the engine water temperature below 83
℃ (Thermostat opening temperature), paraffin is solid, the main
valve is fully closed, the bypass valve is fully open, the outlet 水流
pipe out of the water through the bypass pipe directly into the 入口
Water 小循环出口 Small
pump, it is called small cycles . Since water only flows between inlet cycles exports
the pump and the water jacket, without a Radiator, the cooling 图 7-5 小循环路线 Small circulation route
intensity is weak. So that the engine can be quickly heated to a
suitable engine operating temperature, as shown at right 7-5.

164
 2. 大循环 Great cycle

当发动机水温达 76℃ 以上时，石蜡逐渐变成液态，体积随之增大，

水流入口 大循环出口 Large
迫使橡胶管收缩，从而对中心杆下部锥面产生向上的推力。由于杆的上端 Water inlet circulation outlet

固定，故中心杆对橡胶管及感应体产生向下的反推力，克服弹簧张力使主
阀门逐渐打开，旁通阀开度逐渐减小，发动机水温升高到 95℃ （全开温
度），主阀门完全开启，旁通阀完全关闭，冷却水全部流经散热器。由于
此时冷却水流动线路长，流量大，冷却强度强，使得发动机水温下降，如
右图 7-6 所示。 When the engine temperature reached above 76 ℃, becoming
liquid paraffin, the volume increases, forcing the rubber vasoconstriction, thereby
generating lower central rod cone upward thrust. Since the upper end of the
fixing lever, so that the center bar of rubber tubes and susceptors produce reverse
thrust downwardly against the spring tension of the main valve gradually opens,
the bypass valve opening is gradually reduced, the engine water temperature to
95 ℃ (Full open temperature), the main valve is fully open, the bypass valve is
fully closed, all of the cooling water through the radiator. Since this time the
图 7-6 大循环路线
cooling water flow line length, flow, strong cooling intensity, so that the engine
Large circular route
water temperature dropped, as shown at right 7-6.

165
 7.2.4 水泵 Pump
水泵的功用就是对冷却液加压，保证其在冷却系中循环流动。
The function of is pump to pressure coolant to ensure that their circulation in the cooling
system.
WP12 系列柴油机水泵为离心式水泵，由曲轴皮带轮驱动，水泵中的冷却液被叶轮
带动旋转，在离心力的作用下以一定压力甩出。
WP12 Series diesel engine pumps are centrifugal pumps, driven by the crankshaft pulley,
water pump coolant is rotated by impeller, the centrifugal force thrown at a constant pressure.
水泵由 10PK 多楔带传动，水泵进水口处有皮带涨紧轮，变动其位置，可以调节皮
带的松紧。
The water pump ribbed throw 10PK belt, there is a belt tensioner wheel at the pump inlet,
change its position, you can adjust the belt tension.
WP12 柴油机水泵结构如图 7-7 所示。
WP12 diesel pump structure shown in Figure 7-7.

166
 1- 水泵体 Pump body
2- 轴承 Bearing
3- 水封总成 Seal assembly
4- 水泵叶轮 Pump impeller
5- 皮带轮 Pulley
6- 胶圈 Aprons
7- 水泵盖 Pump cover
8- 螺栓 bolt
9- 节温器盖 Thermostat cover
10- 螺栓 bolt

图 7-7 水泵剖面图 Sectional view of the pump

167
7.3 冷却系统的使用及注意事项 Use of the cooling system and precautions
一、放水螺塞的位置及安装 Drain plug location and installation
WP12 发动机冷却液循环系统放水有两处：一处在散热水箱底部右侧，可放净散热水箱、外部
管路及膨胀水箱内的水；另一处是机身右侧铝质机油冷却器盖后下方的螺塞，它可将发动机缸体内
部水道内的水放出，此处为发动机冷却水位最低点。由于该侧盖为铸铝件，故在拆卸和安装该螺塞
时，应特别仔细，以防损伤螺孔丝扣。
WP12 drain the engine coolant circulation system, there are two: one in the bottom right Radiator, can
put the net cooling water tank, external piping and expansion of water within the tank; the other is on the
right side of the fuselage aluminum oil cooler cover after the bottom of the plug, it may be water inside the
engine block watercourses within the release, here is the engine cooling water level the lowest point. Since
the side cover of cast aluminum parts, so in the removal and installation of the plug should be particularly
careful to avoid injury threaded screw
在上述两处放水螺塞拧入前，应将其上的密封铜垫片表面处理干净，放正，用手旋入螺塞拧靠，
再用扳手稍稍用力拧紧即可。
Before the above-mentioned two drain plug screwed, copper gasket should seal surface on handle
clean, put a positive twist by hand screwed into the plug, with a wrench to tighten a little harder 。

168
 二、加冷却液 Add coolant
冷却液由软化的清洁水和防蚀剂、长效防冻液配制而成，配制时必须严格按照添加剂生产厂商
的规定。 Coolant consists of softened clean water and corrosion inhibitors, long-acting antifreeze, it must
be strictly in accordance with the provisions of the additive manufacturers when formulating
注意：频繁的加水和经常换水，可能会导致冷却系统产生水垢。因此应尽快修复冷却系统的泄
漏，添加时要添加软化清洁水，尽量避免更换冷却液。水箱中放出的冷却液经织物或细网过滤后，
可重复使用。
Note: Frequent water and regular water changes, may cause the cooling system to produce scale.
Therefore, the leak should be repaired as soon as the cooling system leaked, add the softened when you
want to add clean water to avoid the replacement coolant. Coolant tank released after the fabric or fine-mesh
filter, reusable.
可从膨胀水箱给冷却系统加水，这样可避免产生气阻现象。
It can add water to cooling system From the expansion tank, which can avoid the phenomenon of air
resistance.
注意：柴油机每次开机前必须检查冷却液的液面。
Note: You must check the coolant level in front of each start diesel.

169
第八章 润滑系统
Chapter 8 Lubrication System

170
 8.1 润滑系统概述 Lubrication System Overview
一、 润滑系统功用 Lubrication system function
在发动机工作时连续不断地把数量足够的洁净润滑油输送到全部传动件的摩擦表面，并在摩擦
表面之间形成油膜，实现液体摩擦，从而减小摩擦阻力、降低功率消耗、减轻机件磨损，以达到提
高发动机工作可靠性和耐久性的目的 .
When the engine works,it is continuously deliverying enough clean lubrication oil to the surface of
all the transmission parts, and make a film on the surface, to achieve fluid friction, and reduce the frictional
resistance to reduce power consumption, reduce engine wear in order to improve engine reliability and
durability purposes. 。
二、 润滑方式 Lubrication
1. 压力润滑 Pressure lubrication
曲轴主轴承、连杆轴承、凸轮轴轴承 Crankshaft main bearings, Rod bearings, Camshaft
bearings
2. 飞溅润滑 Splash lubrication
气缸壁、配气机构的传动件 Cylinder wall, Valve bodies
3. 润滑脂润滑 Grease lubrication
水泵及发电机轴承
Pumps and Generator bearings

171
 三、 润滑系统组成 Lubrication system components
柴油机润滑系统主要有机油泵、机油滤清器、机油冷却器、油底壳、集滤器等部件
组 成 ， 具 体 参 见 图 8-1 。 Engine lubrication system is mainly composed by oil pump, oil
filter, oil cooler, oil pan, strainer and other components, as Figure 8-1.

图 8-1 WP12 柴油机油机润滑系统组成

Figure 8-1. WP12 lubrication system components

172
 8.2 润滑系统主要部件 Lubrication system main
components
8.2.1 润滑剂 Lubricants
WP12 系列柴油机规定使用 CI-4 级或更高质量等级润滑油，允许以高品位的润滑油
代替 CI-4 等级的润滑油。
WP12 Series diesel engines require CI-4 or more quality lubricants, allows using more
quality lubricant instead of CI-4 lubricants.
柴油机起动前必须首先检查油底壳内机油油面的高度。
First check the height of the oil in sump before diesel engine starts.
由于多级油具有平直的粘度曲线，在润滑要求高的低温和高温范围内，具有良好的
润滑特性，因此推荐使用多级润滑油。
Since the multi-grade oil has a flat viscosity curves , it has a good lubrication properties in
high temperature and low temperature range. Recommend to use multi-grade lubricants
水泵油杯及风扇轴承、前支撑等处的黄油咀注入汽车通用锂基润滑脂 GB/T5671-
85 。
Inject the car Lithium Grease GB / T5671-85 nozzle butter in pump oil cup , fan bearings,
front support and so on.

173
 图 8-2 润滑油牌号的选用 Figure 8-2 lubricant grade
selection
注意：不要在发动机运转时检查润滑油面高度；不同油品的润滑油不允许混用。
Note: Do not check the oil height when the engine is running; never mix different
lubricants.

174
 8.2.2 润滑油路 Lubricating oil path
机油泵通过集滤器将机油从油底壳吸入，由机油泵压出的机油流经机身上的油道，进入两个旋
装式机油滤清器，机油滤清器呈水平放置，并联安装。经过过滤后的机油进入机油冷却器（位于机
身左侧的水腔内），冷却后的机油首先进入主油道，然后经过斜油道润滑凸轮轴轴承、曲轴轴承。
此后一部分进入副油道，通过喷嘴冷却活塞顶部及润滑清洁缸套壁。连杆小头顶部加工有集油孔，
靠飞溅润滑。另一部分通过曲轴内加工的斜油道进入连杆轴承，润滑后进入油底壳。进入副油道的
润滑油又分成两部分：一部分经过喷嘴；另一部分则通过外部油管润滑单缸空气压缩机和高压喷油
泵。在主油道的后端引出一外部油管，用以润滑增压器。从机身到挺柱孔有一细斜油道，用以润滑
挺柱。机油经空心推杆、气门摇臂内油孔以润滑配气机构。
Pump get oil from the sump by strainer, and the oil flow through the oil passage into two spin-on oil
filter. Oil filter was placed horizontally installed in parallel. The filtered oil flow into the oil cooler, and after
cooling, oil enters the main oil passage and lubricating oil passage to lubricate camshaft bearings,
crankshaft bearings. After that part of the oil enters the sub oil passage to cool the piston crown and to
lubricate the cylinder wall through a nozzle. Rod small end formed with the top hole set, by splash
lubrication. Another part of the oil enters link bearing to lubricate and return sump by oblique oil passage.
The oil into the oil passage is divided into two parts: one passes the nozzle and the other enters external tube
to lubricate single cylinder air compressors and high-pressure fuel pump. The end of the main oil passage
leads to an external tubing, to lubricate the turbocharger..There is a fine oblique oil passage from the body to
the tappet bore for lubricating tappet. Oil lubricate the valve rocker arm valve gear through hollow push
rod .

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图 8-3 WP12 柴油机润滑路线

176
 为了防止铁屑进入机油泵，在油底壳内装有磁性螺塞，以吸住进入油底壳内的铁屑，防止铁屑
进入摩擦副表面而引起拉伤、化瓦等事故。在机油泵上还装有机油限压阀，在机油冷却器进油口与机
身主油道间设有旁通阀。
To prevent iron powder into the oil pump, there is a magnetic plug in sump, to prevent iron powder
into the components surface causing accidents. The oil pump is also equipped with the oil pressure limiting
valve. between the oil cooler inlet port and the main oil body has a bypass valve.
WP12 发动机润滑系统与一般车用发动机润滑系统相比，有如下特点：
WP12 engine lubrication system compared with the general vehicle engine , it has the following
characteristics:
（一）润滑油路多采用内部油道，这从结构上消除了润滑油路系统的泄漏，提高了可靠性。
Lubricants path use most internal oil passages, which eliminates leakage of oil from the structure to improve
the reliability.
（二）从机身到气缸盖间无专门润滑油道，缸盖上配气机构的润滑是靠空心推杆作为唯一输油
通道的。 There is no special oil passage from body to the cylinder head.
（三）发动机润滑油的冷却是通过安装于内部的冷却器实现的，隐藏于机身左侧盖内，使发动
机结构更为紧凑。 Engine oil cooling is by the cooler installed inside through implementation, hidden in
the fuselage on the left cover of the engine which made engine more compact.
（四）机油压力限压阀为不可调节式，一旦机油压力降低，说明柴油机润滑系出现故障，提醒
用 户 应 及 时 检 修 。 Oil pressure limiting valve is non-adjustable type, once the oil pressure is reduced,
indicating that the diesel engine lubrication system fails ,which reminds the user to repair timely.

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8.2.3 机油泵 Oil Pump
WP12 发动机机油泵采用转子泵结构，具体结构参见图 8-4 。它具有结构简单、加工方便、工
作可靠、寿命长的特点，所以被广泛应用。
WP12 engine oil pump uses a rotor pump structure,as Figure 8-4. It has a simple structure, easy
processing, reliable, long life characteristics, it is widely used
根据机型不同分为单级机油泵和双级机油泵，而双级机油泵可以看成是两个单级泵的简单串
联组合。一般公路用车装用单级齿轮泵，越野车、工程机械以及其他特种需要的装用双级齿轮机油
泵。因此，这里仅介绍单级泵。
Depending on the model divided into single-stage and two-stage oil pump oil pump, and two-stage
oil pump can be seen as two single-stage pump series of simple combinations. General road vehicles fitted
with a single-stage gear pump, off-road vehicles, construction machinery and other special needs fitted
with two-stage oil pump gear. Therefore, here only a single stage pump.
WP12 柴油机机油泵是由曲轴齿轮直接进行动力传递的，机油泵驱动齿轮为直齿轮，与机油
泵主动轴是热装过盈配合，以此来传递动力，无键槽，转子式机油泵由壳体、内转子、外转子和泵
盖等组成。内转子和外转子中心的偏心距为 e ，内转子带动外转子一起沿同一方向转动。
WP12 diesel engine oil pump is directly by the crank gear for power transmission, oil pump drive
gear is a spur gear, and oil pump drive shaft is mounted thermal interference fit, in order to deliver power,
without keyway, the rotor oil pump housing the inner rotor, the outer rotor and pump cover and other
components. Inner rotor and outer rotor center to the eccentricity e, together with the inner rotor to the
outer rotor rotate in the same direction.

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 图 8-4 机油泵结构图
Fig8-4 Structrure of oil pump

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 工作原理：转子齿形齿廓设计得使转子转到任何角度时，内、外转子每个齿的齿形廓线上总
能互相成点接触。内外转子间形成 4 个工作腔，随着转子的转到，工作腔的容积不断变化。在进
油道的一侧空腔，由于转子脱开啮合，容积逐渐增大，产生真空，机油被吸入，转子继续旋转，
机油被带到出油道的一侧，这时，转子正好进入啮合，使这一空腔容积减小，油压升高，机油从
齿间挤出并经过油道压送出去。
How it works: Toothed rotor tooth profile is designed so that the rotor to any angle, the inner and
outer rotor tooth profile of each tooth of each line is always a point contact. Formed between the inner
and outer rotor four working chambers, with the rotor to the volume of the working chamber is constantly
changing. In the inlet side of the oil passage cavity, since the rotor is disengaged, gradually increasing
volume, vacuum, oil is sucked, the rotor continues to rotate, the oil was taken out of one side of the oil
passage, when the rotor exactly into engagement so that the cavity volume decreases, oil rises, oil
extruded from the oil passage through the teeth and nip out.
为了防止机油泵过载损坏，在压力油腔出口处设置有机油泵安全闷，当压力超过限定安全压
力时，此阀打开，卸掉部分压力油，以保护润滑系的心脏—机油泵
In order to prevent overload damage , oil pump disposed organic stuffy security in the oil pressure
at the outlet chamber when the pressure exceeds a defined safe pressure, the valve opens, relieved some
of the pressure oil lubrication system to protect the heart - the pump

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8.2.4 机油滤清器 Oil Filter
机油在发动机工作时不断被磨屑和来自外界的灰尘污染，同时，在高温下被氧化产生可溶性酸
性物质和不可溶的沉淀物，还受泄漏入曲轴箱内的高温燃气的直接作用，加重了机油的污染。为了及
时清除机油中的机械杂质和胶状沉淀物，清洁机油，延长机油的使用期，保证良好的润滑，故在发动
机润滑系中设置机油滤清器。
when the engine is working ,it continues to be debris and polluted by dust from the outside. In order to
promptly remove the oil and mechanical impurities precipitate gum, clean oil, oil extended period of use, to
ensure good lubrication, it is set oil filter in the engine lubricating system.
对机油滤清器的要求应是：具有足够的滤清能力，流通阻力小，效果好，使用寿命长，安全可
靠，更换方便。 WP12 发动机使用 CI 级中增压柴油机机油，并采用封闭式曲轴箱换气方式，活塞环
的气密性好，减少了灰尘、废燃气进入机油而造成机油变质，故机油滤清器仅采用了旋装式纸质滤清
器，呈水平放置，并联。不但滤清效果好，且阻力小，过滤通过能力强。但这种滤清器不能清洗，应
定期更换。机油滤清器结构参见图 8-5 。
Oil filter requirements: have sufficient filtration capacity, flow resistance is small, the effect is good,
long life, safe, reliable, easy to replace. WP12 engines in turbocharged diesel engine oil CI level, and the use
of closed crankcase ventilation mode, the air tightness of piston rings, reducing dust, waste gas into the
engine oil caused by oil deterioration, so the oil filter using only spin-on paper filter, was placed horizontally
in parallel. Only good filtering effect, and the resistance is small, filtered through ability. However, this filter
can not be cleaned and should be replaced periodically. As Figure 8-5

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图 8-5 机油滤清器结合组
Fig8-5 Oil filter

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 8.2.5 机油集滤器 Oil Strainer
集滤器一般为滤网式，装在机油泵之前。润滑油经过滤网时，粗大的杂质被滤除。机油集滤器
伸入油底壳底部采集机油，以保证机油不问断地连续供给油泵，使润滑系正常工作， WP12 发动机机
油集滤器组件参见图 7-6 。
Strainer generally is strainer, installing before the pump. Oil passing through the filter,big
impurities are filtered out. The bottom of the oil sump strainer extends into bottom of sump to
collect the oil, to ensure that the oil continuously supplies to pump and make lubrication system
normally operate, WP12 engine oil strainer assembly see as Figure 7-6

图 7-6 机油集滤器结合组 Figure 7-6 Oil strainer binding group

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 8.2.6 机油冷却器 Oil Cooler
在高性能、大功率的强化发动机上，由于热负荷大，必须装设机油冷却器。润滑油经滤清器过
滤后直接进入冷却器，在冷却器芯内流动。冷却液在冷却芯外流动。两种液体在冷却器内进行热交换，
使高温润滑油得以冷却降温。具体结构参见图 8-7 。
On the high-performance, high-power engines, since the heat load, set with an oil cooler. Lubricating
oil passes from a filter into the cooler, flowing in cooler core Coolant flow in the outside. Two liquids
exchange heat in cooler, to cool down the high-temperature lubricantion oil.
As Figure 8-7

图 8-7 机油冷却器结构 Figure8-7Oil cooler structure

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 8.2.7 主油道限压阀 The main oil pressure limiting
valve
发动机的机油压力的选定应在保证发动机足够润滑的设计要求的同时，尽量降低机油压力。
过高的机油压力使机件容易损坏，如机油泵、机油滤清器、机油冷却器等，并且大量消耗发动机
的功率，使输出有用功减少。为防止机油压力过高而造成上述弊端，在机油泵内设置有最高压力
限制阀即限压阀。
Selecting engine oil pressure should be sufficient to ensure engine lubrication requirements while
minimizing oil pressure. High oil pressure is easy to damage parts, such as the oil pump, oil filter, oil
cooler and consume a lot of engine power, reduce the output of useful work. In order to prevent the above-
mentioned drawbacks. in the oil pump is provided with a maximum pressure limiting valve .
WP12 系列发动机上采用不可调的主油道限压阀（具体结构参见图 8-8 ），位于机油泵内部，
开启压力为（ 450+60 ） kPa ，与机油泵限压阀结构相同，只是阀内弹簧的弹力不同，两阀均不可
调。
WP12 series engine use non-adjustable main oil pressure limiting valve (as Figure 8-8), located
inside the pump, opening pressure (450 + 60) kPa, and the same with pump pressure limiting valve,
except the spring is different, two valves are not adjustable.

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 限压阀体
限压阀座 Pressure limiting
Pressure limiting valve body
valve seat

弹簧
spring

图 8-8 主油道限压阀结构 Figure 8-8 the main oil pressure limiting valve
structure

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 8.3 润滑系统工作及注意事项
Lubrication system precautions
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。在柴油机
停车后检查油面，至少等 5min 后进行，使机油有充分时间流回油底壳。 油尺低位至高
位的油量差为 3L 。
When the oil level is below the low line or above the high line engraved on the
dipstick ,never start the engine. After the engine stop to check the oil level, wait at least 5min, so
it is enough time that oil can flow back into the oil sump. It is 3L between low line and high line
on the dipstick.
按照使用保养说明书更换机油滤清器滤芯，当集水器满了或旋压过滤器已经替换，
则需要将收集到的水放出。
Replace oil filter cartridge in accordance with the instructions, when the sump is full or
spinning filter has been replaced, you need to release water.

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第九章 起动系统
Chapter 9 Starting System

188
9.1 起动系统概述 Starting System Overview

9.1.1 发动机的起动过程： Engine starting process

为了使静止的发动机进入工作状态，必须先用外力转动发动机曲轴，使活塞开始
上下运动，气缸内吸入可燃混合气，并将其压缩、点燃，体积迅速膨胀产生强大的动
力，推动活塞运动并带动曲轴旋转，发动机才能自动地进入工作循环，见图 9-1 。发动
机的曲轴在外力作用下开始转动到发动机自动怠速运转的全过程，称为发动机的起动
过程。
To make the rest of the engine into operation, you must use external rotation of the
engine crankshaft, piston began moving up and down inside the cylinder inhalation of
combustible gas mixture, and compression, ignition, rapid expansion of volume have a strong
impetus to the movement of the piston and drive rotation of the crankshaft, then the engine
automatically entered into the work cycle, shown in Figure 9-1. Crankshaft of the engine
begins to rotate in the external force to the engine idling automatically the whole process,
referred to as engine starting process

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9.1 起动系统概述 Starting System Overview

9.1.1 发动机的起动过程： Engine starting process

图 9-1 起动机在发动机上的安装 Starter installation on the engine

190
 9.1.2 起动系统的功用： Starting System Function
在正常使用条件下，通过起动机将蓄电池储存的电能转变为机械能带动发动机以足
够高的转速运转，以顺利起动发动机。 Under normal conditions of use, to store electrical
energy into mechanical energy by the starter battery to drive the engine at a sufficiently high
speed operation, in order to smoothly start the engine.
WP12 四气门电控国 IV 柴油机所用起动机见图 9-2 。 WP12 electronically controlled
four-valve diesel engine used in the Emission IV starter Figure 9-2.

图 9-2 起动机
Figure 9-2 starter

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 9.1.3 起动系统起动的条件： Start system startup conditions

起动的主要要求如下 The main starting requirements are as follows

起动迅速可靠 Start fast and reliable

主要要求 连续起动数次 Several consecutive starts

操作和维修方便 Easy operation and maintenance

要使发动机起动成功，必须满足两个基本条件：一是起动转速；二是起动转矩，即
要有一定的起动功率。
For a successful engine start, two basic conditions must be met: First, the cranking speed;
the second is the starting torque, which have a certain starting power.

192
 （一）起动转速：能使发动机起动的曲轴最低转速称为起动转速，起动转速是保证
发动机工作必要的压缩压力和着火燃烧的重要条件； Starting speed: enables the engine start
spindle minimum speed is called start speed, starting speed is important to ensure that the
necessary conditions for the engine compression pressure and ignition combustion
（二）起动转矩：能够使曲转旋转的最低转矩称为起动转矩，起动转矩必须克服压
缩阻力、发动机本身的机件及其附件内相对运动零件之间的摩擦阻力所产生的力矩。起动
阻力矩与发动机压缩比、温度、机油粘度等有关。 Starting torque: the ability to make a
minimum torque transfer song called rotation starting torque, starting torque must overcome
compression resistance, mechanical friction torque of the engine itself and the relative motion
between the parts produced in the annex. Starting resistance torque of the engine compression
ratio, temperature, oil viscosity and so on.
车用柴油机一般所需的起动功率为 5kW 或更大。 Diesel vehicles generally required
starting power of 5kW or greater.

193
 9.1.4 发动机常用的起动方式： Common engine startup mode

人力起动—简单不方便—用于农用车
Human start - simply is not convenient - for agricultural vehicles

辅助汽油机起动—常用于大型柴油机
起动方式 Auxiliary gasoline engine start - commonly used in large diesel
startup mode engines

电力起动机起动—以蓄电池为电源，操作方便、起动迅速，
可重复使用。目前几乎所有的汽车发动机都采用电力起动机起
动。 Electuary Power starter - using battery as a power source, easy
operation, quick start,
It can be reused. Currently, almost all car engines have adopted Electuary
power starter.
广泛使用

194
 9.1.5 起动辅助装置
Starting auxiliary devices
发动机在严寒冬季起动困难，这是由于机油粘度增高，起动阻力矩增大，蓄电池工
作能力降低，以及燃油气化性能变坏的缘故。为使之便于起动，在冬季应设法将进气、
润滑油和冷却水预热。车用柴油机为了能在低温下迅速可靠的起动，常采用一些用以改
善燃料着火条件和降低起动转矩的起动辅助装置，如电热塞、进气预热器、起动液喷射
装置以及减压装置等。
Engine starting difficulties in cold winter, which is due to the oil viscosity, the starting
moment of resistance increases. To make it easy to start in the winter should seek intake, lube
oil and cooling water preheating. To be able to quickly and reliably start at low temperatures,
Automotive Diesel Engine often with some of the starting auxiliary devices to improve starting
torque and lower fuel fire conditions, such as glow plugs, intake air preheater, starting fluid
injection means and decompression devices..

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9.2 起动系统主要部件 Starting system main components
9.2.1 起动机 Starter

起动机通常由三部分构成：直
流电动机、传动机构和控制装置。具
体结构见图 9-3 、图 9-4 及图 9-5 。
Starter usually consists of three parts: a
DC motor, transmission and control
devices. Specific structure shown in
Figure 9-3, Figure 9-4 and Figure 9-5.

图 9-3 起动机的组成 Components of starter

1- 直流电动机 DC motor 2- 传动机构 transmission 3- 控制装置
control devices

196
 电磁开关
Electromagnetic switch

单向器 One-way device

驱动端盖 拔叉
Front cover fork 行星齿轮 转子 定子 碳刷
gear armaturestator brush
图 9-4 起动机剖视图
Sectional view of a starter

197
图 9-5 起动机零部件连接示意图 Connection diagram of Starter Parts

198
 起动机的工作原理是带电导体在磁场中受到电磁力，将电能转变为机械能。
Starter works by electromagnetic force charged conductor in a magnetic field, so
that the electrical energy transmit into mechanical energy.
起动信号通过起动继电器，接通保持线圈和吸引线圈，起动机慢转与齿圈
啮合。啮合完成后，吸拉线圈断开，与蓄电池正极相连的主回路线路接通，起
动机高速旋转，带动发动机正常起动。起动机起动过程示意图见图 9-6 。
Start by activating signal relay coil is turned on keeping and attracting coil, turn
and slow starter ring gear. After the completion of the engagement, suction pull off the
coil, the main circuit wiring and the battery positive terminal is turned on, high-speed
rotation starter, led the normal engine start. Starter starting process is shown in Figure
9-6.

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图 9-6 起动机起动过程示意图
Starter starting process schematic

200
 发动机起动后，在断开起动开关瞬间，接触盘仍在接触位置。此时电磁开
关线圈电流从蓄电池正极到接触盘、吸引线圈、保持线圈。此时吸引线圈与保
持线圈磁力互相抵消，活动铁芯便在弹簧作用下回位，使驱动齿轮退出；与此
同时接触盘也回位，切断起动电路，起动机停止工作。其过程示意图见图 9-
7。
After the engine is started, disconnect the starter switch instantly, the disc is still
in contact with the contact position. In this case the electromagnetic switch coil
current from the battery to the positive contact pads, attracting the coil to keep the
coil. At this time attracting the magnetic coil and holding coil cancel each other core
activities will come back, the driving gear exit; at the same time also the contact plate
back position, cut off the starting circuit, the starter stops working. The procedure is
shown schematically in Figure 9-7.

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 图 9-7 起动开关松开瞬间起动机动作过程示意图
Starter work process schematic when the Starter switch instant released

202
 目前我们使用的起动机主要分为两种类型直驱起动机和减速起动机，如图 9-8 所示。
Currently we are using the starter two main types of direct-drive starter and deceleration
starter, shown in Figure 9-8.

a ）直驱起动机 9-8 起动机类型 b ）减速起动机

Direct drive starter Starter type Deceleration Starter

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 减速起动机较直驱起动机有较大的优势： Deceleration compared with direct drive
starter has a great advantage
（一）从外形看，相同功率的两个起动机，减速起动机体积小，重量轻； (A) From
the appearance, the same power of two starter, Reduction starter has small size and light weight;
（二）从功率上讲，起动机功率大小与扭矩和转速有关，降低输出转速能够增大起
动扭矩，从这点上看减速起动机输出扭矩较大； (B) From the perspective of power, size and
power starter related to torque and speed, reduce the output speed can increase the starting
torque, from this point of view deceleration starter get larger output torque;

图 9-9 减速起动机结构示意图
Figure 9-9 Schematic deceleration starter

204
 （三）从应用上讲，特别是在低温的情况下，减速启动机起动更加迅速，相较而言
增加整车蓄电池的使用寿命。 (C) from an application perspective, especially at low
temperatures, the deceleration start more quickly, compared with the vehicle in terms of
increased battery life.
但减速起动机比直驱起动机内部增加行星减速齿轮，见图 9-9 ，价格上可能相对较
高。 But more than the direct drive reduction starter internal planetary reduction gear, shown in
Figure 9-9, may be relatively high price.

图 9-9 减速起动机结构示意图
Figure 9-9 Schematic deceleration starter

205
起动机一般安装在飞轮壳上，如图 9-10 所示：
Starter typically mounted on the flywheel housing, shown in Figure 9-10:

图 9-10 起动机起动系统典型示意图
A typical schematic diagram 9-10 starter work system

206
 起动机最高工作电压不超过 26V ，可在 -30 ℃ ~+100℃ 的环境温度范围下正常工作，
电磁开关允许持续使用的最大环境温度为 100℃ 。在 120℃ 的环境温度下，起动机的整
个使用时间寿命为正常环境温度范围下的 5% ，且连续使用时间不得超过 30 分
钟。 Starter does not exceed the maximum operating voltage of 26V. Normal work in ambient
temperature range of -30 ℃ ~ + 100 ℃, the solenoid valve allows the continued use of the
maximum ambient temperature of 100 ℃. At ambient temperature of 120 ℃, the whole life
time of starter is 5% than the normal ambient temperature range, and the continuous use of time
should not exceed 30 minutes.
起动机工作受整车钥匙开关控制，当钥匙开关打到 start 档时，起动继电器导通，起
动继电器通过小电流控制蓄电池到起动机大电流的通断，当起动继电器导通后大电流流
经起动机，起动机驱动齿轮与发动机齿圈啮合，从而带动发动机运转。 Starter work by
the vehicle key switch control, when the key switch to start gear, the starter relay is turned on,
the starter relay controlled by a small current to the starter battery large current-off, when the
starter relay conducting of a large current flows through starter, starter drive gear with the engine
ring gear, thereby driving the engine is running.

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9.3 起动系统工作及注意事项
9.3 Starting system work and precautions

起动机使用注意事项： Starter Caution:

1. 起动机为短时间工作器件，每次起动时间不能超过 15s ，相邻二次起动间隔时间
要大于 30s 。 Starter is designed for the short-term operation of the device, each start time
should not exceed 15s, adjacent second start interval is greater than 30s
2. 冬季温度低于零下 5℃ 时，起动前应预热发动机。 When winter temperatures lower
than minus 5 ℃, starter should be preheated before starting the engine
3. 发动机一经起动。应立即松开起动开关，使起动机驱动齿轮与飞轮齿圈脱
离。 Once the engine is started. Should immediately release the starter switch, and starter drive
gear with the flywheel ring gear left.
4. 在发动机停止转动前，不得给起动机通电。防止飞轮和起动机齿轮碰撞而导致损
坏。 We can not energize the starter before the engine stopped. Prevent the collision of flywheel
and starter gear which caused damage.

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 起动机使用注意事项： Starter Caution:
5. 安装起动机时，必须按照起动机接线图接线。拆装起动机前，确保蓄电池与起动
机主起动线路断开。 When install the starter the starter must be wired according to the wiring
diagram. Before dismantling starter, ensure that the battery and starter main starting line
disconnected.
6. 必须经常检查起动机的紧固件及导线绝缘有无损坏，导线接触是否良好，并清除
积污。 Must always check the fasteners and wire insulation damage of starter, Whether wire
contacts are good , and clear the contamination.
7. 起动机的大修年限与其配装的汽车相同。 Starter overhaul life with the same as its
cars equipped
8. 起动受 ECU 控制和匹配自动变速箱车辆不能采用推车的方式起动。 Vehicles
which start mode controlled by the ECU or matching automatic transmission can not use push-
start. .

209
 第三篇 WP12 柴油机的维护保养
Maintenance Manual for WP12 series Diesel Engine

210
第一章 柴油机维护保养指南
Guide For Maintenance Of Diesel Engine

211
1.1 燃料油、润滑油、冷却液和辅助材料
Fuel, Lubricating , Coolant, and Auxiliary materials

• 燃料油
Fuel
• 柴油机润滑油
Diesel engine lubricating oil
• 涨紧轮的润滑
Lubrication of rose
• 发动机冷却系统的防冻添加剂
Antifreeze additive for the engine cooling system
• 辅助材料
Auxiliary materials

212
 1.1.1 燃料油 Fuel
夏季： 0 ＃柴油（ GB252 ）
Summer: No.0 diesel fuel (GB252)
冬季：一般用 -10 号柴油，但当柴油机使用环境温度低于 -15℃ 时应选
用 -20 号柴油。
Winter: general use No.–10 diesel fuel, but when the environment temperature
is lower than 15 ℃ should choose No.- 20 diesel fuel 。
室外温度低于 -30℃ 时，应选用 -35 号柴油。
When outdoor temperature is below - 30 ℃, should choose No.- 35 diesel fuel.
注意：所用燃油必须符合国家标准 GB 20891-2014 中附录 D 表 D.1 规定。
Note: the fuel used must conform to the national standard GB 20891-20891 in
appendix D table D. 1.

213
1.1.2 柴油机润滑油 Diesel engine lubricating oil

潍柴动力国Ⅳ系列柴油机使用 CI-4 级机油，具体标准参见表 1-1 。

Weichai power WP12 Euro IV Diesel Engines using CI - 4 engine oil, specific standard
see table 1-1.
表 1- 1 潍柴动力专用机油选择规范 oil selection for weichai
包装规格
power 适用的主要机型
品种 Type 产品种类 Product class
capacity Applicable engine models

10W/30
4L ， 18L ， 170 国Ⅱ排放柴油机： WD615 、 WD10 、
CF-4 15W-40
kg WD618 、 WD12 、 226B 系列等
20W-50

10W/30 国Ⅲ排放柴油机：
4L ， 18L ， 170
柴油机油 CH-4 15W-40 WP4 、 WP5 、 WP6 、 WP7 、 WP10 、
kg
Oil for diesel 20W-50 WP12 、 WP13 系列等
engine 10W/30 国Ⅳ排放柴油机：
CI-4 15W-40 4L ， 18L,170kg WP4 、 WP5 、 WP6 、 WP7 、 WP10 、
20W-50 WP12 、 WP13 系列等

10W/30 国Ⅴ排放柴油机：
4L ， 18L ， 170
CJ-4 15W-40 WP4 、 WP5 、 WP6 、 WP7 、 WP10 、
kg
20W-50 WP12 、 WP13 系列等

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 潍柴动力专用机油根据温度选择粘度参考表 1-2
Table 1-2:selecting oil’s viscosity according to the temperature
注意： Note
表 1- 2 粘度与环境温度对应表 1 ）柴油机起动前必须首先检查油底壳内机油油

Viscosity corresponding to the 面的高度。

table with the environment temperature Before starting the engine should check the oil
level within the oil sump.
SAE 粘度级 2 ）不要在柴油机运转时检查机油面高度。
适用的环境温度（℃）
别 Don't check the oil level when the diesel engine is
Environment temperature
viscosity running.
3 ）严格禁止潍柴动力专用机油与其他厂家机油
10W-30 -25~35
同时混用
15W-40 -20~40 Strictly prohibited for weichai power oil in
20W-50 -15~50 conjunction with other manufacturers oil to mix

215
 潍柴动力各机型机油加注量及滤芯数量参考表 1-3 。
Table 1-3:the oil filling quantity and filter of each Weichai power engine

滤清器数量 Number of filter

柴油机 diesel engine 气体机 Gas machine

机油加注量
机型 (L) 柴滤
type oil filling
机滤 机滤 燃气滤
quantity 粗滤 精滤
filter filter gas filter
coarse filter fine filter

WP12 25~28 2 1 1 2 1

备注 Note ：
1 ）机油加注量数据仅供参考，实际加注量以油尺为准。 Oil filling quantity data are
for reference only, actual filling amount will be subject to oil dipstick.
2 ）若整车上配置潍柴水寒宝或除水放心滤，在更换柴滤的同时需要一同更换水
寒宝或除水放心滤滤芯。 If there are cold water or water filter ,when replacing the oil filter the
cold water or water filter should be replaced at the same time

216
 1.1.3 发动机冷却系统的防冻添加剂
1.13 Antifreeze additive the engine cooling system

柴油机冷却系统必须添加全部纯冷却液，冷却液具有防冻和防沸的性能，并且含有防锈、防腐

蚀添加剂，对水箱和发动机冷却腔有特别的保护作用，防止缸套穴蚀和冷却系统的锈蚀。

Diesel engine cooling system must be added all pure cooling fluid, coolant with

antifreeze and the boiling ， it have rust and corrosion resistant additives, protect water tank

and engine cooling chamber, prevent the cylinder liner cavitation and corrosion of the cooling

system.

217
1.1.3 发动机冷却系统的防冻添加剂
1.13 Antifreeze additive the engine cooling system

潍柴动力专用冷却液的冰点有 -25℃ 、 -35℃ 、 -40℃ 等规格，请根据当地环

境温度选择不同冰点的潍柴专用冷却液，选择原则是冰点比当地气温低 10°C 左右，
请参见表 1-4 。
The freezing point of Weichai power cooling fluid has - 25 ℃ and - 35 ℃ and - 40
℃ specifications, please selecting weichai cooling fluid according to the local
environment temperature freezing, selection principle is 10 °C lower than the local
temperatures freezing point, See table 1-4.

表 1-4 潍柴动力专用发动机冷却液
Table 1-4: Weichai power cooling fluid

包装规格
品种 Type 产品种类 Species
Specifications
HEC-Ⅱ-25
发动机冷却液
HEC-Ⅱ-35 4kg ， 10kg
cooling fluid HEC-Ⅱ-40

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 1.1.4 尿素溶液
1.1.4 Urea solution

不合适的尿素溶液容易造成 SCR 催化剂中毒失效或还原效率不足（如

尿素溶液中所含的磷、钠、钾、钙元素等成分超标容易造成催化剂中毒；

尿素溶液浓度不符合要求，容易导致 NH3 泄露过量或 NOx 还原效率不足），导致

因排放超标而出现故障灯报警现象。

Poisoning failure or inadequate reduction efficiency of the SCR catalyst may be caused

by inappropriate urea solution(Excessive amounts of the phosphorus, sodium, potassium,

calcium and other components paint in the urea solution cause catalyst poisoning easily, The

excess leakage of NH3 or the reduction efficiency of NOx may be easily caused by

inappropriate urea solution )Trouble light alarm by excessive discharge phenomenon caused by

Inappropriate urea solution.

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 1.1.4 尿素溶液
1.1.4 Urea solution

所使用尿素溶液的质量及性能应满足 ISO22241 标准中规定的内容，具体要求参见

表 2-5 ，应通过正规渠道或到指定单位添加尿素溶液。

The quality and performance of the urea solution shall meet ISO22241 standard ,specific

see table 1-5, add urea solution from the formal channels or designated units.

220
 表 1-5 尿素成分（参照 ISO22241 标准）
组分 单位 最小限值 最大限值
尿素质量百分比 % 31.8 33.2
20℃ 密度 kg/m3 1087 1093
20℃ 的折射率 - 1.3814 1.3843
氨碱质量百分比 % - 0.2
缩二脲质量百分 % - 0.3
比
乙醛 mg/kg - 5
不溶物 mg/kg - 20
磷（四氧化磷） mg/kg - 0.5
钙 mg/kg - 0.5
铁 mg/kg - 0.5
铜 mg/kg - 0.2
锌 mg/kg - 0.2
铬 mg/kg - 0.2
镍 mg/kg - 0.2
铝 mg/kg - 0.5
镁 mg/kg - 0.5
钠 mg/kg - 0.5
钾 mg/kg - 0.5

221
 Table 1-5 Composition of urea (see ISO 22241 standard)
component unit min max
Urea quality percentage % 31.8 33.2
The density of 20℃ kg/m3 1087 1093
The refractive index of 20℃ - 1.3814 1.3843
Ammonia alkali quality % - 0.2
percentage
Biuret quality percentage % - 0.3
Acetaldehyde mg/kg - 5
Insolubles mg/kg - 20
Phosphorus (four phosphorus mg/kg - 0.5
oxide)
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
Aluminum mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5

222
1.1.5 辅助材料
1.1.5 Auxiliary materials

表 1-7 辅助材料 Auxiliary materials

序号 No. 名称 Name 颜色 color 用途与应用 Use

涂在平滑的金属表面防止咬合
Molykotte Pulver 黑色 例如：涂在气缸套外表面等
1 Apply to smooth surface of metal to prevent
（细钼粉） Black
biting, For example: ,Apply to exterior surface
of cylinder liner.
在润滑油压力建立之前起润滑作用
Molykotte G.u.plus 深灰色 例如：涂在进气门杆上等
2 Before in the lubricating oil pressure
（二硫化钼油剂） Dark grey
lubrication , For example: coated in the inlet
valve rod etc

223
 表 1- 8 柴油机施胶参考清单
牌号 主要用途 施胶部位列举 补充说明

飞轮壳螺栓
凸轮轴止推片螺栓
凸轮轴正时齿轮螺栓
中间惰轮螺栓
前端盖螺栓
涂在螺纹表面固持，防 机油滤清器座螺栓 作为可选项，可
潍柴专用 242 止震松，中等力度
机油冷却器螺栓 以 采 用
机油冷却器调节阀的螺塞， DriLoc204 螺 纹
预涂胶进行预涂。
油泵回油管固定装置的螺栓，
空压机轴端螺纹
集滤器螺栓
传感器和线束固定装置的螺栓

涂在螺纹外表面锁紧、
潍柴专用 262 气缸盖副螺栓
密封和防止震松

224
 Tab1- 8 Diesel engine sizing reference list
Additional
Designation Main Applications List of locations
description

Flywheel housing bolts

Camshaft thrust plate bolts
Camshaft timing gear bolts
Applied onto the thread Intermediate idler bolts Front
surface to prevent end cover bolts Oil filter seat
Weichai
loosening due to bolts Oil cooler bolts Screw Alternatively, the
Power 242
vibration, with moderate plug of oil cooler regulator valve DriLoc204 thread
strength Fixing bolts of oil pump return pre-application
pipe Air compressor shaft end sealant can be pre-
thread Strainer bolts Fixing bolts
applied.
of sensor and harness

Applied onto the

external threads to lock, Cylinder head secondary bolts
Weichai
seal, and prevent
Power 262
loosening due to
vibration

225
 牌号 主要用途 施胶部位列举 补充说明

潍柴专用 271 防松紧固 堵油孔的碗形塞

用于芯子与孔之间的密 其余的碗形塞  
潍柴专用 277 封
 
潍柴专用 270 用于密封缸盖顶部表面 推杆管－缸盖
潍 柴 专 用 起涂在光亮的金属表面 机体前面与前端盖 , 后端面  
518 （ 510 的 密封作用 与飞轮壳连接板  
更新产品） 水泵后盖－机体前端面
飞轮壳连接板－飞轮壳
气缸体与机油冷却器盖结合
面
气缸体与机油加油口盖板结
合面

潍 柴 专 用   油底壳与机体结合面  
KB5910

226
 Main Applications Additional
Designation List of locations
description
Weichai Locking and tightening
Bowl plug for oil port
power 271
Weichai For sealing between  
Other bowl plugs
power 277 coreand bore
Weichai For sealing top surface  
Push rod tube – Cylinder head
power 270 of cylinder head
Weichai Applied onto shining Mating faces of cylinder block and crankcase  
power 518 metal surfaces for Front end face of engine block and front end  Water pump rear cap –
cap, rear end face and flywheel housing Engine block front end
(Updated sealing
connecting plate Mating faces of oil filter seat face Flywheel housing
product of and crankcase connecting plate –
510) Flywheel housing Mating
faces of cylinder block and
oil cooler cover Mating
faces of cylinder block and
oil filler port cover

Weichai   The oil pan and the body surface  

power KB5910

227
1.2 日常维护保养 Daily Maintenance
•检查冷却液液面，水温。 Check the coolant fluid level, water temperature
•检查机油液面。 Check the machine oil
•检查燃油液面 . Check the fuel level
•检查三漏。 Check the leakage
•检查风扇。 Check the fan
•检查皮带。 Check the belt
•检查排气颜色是否正常。 Check whether the exhaust color is normal
•检查声音是否正常。 Check whether the sound is normal
•检查转速、振动是否正常。 Check the rotation speed, vibration is normal

228
 一、检查冷却液液面、水温 Check the coolant level and temperature
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。
Observe the coolant level via glass sight hole. If the coolant is insufficient,
open the filler port cap and add 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: To open the water filler cover, you must firstly press down the air release
button so as to prevent personal injuries due to hot coolant when the engine is still
hot enough.
注意：柴油机每次开机前必须检查冷却液的液面。
Note: every time before starting the diesel engine cooling fluid level must be
checked .

229
图 1-1 加水口盖安全标志 图 1-2 膨胀水箱图
Add water to cover safety sign Expansion tank

230
 二、检查机油液面 Check the oil level
检查机油面高度是否在油尺的刻线范围。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。
Check the oil level in oil dipstick scribed line. It’s prohibited to start the diesel
engine when the oil level is below the lower marking of oil dipstick or is above the
upper marking of oil dipstick.
在柴油机停车后检查油面，至少等 5min 后进行，使机油有充分时间流回
油底壳。油尺低位至高位的油量差为 3L 。
After the diesel engine is stopped, check
the oil level after waiting for at least 5min
before checking the oil level, in order to enable
the oil flow back to oil sump. The oil amount
difference between the lower mark and the
upper mark of oil dipstick is 3L.
图 1- 3 机油标尺标示说明 Oil Dipstick

231
三、检查燃油液面 Check the fuel level

检查仪表盘中的燃油液面指示，及时添加燃油。使用的柴油应符合规定。
要注意柴油的清洁，加注前最好静止存放 72 小时以上。柴油应通过内置滤网
注入油箱。

Check the dashboard fuel liquid

level indicator, adding fuel in a timely
manner. Use of diesel should comply
with the rules. To pay attention to the
clean diesel, better still for more than
72 hours before filling. Diesel should
through the built-in filter into the tank.

图 1- 4 检查仪表盘的燃油页面指
示
Check the dashboard fuel page instructions

232
 四、检查三漏 Check for leakages

检查柴油机外表面是否有漏水、漏气、漏
油现象。 Inspection for the surface whether there
is water, air, diesel engine oil leakage.

图 1-5 检查风扇叶片
五、检查风扇 check the fan Check the fan blade

检查风扇叶片有无损坏，塑料风扇是否变形，铁风扇铆钉是否松动，叶片
是否弯曲，连接螺栓是否紧固，确保风扇工作可靠。
Check the fan blade is damaged, whether the plastic fan is distorted . For steel
fan ,check whether the river loosened and the vane is curved, Whether the
connecting bolt fastening to ensure reliable running.

233
 六、检查皮带 Check the belt

皮带通过皮带张紧轮自动涨紧，用户通过手压皮带检查皮带的松紧。用肉
眼检查三角皮带，有无裂纹或擦伤，必要时应更换。

The belt can be tensioned

automatically through the belt
tensioner , and you can check the belt
tension by pressing the belt 。 Check
the V-belts with your eyes to find if
there is any crack or scratch on the V-
belts 。 Replace them if necessary 。

图 1-6 检查皮带 Check the belt

234
 七、检查排气颜色是否正常
Check the color of exhaust gas

正常排气颜色为淡灰色。颜色出现变化
应检查原因并排除。
The color of exhaust gas is normally light
grey. If the color changes, find out the reasons
and eliminate the trouble. As shown in Figure 1-
7. 图 1-7 检查排气
八、检查运转声音是否正常 Check the exhaust gas

Check for abnormal sound of the engine

九、检查转速、振动是否正常
Check speed and vibration of the engine

235
1.3 各级保养内容 Items for various levels of
maintenance
•更换机油 Replace the diesel engine oil
•更换机油滤清器或滤芯 Replace oil filter or filter element
•检查、调整气门间隙 Check and adjust the valve clearance
•更换燃油滤清器芯 Replace fuel filter element
•检查进气系统 Check the air intake system
•检查空气滤清器滤芯 Check the air filter element

236
一、更换机油 Replace the diesel engine oil

拧下油底壳底部的放油螺塞，将机油放净，再旋上放油螺塞；见图 1-8 。
Unscrew the oil drainage plug at the bottom of the oil sump, drain the oil and
then screw on the drainage plug as shown in Figure 1-8.

放油螺塞 图 1- 8 放油螺塞
Oil drain plug Oil drain plug

237
一、更换机油 Replace the diesel engine oil

打开加油口盖， ( 见图 1-9) 从机油加注口加入机油，观察油尺刻度，直

到达到要求，再装上加油口盖。
注意：废弃油要放在指定的地点和容器里，以便回收再利用。

Open the oil filler cap (as shown in Figure

1-9), add oil through the filler port, observe
the oil level through the oil dipstick scale till
the required height is reached, and then
install the oil filler cap.

Note: The waste oil shall be stored with

special container and placed in designated
location for recycling.
图 1- 9 机油加油口
Engine oil filler port

238
二、更换机油滤清器或滤芯
Replace oil filter or filter element
① 卸下旧的机油滤清器；
Remove the original oil filter.
② 向新滤清器中注满干净的机油；
Fill the new filter completely with clean oil
③ 安装新机油滤清器前在胶垫上涂抹机油；
Before installing of new oil filter, apply some oil onto the rubber gasket
④ 胶垫接触到基座后，再拧紧 3/4 圈～ 1 圈，使其密封；
Install the oil filter and make the rubber gasket contact the base and then an
additional twist of 3/4~1 turn.
⑤ 起动柴油机检查是否漏油。
Start the diesel engine and check for oil leakage.

239
三、更换燃油滤清器芯。 Replace the fuel filter element.
① 卸下旧的燃油滤清器芯；如果安装在粗滤器上的集水器皿还可以再
用 ， 请 将 集 水 器 皿 取 下 。 Remove the old fuel filter element; if the water
collecting vessel installed on the strainer can also be used, please remove it.
② 润滑封口。 Lubricate the sealing port
③ 用手拧上滤清器直至封口与接口结合。 Screw down the filter with hand
till the sealing port comes into contact with the connecting port.
④ 继续用手拧滤清器直至滤清器牢固安装（大约 3/4 圈）。
Screw the filter with hand till the filter is securely installed (for approximate
3/4 turn).
⑤ 排气直至无气泡出现。 Exhaust the air till there is no air bubble
⑥ 进行泄漏试验。 Test for leakage

240
 注意：
当更换旋压粗滤器或对输油管进行重装时，那么需要给
粗滤器进行排气。
Note: When replacing the strainer or reinstalling the
fuel delivery pipe, it’s necessary to exhaust the air from
the strainer.
步骤（如图 1-10 所示） Procedures: .
① 停止发动机。 Stop the engine
② 卸下放气螺丝。 Remove the air releasing screw.
③ 使用 手 泵打 气直 到 只 有 油从 放气螺 丝 中 冒
出。 Pump up fuel filter with the manual pump till only the fuel 图 1-10 粗滤器排气

overflows from the Air releasing of the strainer

air releasing screw.
④ 重 新上紧放气螺丝 。 Retighten the air releasing
screw

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 从集水器中将水放出：
Drain the water from the water collector:
注意：当集水器满了或旋压过滤器已经替
换 , 则需要将收集到的水放出。
Note: When the water collector is full or the
spin-on filter has been replaced, it is necessary to
drain the water collected.
步骤（如图 1-11 所示）： Procedures:
① 打开 集水器 1 底部的放油塞 2 让水排
净。 Open the fuel drainage plug 2 on the bottom of
图 1- 11 集水器放水
water collector 1 to fully drain the water. ② 重新上
Drain the water
紧放油塞。 Retighten the fuel drainage plug.

242
 更换集水器： Replace the water collector
步骤（如图 1-12 所示）： Procedures:
① 关闭发动机。 Stop the engine.
② 从集水器中排出水。 Release the water in
the collector
③ 如果可能的话，用手将集水器的螺丝 1 卸
下。如果太紧，使用新集水器中的装卸工具。
If possible, remove the screw 1 of the water
collector with hand. If the screw 1 is too tight, use the
tool attached in the new water collector.
图 1- 12 更换集水器
Replace the water collector

243
 更换集水器： Replace the water collector
④ 用几滴油润滑新集水器的密封圈 2 。
Lubricate the seal ring 2 of the new water
collector with several drops of oil.
⑤ 用手将螺丝装上，用工具将它拧紧。
Install the screw with hand and tighten it with
tool.
⑥ 如果集水器皿在一个新的旋压过滤器上再
用，要检查一下有没有损伤。
If the water collector is to be used again on a new
spin-on filter, check for any damage.
图 1- 12 更换集水器
⑦ 使用扭矩扳手安装，扭矩 20N.m 。 Replace the water collector
Install with torque wrench and tighten to 20N.m.

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五、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。 进气管 Inlet pipe

Check the intake hose for

aging or cracking and check
the hoop for looseness. When
necessary tighten or replace
parts to ensure air-tightness of
the intake system.

图 1-13 进气系统 air intake system

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六、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限值时，应按制造厂的规定清
洁或更换滤芯。
Maximum allowable inlet
resistance is 7 kpa ， diesel engine
biggest intake resistance must be
checked when calibration speed and
full load operation ， when the air
intake resistance to achieve maximum
allowable limit, clean or replace filter
should be according to the provisions
of the factory.

图 1- 14 空气滤清器 air filter

246
 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。
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）。图 1-15 为空滤器滤芯清理示意图。
注意：不得吹破滤纸、不得用水和油清洗滤纸、不得用力拍打或敲打滤芯
Note: The engine must not be allowed using when
there is no air filter ， otherwise engine will be
early wear for the dust and impurities opportunities
into diesel fuel.
Remove the air filter from the air filter, dust falling
gently pat face, also can use compressed air to
blow (by blowing outside introversion. Figure 1-15
to clean air filter element.
Note: filter paper shouldn’t be broken, clean water
and oil filter paper isn’t allowed, filter paper flap
forcibly or knock filter is not allowed 图 1- 15 清理滤芯
Clean filter element

247
七、检查尿素泵滤芯 Check urea solution pump filter
element
每次保养时，需要将尿素泵的滤芯拆下，并用清水清洗干净后进行安装。
不得用力拍打或敲打滤芯。
During maintenance, it’s necessary to remove the filter element of urea solution
pump and thoroughly clean with clean water before installation. Do not flap or
knock the filter element forcibly.
注：在每次更换或拆装尿素喷嘴时，需要检查尿素喷嘴的状态，如有损坏
或变形，则需要更换尿素喷嘴。
Note: At each replacement or disassembly/installation of urea solution nozzle,
it’s necessary to check the nozzle gasket. In event of damage or deformation, replace
the nozzle gasket.

248
八、检查尿素泵滤芯 Check the urea pump filter

在做保养时，需要检查尿素箱及滤芯的清洁度，必要时需对其进行清洗。
When doing maintenance, need to check the urea box and the purity of the filter
element, do cleaning when necessary.

249
1.4 长期存放保养
Maintenance for long-term storage of diesel engine
一、清洁 Clean the diesel engine
① 暖机后放出机油，清洗机油滤清器，加防锈油；
When the engine is hot, discharge the oil, clean oil filter, and add anti-
rusting oil.
② 放出燃油，重新加入防锈混合油；
Drain out the fuel and refill with anti-rusting oil mixture
③ 放水，加入带防锈剂的冷却液；
Drain the water and add coolant with anti-rusting agent.
④ 开机并空转 15min ～ 25min ；
Start the engine and run at idle speed for 15~25min

250
 ⑤ 放净机油、燃油、冷却液及尿素溶液；
Fully drain out the oil, fuel, coolant and urea solution
⑥ 对其他部位进行防护；
Take protective measures for other positions.

二、防护 Protection during storage

用盖子或用塑料布捆扎封堵个油、气、水的进出口，用气象防锈膜封存整
台柴油机。
Use covers or plastic sheets to strap and seal all oil, gas and water inlets and
outlets; use VCI antirust film to seal the whole diesel engine.
注：如果需要运输则应该外加包装。
Note ： If transport is required, the outer package shall be supplemented.

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三、油封 Oil seal

柴油机的油封期为一年，凡超过 1 年的需重新油封，具体要求及措施：
Diesel engine oil seal period is one year, any more than 1 year need to seal, the
specific requirements and measures ：
1) 油封操作应在清洁的环境中进行，且整机及零部件油封前应清理干
净，无锈蚀、油污及灰尘。
2) 根据具体要求，可采用浸、喷、涂、充填等方法进行油封。
1) oil seal operation should be done in a
clean environment, and the whole machine
and spare parts should be cleaned before oil
seal, no rust, oil and dirt.
2) according to the specific requirements,
soaking, spraying, painting, such as filling
method can be used for oil seal.
图 1- 16 气动喷枪外形示意图 Pneumatic spray gun

252
第五节 柴油机的定期保养 Periodic maintenance

一、汽车配套使用条件分类
categories of operating conditions with vehicle
表 1-9 汽车配套三类使用条件
Three categories of operating conditions with vehicle

（ WGⅠ 类） （ WGⅡ 类） （ WGⅢ 类）

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 年 行 驶 里 程 不 足 年 行 驶 里 程 超 过
政工程车，扫雪车，消防车） 6×104km ， 短 中 距 离 6×104km 的 远 距
或 汽 车 年 行 驶 里 程 不 足 运输（用于送货） 离运输汽车
2×10 km 或 年 工 作 时 间 不 足
4

600h

253
第五节 柴油机的定期保养 Periodic maintenance

表 1-9 汽车配套三类使用条件
Three categories of operating conditions with vehicle

（ WGⅠ ） （ WGⅡ ） （ WGⅢ ）

Under severe operating
condition (e.g. cold or hot
weather, high dust content,
Annual running mileage Annual running
short-distance transportation,
of the vehicle less than mileage of the
service in construction site and
6×104km, for short- or vehicle more than
bus, municipal engineering
medium-distance 6×104km
vehicle, snow sweeper, fire bridge
transportation (for for long distance
vehicle), annual running mileage
goods). transportation
of the vehicle less than 2×104km
or annual operated time less than
600h.

254
二、保养周期分类 Maintenance cycle classification
表 1-10 保养周期
Oil replacement period during vehicle maintenance

使用条件
（ WGⅠ ） （ WGⅡ ） （ WGⅢ ）
项目
行驶 1500 ～ 行驶 1500 ～
行驶 1000 ～ 1500km 时 2000km 时 2000km 时
第一次检查
行驶 30 ～ 50 时    
每隔 5000km ；每隔 每隔
例行检查 150h 每隔 1×104km 1.5×104km
每隔 1×104km 每隔 3×104km
1 级保养 每隔 2×10 km
4
每隔 300h  
每隔 2×104km 每隔 4×104km 每隔 6×104km
2 级保养
每隔 600h    
每隔 4×104km 每隔 8×104km 每隔 12×104km
3 级保养
每隔 1200h    
每隔 8×104km 每隔 16×10 km 每隔 24×104km
4
4 级保养
每隔 2400h    

255
二、保养周期分类 Maintenance cycle classification
表 1-10 保养周期
Oil replacement period during vehicle maintenance

Operating
（ WGⅠ ） （ WGⅡ ） （ WGⅢ ）
Condition/Item
Running
The first Running Running
1,000~1,500km or
inspection
30~50h 1,500~2,000km  1,500~2,000km 
Periodical Every 5,000km or Every1.5×104k
Every 1×104 km
inspection 150h m
Level 1 Every 1×104 km or Every3×104km
Every 2×10 km
4
maintenance 300h  
Level 2 Every 2×104 km or Every6×104km
Every 4×10 km 
4
maintenance 600h  
Level 3 Every 4×104 km or Every12×104km
Every 8×10 km
4
maintenance 1,200h  
Level 4 Every 8×104 km or Every24×104km
Every 16×10 km 
4
maintenance 2,400h  

256
三、柴油机保养规范 Diesel engine maintenance
表 1-11 汽车保养制度的机油换油期
Oil replacement period during vehicle maintenance

使用条件 （ WGⅠ ） (WGⅡ) （ WGⅢ ）

项目 年行驶里程 年行驶里程 年行驶里程
不到 2×104km 不到 6×104km 超过 6×104km

第一次检查 行 驶 1000 ～
行驶 1500 ～ 行驶 1500 ～
1500km 时
2000km 时 2000km 时
例行检查 每隔 5000km 每隔 1 万 km 每隔 1.5 万 km
1 级保养 每隔 1 万 km 每隔 2 万 km 每隔 3 万 km
2 级保养 每隔 2 万 km 每隔 4 万 km 每隔 6 万 km
3 级保养 每隔 4 万 km 每隔 8 万 km 每隔 12 万 km
4 级保养 每隔 8 万 km 每隔 16 万 km 每隔 24 万 km

257
三、柴油机保养规范 Diesel engine maintenance
表 1-11 汽车保养制度的机油换油期
Oil replacement period during vehicle maintenance
Operating
（ WGⅠ ） (WGⅡ) （ WGⅢ ）
Condition/Item
Annual running Annual running Annual running
mileage mileage mileage
<2×104 km <6×104km <6×104km
Running Running Running
The first inspection
1,000~1,500km 1,500~2,000km  1,500~2,000km 
Periodical
Every 5,000km Every 1×104 km Every1.5×104km
inspection
Every3×104km
Level 1 maintenance Every 1×104 km Every 2×104 km
 
Every6×104km
Level 2 maintenance Every 2×104 km Every 4×104km 
 
Level 3 Every12×104km
Every 4×104 km Every 8×104 km
maintenance  
Every24×104km
Level 4 maintenance Every 8×104 km Every 16×104 km 
 

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 表 1-12 柴油机保养规范 Diesel engine maintenance
柴油机保养项目 第一次 例行 1级 2级 3级 4级
更换机油 ● ● ● ● ● ●
更换机油滤清器或滤芯 每次更换机油时
检查调整气门间隙 ●   ● ● ● ●
更换燃油滤清器芯     ● ● ● ●
检查冷却液容量并加足 ● ● ● ● ● ●
紧固冷却管路管夹 ●          
紧固进气管路、软管和凸缘连接 ●   ● ● ● ●
件

检查空滤器保养指示灯或指示器     ● ● ● ●
清洗空滤器的集尘杯（不包自动   ● ● ● ● ●
排尘式）

259
 表 1-12 柴油机保养规范 Diesel engine maintenance

Maintenance items The first Period Level 1 Level 2 Level 3 Level 4

ical
Replace oil ● ● ● ● ● ●
Replace oil filter or filter element When replacing oil every time
Inspect and adjust valve clearance ●   ● ● ● ●
Replace fuel filter element     ● ● ● ●
Inspect coolant capacity and fill ● ● ● ● ● ●
Fasten cooling pipe clamp ●          
Fasten connecting parts of air inlet
●   ● ● ● ●
pipe, hose and flange
Inspect air filter maintenance light
    ● ● ● ●
or indicator
Clean dust pocket of air filter
  ● ● ● ● ●
r(except auto dust exhaust style)

260
 柴油机保养项目 第一次 例行 1级 2级 3级 4级
清洗空滤器主滤芯 当指示灯亮时
更换空滤器主滤芯 参看说明书有关规定
更换空滤器安全滤芯 清洗 5 次主滤芯以后
检查、紧固三角皮带 ● ● ● ● ● ●
检查增压器轴承间隙           ●
检查、调整离合器行程 ● ● ● ● ● ●
尿素泵滤芯     ● ● ● ●
尿素喷嘴垫片 每次拆卸尿素喷嘴时
清洗尿素箱及尿素箱滤芯     ● ● ● ●
注：●需要保养标记

停放半年以上的柴油机必须进行相应的维护保养，潍柴将根据用户请求提
供维护建议。

261
 Maintenance items The first Period Level 1 Level 2 Level 3 Level 4
ical
Clean air filter main element When indicator light comes on
Replace air filter main element Refer to the relevant provisions in the manual
Replace air filter safety element After 5 times of cleaning of main filter element
Inspect and fasten V belt ● ● ● ● ● ●
Inspect supercharger bearing           ●
clearance
Inspect and adjust clutch travel ● ● ● ● ● ●
Urea pump filter     ● ● ● ●
Urea nozzle gasket Every time remove the urea nozzle
Clean urea box and urea box filter     ● ● ● ●
Note: ● Maintenance is needed

For the diesel engine that is stored for more than 6 months , relevant maintenances must
be conducted. Weichai will provide maintenance suggestions upon requests of the users.

262
第二章 专用工具的使用

263
 后处理专用工具示意图见图 3-1 。

a) 诊断仪：读取 / 清除故障代码，读取数据流，执行外部功能测试

b) 断线盒：测量 ECU 和线束端所有接线的信号

c) 线束测试套件：传感器、执行器的 Y 型线束接头，断线测量信号

d) 喷油器回油量测量工具：两气门喷油器回油量测量

e) 万用表：测量信号，如电压，电流，电阻等

f) 示波器：测量电信号及其波形

g) 低压油路测量工具：配备有各种压力表及 Y 型管路，可测量低压油路部分压力

h) 高压油路测量工具：配备有压力传感器及其他管路接头，可测量高压油路部分

压力。

264
 Special post-processing tool is shown in Figure 3-1.

a) diagnostic: Read / Clear fault code, read data stream, perform an external function test

All the wiring harness and ECU signal measurement end: b) disconnection box

c) Harness Test Kit: sensors, actuators Y-harness connector, the measurement signal disconnection

d) Injector return fuel measuring tools: two-valve injectors back oil measurement

e) Multimeter: Measuring signals such as voltage, current, resistance, etc.

f) Oscilloscope: Measuring signals and waveforms

g) Low oil measurement tools: all kinds of pressure gauges and equipped with Y-pipe, measure the

partial pressure of the low pressure oil passage

h) the high pressure measurement tools: equipped with pressure sensors and other pipe fittings,

measure the partial pressure of the high pressure.

265
 图 3- 1 专用工具
Fig3-1 Special tools
注：供电状态， can 和 ECU 断开；先断开电才可将两者断开 .
Note: The power supply status, can and ECU disconnect; disconnect the power before to disconnect the two.

266
267