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WD615

Maintenance Manual for WD615 Series EuroDiesel Engine

1.
Usage Instructions
1.1 WD615
The signification of the code of WD615 Series Diesel Engines
W D 6

15

X X

X X

Design code for developed


diversity model

Application code:

Basic product code

Single cylinder displacement

Number of Cylinder

Diesel engine

Water cooled

C
Marine diesel
engine
D
Diesel engine for
generating set
G
diesel engine for
construction
machinery
T
Diesel engine for
bulldogets
Q
Diesel engine for
trucks
K
N

1.2
Operating notice for new diesel engine
2000km60h
80%
For vehicle engines, the engine's rotating speed shoule be limited within 80% of its rated
speed during its initial 2000km running (approximately 60h).
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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

60h ( 3 4
)
For construction machinery applicationthe engine should be running under part
load(the accelerograph should be controlled under 3 4 full load)during its initial 60h
running.

The lubricating oil should be replaced after the primary running periodotherwise the
engine parts possibly be over worn or damagedProper protection and maintenance will
ensure your engine with better performancemore economical and longer service
1ife

2 1000-1500
2 1500-2000

First oil change period:


For vehicle the annual running mileage is less than 20,000km the first oil change perild is
1,000-1,5000km.
For vehicle the annual running mileage is less than 20,000km the first oil change perild is
1,500-2,000km

Perform daily maintenance work as specified in this manual.

1.3
Unpacking the Diesel Engine
1

When opening the packing of engine, you should firstly check the surface of engine and
the amount of accessoried as per packing list, then proceed on as following;
2
Clean the anticorrosive coating and preservative of outer parts.
3

Drain off the seal diesel oil from fuel filters and ruel supply system (the engine is also
allowed to be started before seal diesel oil draining, but not allowed to be operated at full
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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

load until the seal diesel iol of fuel supply system has been used up and the usral fuel has
been provided)
4
Turn the flywheel and inject solvent to air intake manifold till the seal oil of cylinder has
been drained off.
5
Inject solvent to the air outlet of turbocharger till the seal oil has been drained off
6
As per the agreement between Weichai and the customerthe engines supplied with empty
oilsumps should be filled with oil
7
-30 -35 pH
d[9-27 f( )]
40
As per the agreement between Weichai and the customer,and as per customers
requirementbefore deliverycoolant performance should be checked if the engine has been
filled up with coolant.The coolant could be remained to use if its antifreezing performance
could meet-30 or-35 and pH is 7-8(1itmusless)and its total rigidity number is 5-15 d
9-27of(rigidity)]otherwise it should be drained off and replaced by new coolant containing
antifreezeThevolume of coolant filled to engine is approximately 40 liter

1.4
Inspection before starting

Inspect the coolant level

Inspect the fuel level

Inspect the lubricating oil level

1.5
Starting

Put the power switch and starting key at the starting position

Put the gearlever at empty gear-matching position


(
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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

)
1

Step down footplate of clutch and footplate of accelerographpull the handle of extra
fuelsupply device for starting(if have)and starting the engineThe handle of the device should
bereset after engine's startedIf the engine cant be startedrepeat the above operating after
about l minuteOil pressure gauge should immediately indicate number values after engine
startedThe extra fuel supply device for auxiliary starting device should not to be used during
starting in thermal state

Low temperature starting

With electronic control flame preheating device


-23 50S
850-950
-25
When the temperature of coolant inside the engine is lower than-23

turn on the

electronickeythe preheating indicator lightingthe heating plug is heatedand the preheating


indicatorwill be automatically flickered after 50SWhen the heating plug is heated to
850-950 pressdown the start buttonconnect the starterthe electromagnetic valve will
be automaticallyopenedand the heating plug will be provided with fuel to proceed flame
preheatingand theengine can be easily started under-25

With low temperature auxiliary starting device


50

One bottle of starting fuel will be provided with the truck which fitted with low
temperatureauxiliary startlng device.It can't be preserved when the ambient temperature is
higher than 50To prevent from fireit should be put at a cool place in summer.

Starting process

40
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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Input starting fuel to the tank under the instrument plate in the driver-cabpull the hand
pump three times before connecting the starterafter the engine run several rotations continue
to pull the hand-pump till the engine startedbut dont pull too many times before starting in
the case of very low temperaturecontinue to pull the hand-pump after starting till the engine
runs smoothlyWith this auxiliary devicethe engine can be started easily under-40 .

1.6
Engine's running
1 min
When the engine running at the speed lower than the speed of the biggest torqueit is
notallowed to continue running on full load over l min
3-5 min
After running on full loadthe engine should run in idling speed for 35 minutes
beforestopped

Often watch and check the oil pressure gauge and coolant temperature meter

Stop the engine if the pressure and temperature cannot meet the standard requirement
60 100
NoteDiesel engine can not continue to run when the coolant temperature is lower than
60 or higher than 100because this would damage the engine

Engine'S running stop

Put the hand-accelerograph of injection pump at zero positionstop the engineand


readjust the hand-accelerograph
1-2min
NoteThe engine should run in idling speed for 1-2 minutes before stopped

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

2.
Maintenance Guide
2.1
Daily Maintenance

Inspection

Check the oil level

Check the coolant level

Check the fuel level

Check whether the fan is damaged

Check whether the V-belt is cracked or scratched

Check whether the accessories are fixed well;


;
Check whether the water or oil is leaking;
;
Check whether the charging indicator light is in order;
;
Inspect sufficient grease;
;
Inspect toil pressure and water temperature are normal condition
;
Inspect that exhaust temperature, sound and vibration are normal condition

Inspect rotary speed is stable.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

2.2
Regular Maintenance

Regular maintenance can be conduct on as per the following tableIf the operating
condition is heavy dust content or the engine running on started-stopped frequentlythe
regular maintenance period should be shortened accordingly
2.2.1
Maintenance period
2-1
Three categories of operating conditions with vehicle
(WG)

(WG)

6
4

6
4

10 km

10 km

Annual running mileage of the

Annual running mileage of the

vehicle more than 6104km for

vehicle less than 610 4km,,

long distance transportation.

210 km

for short- or medium-distance

600h

transportation (for goods).

Under severe operating


condition (e.g. cold or hot
weather, high dust content,
short-distance transportation,
service in construction site and
bus, municipal engineering
vehicle, snow sweeper, fire
bridge vehicle), annual running
mileage of the vehicle less than
210 4km or annual operated
time less than 600h.

--

(WG)

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
2-2,
Table 2-2 The first inspection,routine inspection and maintenance period

Operating
condition

(WG)

(WG)

(WG)

1
The first inspection

10001500km
3050h
Running
1,000~1,500km or
30~50h

15002000km
Running
1,500~2,000km

15002000km
Running
1,500~2,000km

Routine inspection

5000km
150h
Every 5,000km or
150h

1x104km
Every 1104 km

1.5x104km
Every 1.5104 km

1
Level 1 maintenance

1x104km
300h
Every 1104 km or
300h

2x104km
Every 2104 km

3x104km
Every 3104 km

2
Level 2 maintenance

2x104km
600h
Every 2104 km or
600h

4x104km
Every 4104 km

6x104km
Every 6104 km

3
Level 3 maintenance

4x104km
1200h
Every 4104 km or
1,200h

8x104km
Every 8104 km

12x104km
Every 12104 km

16x104km
Every 16104 km

24x104km
Every 24104 km

Item

8x104km
4
Level 4 maintenance

2400h
Every 8104 km or
2,400h

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
2-3
Table 2-3 Oil Replacement Period in SteyrVehicle Maintenance System

(WG)

(WG)

(WG)

2x104km
Annual running mileage
<2104 km

6x104km
Annual running mileage
< 6104 km

2x104km
Annual running mileage
> 6104 km

1
The first inspection

10001500km
Running 1000~1500km

15002000km
Running 1500~2000km

15002000km
Running 1500~2000km

Periodical inspection

5000km
Every 500km

1x104km
Every 1104 km

1.5x104km
Every 1.5104 km

1
Level 1 maintenance

1x104km
Every 1104 km
Every 2400h

2x104km
Every 2104 km

3x104km
Every 3104 km

2
Level 2 maintenance

2x104km
Every 2104 km
Every 2400h

4x104km
Every 4104 km

6x104km
Every 6104 km

3
Level 3 maintenance

4x104km
Every 4104 km
Every 2400h

8x104km
Every 8104 km

12x104km
Every 12104 km

4
Level 4 maintenance

8x104km
Every 8104 km
Every 2400h

16x104km
Every 16104 km

24x104km
Every 24104 km

Operating
condition

Item

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

2.2.2

Maintenance Items

Items


Replacement


Adjustment


Inspection

1
The 1st
inspection

Oil

Oil filter

Valve clearance

Tighten pipe clamps

Tighten V-belts

Periodical inspection

Oil

Oil filter

Tighten V-belts

1
WD1

Oil

Oil filter

Fuel filter

Valve clearance

Air filter

Air intake system

Tighten pipe clamps

Tighten V-behs

2
WD2

Oil

Oil filter

Fuel filter

Valve clearance

Air filter

Air intake system

Tighten pipe clamps

Tighten V-belts

-11-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Items

3
WD 3

4
WD 4

-12-


Replacement

Oil

Oil filter

Fuel filter

Coolant

Air filter

Oil

Oil filter

Fuel filter

Coolant

Air filter


Adjustment


Inspection

Valve clearance

Air filter

Air intake system

Tighten pipe clamps

Tighten V-belts

Inspect and adjust the


injection
fuel pump on test
bench

Valve clearance

Air filter

Air intake system

Tighten pipe clamps

Tighten V-belt

Check the bearing


clearance of
turbocharger

Inspect and adjust the


Injection
fuel pump on test
bench

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

2.3
Maintenance Record

Date

Engine number

Engine model

User name

Equipment name

Running
Kilometershours
or interval hours

Actual
Kilometers

Maintenance
contents

Operator

Remark

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...

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Maintenance Contents
3.1
Daily Maintenance

Preventive maintenance should be


done everyday in order to understand
the engme's condition

Before starting the engine


should check the oil level coolant
level and the fuel level.

Inspect

Leakage

Fast wearing parts

Any unconventionality

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Inspect the oil level height

When the oil level is lower than the


lower limit or higher than the upper
limitit is not allowed to start the
engine

5

After the engine stopped inspect


the oil level at least 5 minutes later
in order to ensure the oil can flow
back to the oil sump

3
The oil volume tolerance between
the lower limit and the upper limit is
3 liters

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Inspect the coolant level

Inspect the coolant level through the


vitreous view holeif the coolant is
not sufficientopen the inlet cover
and fill into the coolant.

Note:When opening the inlet


covermust press down the
exhaust button firstly to prevent
hot coolant from injuring people.

Inspect the fuel level

-17-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Inspect the fan

Check whether the plastic fan is


distorted.For steel fancheck
whether the rivet loosened and the
vane is curved to ensure reliable
running

Inspect the V-belts

Inspect the V-belts with your


eyes to find if there is any crack or
scratch on the V-beltsReplace
them if necessary

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Drain off the water and deposit from


the small filtercup fitted on the fuel
delivery pump.

Unscrew the bottom bolt of the


small filter cupdismount it and
drain off the water and deposit
then re-install the cup again

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

3.2
Maintencnce items of various
maintenances

The following contents will


be added except daily maintenance
items

Replacement of the oil and oil


filter

The oil will be polluted after


usingthe pollution contents is of
accordance with the consumption of
fuel and oil

250h(1 )
Note:The replacement period
of oil under proper using
condition cannot beyond 250h
(10,000Kilometers)

-20-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace the oil and oil filter to clean


the impurities containing in oil.

Note:The oil should be drained


off when it iS hot
32mm
Tool:32mm open-ended wrench

20L

Remove the whorl plugprepare a


container tocollect 20L of oil

NoteHot oil can injure people.

-21-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Tool:The special wrench for filter

Clean the end surrounding of the


filterand remove it

Install the new oil filter


,
-

NoteAdjust the seal ringand


smear some lubricating oil on it
while fitting the oil filter

-22-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

32mm
Tool:32mm open-endedwrench

Check and clean the screw thread


and seal ringand then install the
whorl plug .

20L
Fill the clean oil up to the upper
limitthe capacity of the oil sump
is 20L
55
Note:Selection of oil see page
55

-23-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Run the engine at idling speed and


check the filter to find whether it
leaks or not

5min

Stop the engine and make the oil run


into the sump from theupper parts
5 minutes laterthen check the oil
levelfill oil up to the upper limit if
necessary

-24-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Check and adjust the valve


clearance
13mm
Tool1 3mm sleeve wrench
6
Disassemble 6 cylinder head covers

32mm
Tool: 32mm wrench for turning the
crankshaft
,
OT

(
)
Tum the flywheel until its OT
scale and the mark on its housing
are aligned,push the piston to the
position of TDC of compression
stroke of 1st cylinder(the intake and
exhaust valve of 1st cylinder are
dosed)

-25-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

ToolClearance guage
0.30mm
The clearance of intake valve is
0.30mm
0.40mm
The clearance of exhaust valve
is 0.40mm
WEVB 0.25mm
The Clearance of WEVB
systerm is 0.25mm

60

Note:When check the clearance


of valvethe engine should
be at the cool conditionits
temperature is less than 60.
When the clearance guage
glides between the top of valve
rod and rocker arm and can be
felt retarded and stickythe
measuring result is proper

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

WEVB ( 1)
After WEVB system is used, the adjustment method of exhaust valve clearance is as
follows (see Fig. 2 for part serial numbers)
1
1. The cylinder piston to be adjusted is located on the top dead center of the compression
travel.
2 2 , 2 , ,
10 , 0.4mm,

2. As shown in Fig. 2, loosen No. 2 adjusting bolt assembly. In case that the oil seal plane
of exhaust valve rocker arm is not pressed, first by using No. 10 valve clearance adjusting screw
at the push rod end, adjust the total valve clearance to 0.4mm. Tighten check nut.
, 5

Caution: During adjustment, turn the valve clearance adjusting screw until the clearance
gauge is clamped so that No. 5 valve rocker arm piston is pressed to its bottom. There is not
clearance between No.5 valve rocker arm piston and the piston installation hole bottom plane in
exhaust valve rocker arm.
3 3 5
0.25mm 2 0.25mm,

3. Then as shown in Fig. 3, insert the clearance gauge between No. 5 valve rocker arm
piston and the exhaust valve rod end or valve rod cap. By turning No.2 regulating bolt, adjust
the valve clearance to 0.25mm. Tighten check nut.
2 5

Caution: During adjustment, turn No. 2 regulating bolt until clearance gauge is clamped so
that No. 5 valve rocker arm piston is pressed to its bottom. There is not clearance between No.5
valve rocker arm piston and the piston installation hole bottom plane in exhaust valve rocker
arm.
-27-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
1. Valve clearance adjusting nut

2. Regulating bolt assembly

3. Exhaust valve rocker

arm assembly 4. Steel ball 5. Valve rocker arm piston 6. Rocker arm piston spring
7. Needle 8. Ball valve spring 9. Valve rocker arm seat assembly 10. Valve clearance
adjusting screw 11. Hexagonal bolt 12. Support arm

2 0.4mm

-28-

30.25mm

Fig. 2 Total Valve Clearance of Cold-State

Fig. 3 End Valve Clearance of Cold-State

Exhaust Valve 0.4mm

Exhaust Valve 0.25mm

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6# 14mm
Tools6#screwdriver and14mm double
offset ringwrench

A
Step A

The piston of 1 cylinder is atTDC of


the compressionstroke
A
(I E )
Check and adjust the valveclearance
as step A(I-airintake Valve E-air
exhaustvalve)

Adjust the clearance by guage and


tighten the fixing nut ofrocker arm
re-check theclearance till it meets the
requirement

-29-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

360
360
Turn the crankshaft 360 by
the spannerit can also be turned
360after marking on the vibration
damper.

B
Adjust the valve clearance as step B

Loosen the fixing nut of rocker


armadjust the c|earance by guage
then tighten the nut again.

-30-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tool:13mm sleeve wrench

Install the gasket and cylinder


head cover
23Nm(
)
The tightening torque of bolt is
23Nm(recommended)

Check the tension of V-belts

l0mm
Measure the flexibility of the V
belt at the middle of its biggest
spangenerally the requirement
result should be less than l0mm
under strong press by your thumb

-31-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm
16mm open-ended wrench
l0mm

If the flexibility is more than


l0mmit means the V-belt has
been loosenthe nut for tension
pulley needs to be relaxedstrain
the Vbelt again and tighten the
nut

Check whether the rubber pipes of


cooling system is aging or cracked
the steel wire hoop is loosening
If it is necessarytighten or replace
the parts to ensure good sealing
pertormance.

-32-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace the fuel filter


13mm
Tool13mm open-ended wrench

Clean the end surrounding of the


fuel filterunloosen the upper bolt
and disassemble the fuel filter.

Install the new fuel pre-fiher


element and filter element

-33-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Install the replaced fuel filter on the


bracket and tighten the bolt.

Drain off the air from the fuel


delivery pipe and fuel tilter

Open the fuel draining bolt at the


inlet of injection pump.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

,
Press the fuel delivery pumpplug
till the fuel drained off from the
draining bolt outlet does not contain
airthen tighten the bolt

Check the air intake system

Check whether the air intake rubber


pipes are aging or crackedthe
steel wire hoop is looseningIf
it is necessary tighten or replace
the parts to ensure good sealing
performance

-35-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Check the air filter element

7kPa

The maximum air intake resistance


of the engine should be less than
7kpait should be checked while
the engine running at rated speed
and full load When the resistance
reaches the maximum limit or the
indicator light glowsthe air
filter element should be cleaned
or replaced as per the maintenance
guide from the manufacture.

Notelt is not allowed to use


the engine without air filter
otherwise the dust and impurity
will cause early wearing of the
engine.

-36-

1
Paper foltering element
2
Blanketry sofety futering
element

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

( )
Remove the filter core from the air
filter element and beatthe side of
the element lightly to make dust fall
down,or blow the element backward
(blow back from inside to
outside)by compressed air

Nole

Don't blow off the airfiltering


paper

Don't clean the air filtering


paper by water and oil

Don't beat the core forcibly

-37-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

3.3
Maintenance of Diesel Engine during Long-term Storage

In order to prevent rust and corrosion, the diesel engine is oil sealed before ex-work.
Usually, the oil seal period for the diesel engine is one year. Whenever the oil seal period
exceeds one year, check and take necessary supplementary measures.
15-25
2

Preservation: First fill the diesel engine with sealing oil and coolant with anti-rust agent,
start the engine and run at idling speed for 15~25min. Spray sealing oil to air compressor intake
2min before stopping of the engine. After stop, remove the pipeline connecting intercooler and
engine, so that the starter drives the engine to rotate. The sealing oil is sprayed into the cavities
of intake pipe, turbo-supercharger, etc. Apply sealing oil on all the exposed surfaces and the
extended shaft ends.

Protection in storage period: Use covers or plastic cloth to tie and block all the intake and
outlet ports. Use weather anti-rust film to seal the whole engine.

Pack the engine if transportation is necessary.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

4
The Main System Flow Chart of Engine

Lubricating system

Cooling system

Intake and exhaust system

Fuel supplying system

To understand the main system flow chart of the engine will give help to you for operating and
maintaining the engine

4.1
Lubricating system
1
Strainer
2
Oil pump
3
Oil filter
4
Oil cooler
5
Main oil passage
6
Safety valve of oil pump
7
Safety valve
8
Oil release valve for main
oil passage
9
Bypass valve of oil filter
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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Lubricating for main moving parts


1
The oil flowing from the oil
cooler
2
Main oil passage
3
Oil to the main crankshaft joumal
4
Connecting rod joumal
5
The main journal of crankshaft
6
Oil to connecting rod beating
7
The branch oil passage passing
to main Dearing
8
Sub-passage of oil
9
Oil injection nozzle to cool piston
10
Camshaft beating
11
Lubricating air compressor
through the oil from sub-passage
12
Lubricating fuel injection pump
through the oil from sub-passage

-40-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Lubricating for rocker arm


system
1
Oil flowing from the oil
branch passage
2
Tappet oil hole
3
Push rod oil hole
4
Oil hole of rocker arm bolt
5
Oil hole of rocker arm

Lubricating
turbocharger
1
Oil from the main oil
passage
2
Oil inlet of turbocharger
3
The oil outlet of turbocharger

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

4.2
Cooling system
1
Water pump inlet
2
Water pump
3
Water channel of oil cooler
4
Water jacket of cylinder block

1
Water jacket of cylinder block
2
Cooling water flowing from
water jacket of cylinder block
3
Cylinder head gasket
4
Cooling water passing through
the water passage of cylinder
head
5
Cooling water outlet

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

1
Coolant flowing from
cylinder block
2
Thermostat
3
Bypass valve
4
Coolant flowing into water
pump
5
Bypass valve closed
6
Coolant flowing into the radiator

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

4.3
Intake and exhaust system
1

The fresh air passing through the


air filter flows into turbocharger
2(
)
The turbocharged air passing
through intercooler There is no
intercooler for turbocharged but
not inter-cooled engine)
3()
Intercooler(The engine supplied
without intercooler when
delivering out of our company)
4
Intake manifold
5
Intake valve

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

1
Exhaust Valve
2
Exhaust manifold
3
Exhausting gas flowing into the
turbo of turbocharger
4
Exhaust outlet of turbocharger

4.4
Fuel supplying system
1
Fuel from the fuel tank
2
Fuel delivery pump
3
Fuel filter
4
Fuel delivery pipe
5
Air connecting pipe for smoke
controlling device
6
Fuel injection pump
7
High pressure fuel pipe
8
Injector
9
Fuel returning pipe of
injector
10
Fuel pipe back to the fuel tank

-45-

...

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

5
Tightening Torque And Tightening Method
of High Strength Bolts
1
Main-Bearing Bolt
14 M 1 8 22
T0tal nos14 pcs M 1 8 boltsTool22mm sleeve wrench

( ) 80Nm 250+25Nm
Tighten bolts in twice(tightening sequence see the figure above) The first time80Nm
The second time250+25 Nm
2
Cylinder Head Bolt
24M1 622
Total nos24 pcs M16 main boltsTool22mm sleeve wrench
7M 1217
Total nos7 pcs nuts of M 1 2 auxiliary boltTool17mm sleeve wrench

-47-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Following such tightening sequence


30Nm

Step 1Align cylinder head after assemblyiethe exhaust port side of cylinder heads
should be in the same planeAll the bolts should be tightened beforehandand the torque is
30Nm
24 200Nm
Step 2Tighten 24 pcs main bolts as the sequence in above figureand the torque is
200Nm
7 100Nm
Step 3Tighten 7 pcs auxiliary bolts as the sequence in above figureand the torque is
100Nm
90
Step 4Turn the main bolts 90as the sequence in above figure
90
Step 5Turn the auxiliary bolts 90 as the sequence in above figure
90 240-340 Nm
Step 6Turn the main bolts 90as the sequence in above figure againand the torque
range is 240340 Nm
90 120~160Nm
Step 7Turn the auxiliary bolts 90as the sequence in above figure againthe torque
range is 120 160 Nm
3
2
Replace those bolts that cannot reach required torque rangeThe main bolt is allowed to
be reused for 3 timesand the auxiliary bolt is allowed to be reused for 2 times
3
Connecting rod Bolt
M14x1.5 19mm
Total nos2 pcs M14x1.5 for each connecting rod Tool19mm sleeve wrench

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

120Nm
Step 1Tighten tightlythen tighten these bolts symmetrically with a torque of 120N
905 170~250 Nm
Step 2Turn these bolts 9050 and the torque range is 170~250 Nm

Replace those bolts that can not reach required torque range

NoteThe connecting rod bolts that have been used should not be reused
4
Flywheel Bolt
9M14x1.5 22
Total nos9 pcs M14x1.5

Tool22mm sleeve wrench

60Nm
Step 1Tighten these bolts symmetrically with a torque of 60Nm
18050230~280 Nm
Step 2Turn these bolts 1 805and the torque range is 230~280 Nm

Replace those bolts that can not reach required torque range
2
NoteThe flywheel bolt is only allowed to be reused for 2 times
5
Bolt for Flywheel Housing
13M12
Total nos1 3 pcs M 12 bolts Toolbox wrench
40Nm
Step 1Tighten these bolts with a torque of 40Nm
12050110~140Nm
Step 2Turn these bolts 1 205respectivelyand the torque range is 110~140 Nm

Replace those bolts that can not reach required torque range
2
The flywheel housing bolt is allowed to be reused for 2 times

NoteSmear thread and bearing surface of high strength bolts described above
with lubricating oil before tightening
-49-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6
Bolt for Intermediate Gear Shaft
4 M10
Total nos4 pcs M10 bolts

Tool:sleeve wrench

60Nm
Step 1Tighten these bolts symmetrically with a torque of 60Nm
90 100~125 Nm
Step 2Turn these bolts 90and the torque range is 100~125 Nm

Replace those bolts that can not reach required torque range
242
Smear the thread with LOCTITE 242 THREADLOCKER before tightening
3
The bolt for intermediate gear shaft can only be used three times.

Bolt for Intermediate


Gear Shaft

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

7
BoltOil Pump Idler
Gear Shaft
M10 16mm
T0tal nos1 piece M10 bolt
Tool16mm sleeve wrench
60 +5Nm
Tighten the bolt with a torque of
60 +5Nm

242
Coat the thread with LOCTITE 242
THREADLOCKER before tightening

8
BoltRocker-Arm Support
12M12
Total nos12 pcs M12 bolts
18mm
Tool18mm sleeve wrench
100Nm
Tighten these bolts with a torque
of 100Nm

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Hex head Bolt Binding Coupling


and Injection Pump
M14x15
Total nos1 piece M14x15 bolt
18mm
Tool18mm box wrench
1500+15Nm
Tighten the boh with a torque
of 1500+15Nm
242
Coat the thread with LOCTITE 242
THREADLOCKER before tightening

10
Tight NutInjection Pump Driving
Gear M24x1.5
Total nos:1 piece M24x1.5 nut
36mm
Tool36mm sleeve wrench
450~500Nm
Tighten the nut with a torque 0f
450~500Nm
242
Coat the thread with LOCTlTE 242
THREADLOCKER beforetightening

-52-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

l 1
Bohs|Camshaft Gear
4M8
Total nos4 pcs M8 bolts
13mm
Tool13mm sleeve wrench
35Nm
Tighten these bohs aymmetrically
with a torque of 35Nm

242
Coat the thread with LOCTITE
242 THREADLOCKER before
tightening

12

BoltAttaching Damper Pulley and


Crankshaft
8M10
Total nos8 pcs M10 bolts
16mm
Tool16ram sleeve wrench
60+5Nm
Tighten these bolts symmetrically with
a torque 0f 60+5 Nm

-53-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

1 3
Tight boltsAttaching
Injection Pump and Bracket
4M10
Total nos.4 pcs M10 socket head
bolts
6mm
Tool6mm inner hexagon wrench
450+5Nm
Tighten these bolts in sequence
and the torque is 450+5Nm

14
BoltsExhaust manifold
12M10
Total nos12 pcs M 10 bolts
(65-80)Nm
Tighten these bolts symmetrically
with fl torque of (65-80)Nm.

Note:Coat the thread and bearing


surface with Molybdenum disulfide Lube
before tightenin

2
The bolt for exhaust manifold can
only be used two times

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6
Fuellubricantcoolant and Auxiliary Materials
6.1
Fuel

GB252

-10

GB252

In Summer No.0 Diesel Fuel GB252 In Winter No.-10 Diesel Fuel GB252
-15-20-30-35
In winterwhen the temperature is-15

you should use No.-20 Diesel FuelIf the

temperature is below-30you should use No.-35 Diesel Fuel

6.2
Lubricant
6.2.1 300PSCD300PSCF-4
For engines with power of lower and higher than 300PS,grade CD and CF-4 oil are
recommende respectively.
6.2.2
It is allowed to replace low-grade oil with high-grade oil
6.2.3-15CD15W/40-155W/20
CD15W/40 oil showld be used when the ambient temperature is higher than -15,and
5W/20 oil when the temperature is lower than -15.
6.2.4
Please reference the following chart to choose viscosity of lubricant

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6.2.5 203

()2000(50)

The approximate volume of the oil sump is 20 litres when the oil level stays at the upper
limit of oil dipstickThe fall between upper and lower limit of oil dipstick is about 3 litr
According to the agreement between Weichai and customersthe engine could be supplied
with or without the oil in the sump of the engineIf the engine was supplied with the oil in the
sumpsome special anticorrosive agent was containedThe customer can replace it with new
oil after running 2000km or 50hs)

6.3 GB/T5671
GreaseFill GB/T5671 lithium grease into the grease cup of the water
pump.
6.4 40(
)
CoolantFill the cooling system with 40 litres anti-freeze coolant which can
prevent rust and frostbite(Please reference the Operating Instruction
Manual of Coolant for mixture ratio)
6.5
Auxiliary Materials
6.5.1 510242271277,262

LOCTITE 510242271277262 sealing glue and cohesive material can be used


during tne process of mounting and repalnng
6.5.2
Fine molybdenum powder
6.5.3
Please reference the following table for detailed application of auxiliary materials

-56-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
WD615
Auxiliary Materials List of WD615 Series Diesel Engine

Serial No

Name

Color

Purpose and Application

Fine
Molybdenum
Powder

Black

Apply to smooth surface of metal to prevent biting.

egApply to exterior surface of cylinder liner.

To prevent adhesion of parts under higher


temperature

egApply to the bolts of exhaust outlet


of turbocharger

Molybdenum disulphide ointment


Lube

Deep
gray

242
LOCTITE 242 glue

Blue

Apply to thread to seal

egApply to bolts and thread

Red

Apply to thread to lock and seal

egApply to auxiliary bolts of cylinder


head

262
LOCTITE 262 glue

510
LOCTITE 510 glue

Red

Apply to surface of metal to seal

egApply to bond surface of"cylinder


block and crankcase

271
LOCTITE 271 glue

Red

Apply to surface of metal to seal

egApply to oil channel plug

962
LOCTITE 962

Red

Sealing of plug and hole

egApply to the water reservoir plug of


cylinder block

Lithium grease glue

Red

Grease for Water Pump

-57-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

NoteTo ensure the proper operation of our diesel enginesplease use the
correct brand fueI and oil as this manuaI described

-58-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

7
Electrical Appliance

This section consists of generatorstartersensor of water temperature indicator


induction plug of oil pressureetc

Generator

The generator is three-phase alternatorafter silicon rectification the current change into
direct current
28V27A(35A55A)
Output Voltage28V DCCurrent27A(In order to meet customer's demandthe
currents of 35A and 55A are available for option)Rotation Directionclockwise
11000
Maximum Allowable Speed11000 r min
6000
Rated Load Speed6000 r min

Circuit Diagram

-59-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Connection Pole
D+

M4

D+connect to Charging(electri6cation)Indicating Lampthe screw specificationM4


W

M5

Wconnect to Speed Measuring Motorthe screw specificationM5


B+

M6

B+connect to the positive electrode of batterygenerator shell is groundedthe screw


specificationM6

Starter
24V,5.4kW,7.5kW8.1kW()
The starter is DC starterVoltage24V,Power5.4kW,7.5kW or 8.1 kWRotation Direction
clockwise(View directionface to the output end of the engine)
39(SAE II)11(SAE16I 35)(7
5kW81kW9)3.5101111Bosch
3.5101111Bosch
There are two types of starter with modulus is 39 teeth(apply to SAE II flywheel housing)
11 teeth(apply to SAEI and 6I 35 flywheel housing)75kW and 8.l kW starters with 9 teeth are not
available currently

Circuit Diagram

Extemal Connection Pole


30 M10
30 connect to the positive electrode of batterythe screw specificationM10
3 1 M10
3 1 grounding the screw specificationM10
50 M6
50 connect to the electromagnetic switch the screw specificationM6

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Induction plug of oil pressure


-25~100
Operating Temperature-25~100
0~500kPa
Measurement Range0~500kPa
45~75kPa
Alarm Pressure45~75kPa
6~24V
Rated Voltage6~24V

Sensor of water temperature meter


-25~120
Operating Temperature-25 120
6~24V
Rated Voltage6~24V

Battery
2x12V 135Ah 165Ah 195Ah
212V 135Ah or 165Ah or 195Ah
-61-

...

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

8
Adjustment and Replacement of Main Components

8.1
Cooling System

Replace the V-belts


16mm
Tool16mm open-ended
wrench

Loosen the tightening nut of


the generator to remove
generator belt

16mm
Tool16mm open-ended
wrench
M102

Loosen the M10 self-lock nut


(2)of tension pulleyremove
the V-beh of water pump

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace the V-beltstighten


self-lock nuts (2)and the nuts
of tension bolts again

Replace Water Pump


16mm
Tool16mm open-ended wrench

Loosen the tightening bolts of


generator to remove the V beIt

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tool13mm open-ended wrench

Loosen the bolt from the generator


mounting plate

13mm
Tool13mm open cnded wrench

Remove the tightening bolts and


hexagon nuts attaching gear case

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove generator

16mm
Tool16mm open-ended
wrench

Loosen the hexagon lock nuts of


tension pulley to remove the V-belt of
water pump

-66-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6#
Tool6# Screwdriver

Loosen the rubber hose clamp


of water pipe joint

13mm
Tool13mm sleeve wrench

Loosen the bolt of water pipe


joint to remove water pipe joint

-67-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tool13mm open-ended
wrench

6
Loosen the 6 hexagon nuts
attaching water pump and gear
case

Remove water pump

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine


Clean the seal surface of
water pump

Replace the seal gasket of


water pump

-69-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tool13 mm open-ended
wrench
6
(
)
Install the new water pump
a s s e m b l y t i g h t e n 6 h e x a g o n
nuts.(There is a nut in the inner side
of water pipe joint)

120cm3

NoteFill the Iumen of water


pump with 120cm3 general
Iithium greaseRefill lithium
grease with grease cup
periodically

13mm
Tool13mm open-ended wrench

M8

Install the water pipe jointtighten


two M8 bolts of water pipe joint
then i nstall the rubber hose

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Install generator

16mm
Tool16mm open-ended
wrench and pontil

M10

Install the V-belt and


adjust the tensity, tighten M10
hexagon lock nuts of tightening
pulley

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm16mm

Tool13mm and 16mm


open-ended wrench

Install the V-belt of


generator and adjust the tensity
tighten top nuts of tightening
bolts and nuts of mounting
plate.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

8.2
Lubricating System

Replace the oil cooler core


13mm
Tool13mm sleeve wrench

M8
()
Loosen all of the M8 bolts on
the oil cooler cover to remove oil
cooler cover(Discharge coolant
before demounting the oil cooler
cover)

Clean the oil cooler cover


and seal surface of the cylinder
block,replace with new gasket of oil
cooler cover.

-73-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6mm
Tool6mm sleeve wrench
4M8

Loosen the 4pcs M8 bolts


of oil cooler element.

Remove element of oil


cooler and clean the bonding
surface of flange of oil cooler
element.

-74-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace seal ring of oil


cooler element.

13mm
Tool13mm sleeve
wrench

M8
Install the new oil cooler
element and tighten the M8
hexagon bolts

242
NoteCoat the thread with
L O C T I T E

2 4 2

THREADLOCKER before
tightening

-75-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tool13mm sleeve
wrench
,
M8

Install the oil cooler


cover and tighten all the
peripheral M8 hex head
bolts.

Replace the release


valve of main oil channel
13mm
Tool13mm sleeve
wrench
M8

Loosen all peripheral


M8 hex head bolts of oil
pan.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove retainerthen
remove 0il pan

27mm
Tool27mm open-ended
wrench

Remove the release valve


of main oil channel

When removing the release


valve of oil channel,move the
male end of hexagonal part on
valve body.

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WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

27mm
Tool27mm open-ended
wrench

242

Install new release valve


coat the thread with LOCTITE
242 THREADLOCKER before
tightening

When installing new


release valvemove the male
end of hexagonal part on valve
body

13mm
Tool:13mm open-ended
wrench
M8

Install oil pan and tighten


the M8 hex head bolts

NoteMake sure
packing washer of oil pan
was pressed well

-78-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace Oil Pump


13mm

16mm

Tool13mm sleeve
wrench and 16mm openended wrench

Remove oil pan and


suction pipe.

l0mm
Tooll0mm open-ended
wrench

( )
Loosen the mounting
plate of oil suction pipe(twostage oil pump)

-79-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm (
)
Tool16mm open-ended
wrench(two-stage oil pump)
M10

Loosen the M10 hex head


bolts of oil suction pipe to remove
oil suction pipe

16mm 16mm

Tool16mm open-ended
wrench and 16mm sleeve wrench

Loosen the hex head bolts


of tension pulley and the bolts of
crankshaft pulley

-80-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove the pulley and


d a m p e r t h e d a m p e r a n d
crankshaft is transition fitthe
damper can be knocked slightly
if it is necessary for removing

22mm
Tool22mm open-ended
wrench

Remove the hex head plug


screws of gear case

-81-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm
Tool16mm sleeve wrench

Remove the bolts of


intermediate gear shaft of oil
pump.

Remove intermediate gear


shaft of oil pump with special
tool

-82-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove intermediate gear of


oil pump

16mm
Tool16mm sleeve wrench

Remove the hex head bolts


from the hex plug and another hex
head bolt

-83-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove oil pump

Clean the seal Surface between


crankcase and 0il pump

-84-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm
Tool:16mm sleeve wrench

(
)
Install new oil pump and
gaskettighten the hex head
bolts.(one of them is in the
hex head plug)

()
Install intermediate gear of
oil pump
(Noteconvex towards inside)

-85-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Install intermediate gear shaft


of oil pump

16mm
Tool16mm sleeve wrench

Install the bolts of intermediate


gear shaft and tighten them
60+5Nm
Tightening torque60+5Nm

-86-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Install damper and pulley

16mm
Tool16mm sleeve wrench
,
Install the bolts of pulley and
tighten them
60+5Nm
Tightening torque605Nm

-87-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm
Tool16mm open-ended
wrench

Install the Vbelt pulley


and adjust the tensitythen
tighten the hex head lock nuts

-88-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

83
Fuel Supplying System

Replace injection pump


16mm
Tool16mm open-ended
wrench

Remove the joint between the


high pressure pipe and injection
pump

OT

Rotate flywheel slowlyalign


the calibrating line of flywheel
housing toOTcalibrating line
to fix the position of TDC of
compression stroke of the first
cylinder

-89-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm
Tool16mm sleeve wrench

Remove the screws attaching


shaft coupling and driving shaft

16mm 16mm

Tool16mm open-ended
wrench and 16mm double offset
ring wrench

-90-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6# 0.5kg
Tool6# screwdriver O.5 kg

Open the gap on the angle


regulating plate connecting the
coupler and the driving shaft.

Push shaft coupling backward

-91-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

8mm
Tool8mm inner hexagon
wrench
4

Remove the 4 pcs socket head


bolts attaching injection pump and
bracket

19mm
Tool19mm open-ended
wrench

Remove all the connecting


pipes from the injection pump.

-92-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove the injection pump


and install new injection pump and
socket head bolts

8mm
Tool8mm sleeve wrench

Tighten socket hexagon bolts


of injection pumpconnect pipeline.
45+5Nm
Tightening torque
45+5Nm

-93-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

16mm 16mm

Tool16mm open-ended
wrench and 10mm(double offset
ring wrench

242
110Nm
Install bolts attaching injection
pump and shaft couplingcoat
the thread with LOCTITE 242
THRERADLOCKER before
tighteningTightening torque
110 Nm

-94-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Rotate shaft coupling to watch


the fuel oil jiggle at the outlet of any
cylinder of the injection pump,then
stop rotation.

Rotate flywheel to align the


indicated needle of flywheel to
fuel supply advance angle.(Please
reference fuel system mating list for
fuel supply advance angle of each
cylinder)

-95-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

The calibration tails of injection


pump is aligned with calibration tails
of tining adwance unit(or flange).

16mm
Tool:16mm sleeve wrench


242
1500+5Nm
Install bolts attaching shaft
coupling and driving shaft.
Coat the thread with LOCTITE
242 THREADLOCKER
before tightening.Tightening
torque:1500+5Nm.

-96-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Rotate flywheel to recheck


the advance angle of fuel supply
remove bolts attaching shaft
coupling and driving shaft for
readjustment if necessary

Replace Injection Pump


17mm
Tool17mm open-ended
wrench

Clean all round of the injector


remove the joint attaching high
pressure fuel pipe and injector

-97-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove fuel return pipe of the


injector

13mm
Tool13mm open-ended wrench

Loosen bolts of mounting plate


then remove mounting plate

-98-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Remove injectors

Clean seat hole of injector

-99-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace with new copper washer

Replace with new injector and


install new rubber seal ring

-100-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Install new injector into the seat


hole.

NoteIt is not allowed to appear


any mark of pressing rubber
cushion after mounting injector

Install the mounting plate of


injector.

-101-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

13mm
Tooll3mm sleeve wrench

25Nm
Install bolts or hex head nuts
of mounting plateTightening
torque25Nm

13mm 17mm

Tool13mm and 17mm open ended


wrench

Tighten the joint attaching injector


and high pressure fuel pipeinstall
fuel return pipe

-102-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

8.4
Air Intake System

Replace Turbocharger
6mm
Tool6mm screwdriver

Loosen rubber hose clamps from the


inlet and outlet of compressor

6mm
Tool6mm screwdriver

Loosen hose clamp from


turbocharger oil retum pipe

-103-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

6mm
Tool6mm inner hexagon wrench

Remove inner head bolts from


turbocharger oil inlet sucker, raise
flange of sucker

16mm
Tool16mm open-ended wrench

Remove the self-locking nuts


from exhaust manifold to remove
turbocharger

-104-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Replace with new tu rbocharger

NoteIf the turbocharger is not


replaced immediatelythe intake
and exhaust manifolds should
be cove red to prevent anything
falling into cylinder

6mm
Tool6mm inner hexagon wrench

Replace with new gasket for


inlet pipe,fighten bolts of oil inlet
pipe.

NoteMake sure to adjust the


gasket oil hole and tu rbocharger
flange oil holeadd some clean
oil and rotate turbo impeller to Iet
oil flow into bearing Case

-105-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.
Common Troubles and Remedy
9.1
Diesel engine can not start

Cause

Remedy

1.
Fuel intake filter screen of supply pump or hose
clogged

Clear away the dirt and check if the fuel is clean

2.
Air entered into the fuel system

Drain off the air, check the sealing of the


connector and repair it

3.
Injection pump damaged

Check plunger, fuel outlet valve and repair or


replace the broken parts

4.
Injector damaged

Check the atomization of injector, and repair it

5.
Initial angles of valve gear or fuel delivery
is wrong

Cheek and adjust it

6.
High pressure line damaged or leaked

Repair or replace

7.
Insufficient pressure in cylinder

Check the sealing of the valve and cylinder gasket


and the wear of the piston ring. Repair or replace
them

8.
The temperature is too low

With the addition of start-assist device

-107-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.2
Stop soon after starting
1.
Fuel filter clogged

Dismantle and clean away dirt and water, replace


the filter element if necessary

2.
Air entered into fuel system

Check fuel pipe and sealing of the


connector,tighten air venting bolt, and drain off
the air

3.
Supply pump doesn't work

Check piston and valve of supply pump, clean


and repair

4.
Poor quality of fuel

Clean fuel filter and renew fuel

5.
Idling speed is too low

Readjust it

-108-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.3
Insufficient output
1.()
Air intake clogged (air cleaner choked)

Check the air cleaner and air intake pipe,clean or replace filter
element

2.
Exhaust back pressure is too high

Check the valve-timing and exhaust pipe, adjust and repair

3.
Insufficient pressure in supercharging system

Check and block up the leakage of pipeline

4.
Faults in turbocharger

Replace the turbocharger assembly

4.1
Compressor and turbine streets choked up

Clean or replace

4.2
Floating bearing cease to be in effect

Replace

4.3

Carbon deposit or greasy filth in clearance of turbine and


Clean
compressor back
5.
Intercooler damaged

Replace or repair

6.
Leakage or choke of fuel line

Check the sealing of fuel pipe and connector, fuel filter and fuel
line, repair, clean or replace the filter element

7.
Poor quality of fuel

Clean the fuel tank, filter parts and fuel pipe. Renew the fuel

8.
Excessive wear for injection pump or governor

Repair or replace

9.
Smoke -limiter diaphragm of injection pump damaged

Repair or replace

10.
Air pipe of smoke-limiter damaged

Replace

11.
Poor atomizing

Check the injecting pressure, clean away the carbon deposit in


nozzle, adjust and repair in-jector

12.
Incorrect timing of valve gear or fuel delivery

Check and adjust it

13.
High-speed of governor is adjusted too low

Check the speed-governing and adjust

14.
Oil level in the oil sump is too high

Check the oil-dipstick, and drain off unnec- essary oil

15.
Leakage in cylinder gaskets

Check the compressed pressure at hot state, replace cylinder


gaskets

16.
Piston ring broken, the clearance of main bearing is too large

Replace worn parts or overhaul the engine

17.
Cylinder liner or piston worn, or piston scuffing

Overhaul the engine

-109-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.4
Fuel consumption is too high
1.
Air intake clogged (air cleaner choked)

Check air cleaner and air intake pipe, then


clean them

2.
Exhaust back pressure is too high

Check exhaust pipe and brake valve, then clean


them

3.
Poor quality of fuel

Renew the fuel according to requirements

4.
Fuel line choked

Check and repair

5.
Fuel line leaked

Check and repair

6.
Poor atomizing

Check, adjust and repair

7.
Incorrect timing of valve gear or fuel delivery

Adjust valve clearance and injection ad-vance


angle according to requirements

8.
Leakage in cylinder gasket

Check compressed pressure

9.
The clearance of main bearing shell is too large
Engine need to overhaul

Check and overhaul

10.
Piston scuffing

Replace cylinder liner, piston and piston ring

11.
Insufficient pressure in supercharging system

Check and block up the leakage of pipeline

12.
Faults in turbocharger

Check and replace

13.
Intercooler damaged or leaked

Replace or repair

-110-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.5
Black smoke exhaust
1.
Air intake isn't free or exhaust back pressure is
too high

Clean

2.
Poor quality of fuel

Clean and renew

3.
Incorrect timing of valve gear or fuel supply

Adjust according to requirements

4.
Poor atomizing

Check, repair or replace injector

5.
Excessive injection quantity

()
Check and adjust (by manufacturer)

6.
Insufficient pressure in supercharging system

Check and block up the leakage of pipeline and


connector

7.
Faults in turbocharger

Check and replace

8.
Intercooler damaged or leaked

Replace or repair

9.
Incorrect working point of smoke-limiter

()
Readjust ( by manufacturer)

-111-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.6
White, blue smoke exhaust
1.
Poor quality of fuel, contains water

Renew fuel

2.
Temperature of cooling water is too low

Check working temperature of thermostat, replace


if necessary

3.
Incorrect timing of valve gear or fuel delivery

Check and adjust

4.
Poor atomizing

Check and repair

5.
Incomplete combustion, scuffing and the
compressed pressure is too low

Check piston ring,cylinder liner,cylinder


gasket,and repair them

6.
Wear-in between the piston rings and cylinder
liners is not good

Go on wearing-in

7.
The gaps of the piston rings are not staggered

Adjust, reassembly

8.
Piston oil rings cease to be in effect

Replace

9.
The fit clearance between piston and cylinder
liner is too large

Repair or replace

10.
The sealing ring of turbocharger worn

Check and replace

11.
The thrust bearing of turbocharger worn

Check and replace

12.
The oil return pipe of turbocharger choked.

Clean or repair

-112-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.7
Lub-oil gathered in air intake port and air intake pipe of turbocharger
1.
The sealing of turbocharger cease to be in effect

Repair or replace turbocharger

2.
The gas-oil separator cease to be in effect

Replace

3.
Lub-oil level in oil sump is too high

Drain off unnecessary oil according to requirements

9.8
Uneven engine speed
1.
Poor quality of fuel, mingled with water or wax

Clean fuel system, and renew fuel

2.
Air entered into fuel suction pipe

Check the sealing of fuel pipe and connector,


drain off air

3.
Faults in flyweight of governor and speed
governing spring

()
Check and repair (by manufacturer)

4.
Uneven fuel delivery

()
Check and adjust (by manufacturer)

5.
Unstable atomizing

Check and repair

6.
Surge in turbocharger

Check, Wash compressor streets, clean a-way the


carbon deposit from exhaust passage

7.
Bearing of turbocharger damaged

Replace it

-113-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.9
Lub-oil pressure is too low
1.
Oil level in oil sump is too low

Check oil leakage, add oil

2.
Faults in pressure regulating valve of main oil
passage

Check valve, clean and repair

3.

Strainer, oil pipes, connector gasket


choked or broken

Check strainer and connector , check if there is


any sponge in oil passage, repair

4.
Lub-oil doesn't conform to specifications

Renew the lub-oil according to requirements

5.
Intake pipe of oil pump leaked

Check the oil pipe and connector, repair or


replace

6.
Water temperature in cooling system and oil
temperature are too high

Check cooling system, and correct it

7.
Excessive resistance of oil filter

Renew the filter element

8.
Oil cooler choked

Check and clean

9.
Main oil passage choked

Check and clean

10.,
The clearance of bearing is too large or bearing
damaged

Check and replace

11.,11. Excessive wear of


parts, need to over-haul

,
Check the working time of the engine, over haul

-114-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.10
Cooling water temperature is too high
1.
Water level in water tank is too low

Check water leakage, add water

2.
Water tank clogged

Clean or repair

3.
The belt of water pump loosened

Adjust tension according to requirements

4.
Water pump gasket damaged, water pump
impeller worn

Check and repair, or replace

5.
Faults in thermostat

Replace it

6.
Water pipe damaged and air entered

Check the water pipe, connector and gasket.


Renew the damaged parts

7.
The oil level in oil sump is too low

Check oil leakage, repair and add oil

-115-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.11
Parts wore quickly
1.1. Filter element
of air cleaner is unqualified or damaged

Check and replace filter


element

2.2. Air leakage in air intake


system
Check air intake pipe, gasket and connecting sleeve, repair or replace

3.

4.

5.

6.

7.

8.

9.

10.

11.

-116-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.12
Noise is too high
1.
Poor quality of fuel

Renew fuel

2.
Temp of cooling water is too low

Check thermostat, replace it if necessary

3.
Incorrect timing of valve gear or fuel delivery

Check, repair and adjust

4.
Poor atomizing

Check, repair and adjust

5.
Excessive injection quantity

()
Check and adjust (by manufacturer)

6.
Vibration damper damaged

Check connecting bolt and replace damaged parts

7.
Leakage in valve or adjusted unsuitably

Dismantle and check valve, readjust it

8.
Excessive gear clearance or tooth broken

Check and replace damaged parts

9.
Cylinder liner or piston worn, or piston scuffing

Check and repair, or replace

10.
Push rod bended or broken

Replace it

11.
Piston rings broken or worn

Check and replace damaged parts

-117-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.13
Starting motor doesn't work
1.
Insufficient charging for battery

Check, charge or replace

2.
Bad contact in connecting wire

Check up circuit, tighten terminal

3.
Fuse broken

Replace

4.
Bad contact in brush

Clean brush surface or replace brush

5.
Short circuit in starting motor

Check and repair it, or replace the motor


assembly

9.14
Starting motor is powerless
1.
Insufficient voltage of battery

Charge or replace

2.
Bearing bush worn

Replace bearing assembly

3.
Bad contact in brush

Clean brush surface or replace brush

4.
Commutator unclean or sintered

Clean away the dirt and furbished using


sandpaper, or replace commutator assembly

5.
Sealing off at wire end

Reweld

6.
Bad contact for switch

Check and repair

7.
wore clutch slipped

Adjust working moment of clutch or replace

-118-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.15
Generator doesn't work
1.
Wire connecting broken, short circuit, joint
loosened

Check the connecting wire of generator or


galvanometer repair

2.
Coil of rotator and stator shorted, broken

Repair or replace

3.
Rectifier tube damaged

Replace

4.
Terminal damaged, wire broken

Repair

5.
Voltage regulated by regulator is too low

Repair

6.
Contact of regulator fused

Repair or replace

-119-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.16
Insufficient charging of generator
1.
Connecting wire broken or shorted, terminal loosened

Repair

2.
Coil of rotator and stator shorted or broken partially

Repair or replace

3.
Belt of generator loosened

Check and adjust tension

4.
Rectifier tube damaged,bad contact in brush

Repair

5.
Insufficient voltage of regulator

Regulate

6.
Field coil or resistance connecting wire
broken

Repair or replace

7.
Insufficient electrolyte of battery or battery is too old

Add electrolyte or renew battery

9.17
Uneven charging current
1.
Coil of rotator or stator will short or break

Repair or replace

2.
Bad contact in brush

Repair

3.
Terminal loosened and bad contact

Repair

4.
Voltage regulator damaged

Repair

5.
Incorrect regulated voltage

Check and regulate

-120-

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

9.18
Generator over-charged
1.
Shorted in battery

Repair or replace

2.
Voltage of regulator is too high

Repair and regulate

3.
Bad contact in regulator

Repair

4. , ,
Faults in regulator contact, voltage coil or resistance
connecting wire broken

Repair or replace

9.19
Abnormal sound in generator
1.
Incorrect mounting for generator

Repair

2.
Bearing damaged

Replace

3.
Moving parts bumping to fixed parts

Repair or replace

4.
Rectifier shorted

Replace

5.
Stator coil shorted

Repair or replace

-121-

WD615

20077

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Special Attention

Prior to the operation, the operator shall read the Diesel Engine Operation
and Maintenance Manual carefully, and comply with the operation and
maintenance procedure thereof strictly.
,
In order to protect legitimate right and interests of userit is forbidden to
dis-mantle lead sealing of injection pump privately

Once injection pump is adjusted or lead sealing is dismantledthe
guarantee ceases to be in effect

Injection pump is of precision parts,it is forbidden to dismantle by user,or
the guarantee cease to be in effect

( )

The rotator of turbocharger is a high speed rotating component. It is


prohibited to allow any moving objects (such as hands, tools, cotton yarn) to
approach the inlet of supercharger for prevention of the people from injury
or of machine from damage. No one other than the professional maintenance
personnel on supercharger or professional maintenance station authorized by

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Weichai is entitled to dismantle the rotator assembly;


There are strict demands on torque and turned angle for main bearing bolts
and connecting rodloosening and dismantling is forbiddenor the guarantee
cease to be in effect

Before starting the diesel enginecheck whether the coolant is full and
whether the lub-oil is enough

Connecting rod bolts can be used only once time

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine


Points for Attention
1

1. This diesel engine has been tested strictly in accordance with the test
stipulations before delivery. The accelerator is lead sealed and limited. It is not
allowed to remove the lead seal and to expand the accelerator privately. Or our
company will not be responsible for guarantee of repair, placement and return of
the product. Please pay your attention to it.
2 50 .
The user shall conduct a 50 hours run-in of the new engine before
operation.
3
5 1 0

Provided the diesel engine is started from the cold state, its rotary speed
shall be increased gradually, rather than making it operate at high speed suddenly
or idle for a long time. At the end of running with heavy load, do not shut down
the engine immediately (other than under particular circumstance), but run at low
speed for 5 to 10 minute, then shut it down.
4 0

After the engine is stopped, if the environmental temperature is lower than

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

0 and no anti-freeze additive is used, the water in water tank and in diesel
engine should be drained off.
5

Do not allow the diesel engine to operate without air filter for the sake of
avoiding the air from entering into the cylinder directly without filtering.
6
72
The brands of engine oil or fuel added to the diesel engine shall comply
with the provision of Operation and Maintenance Manual, and be filtered by the
special filters. The fuel needs more than 72 hours sediment.
7
The inspection and repair of all the components in electric system shall be
done by professional electric technical personnel;
8

For the sake of preventing corrosion, the diesel engine is oil sealed before
delivery from our company. Generally the oil seal period is one year. If the oil
seal period exceeds one year, inspection and necessary actions should be taken.
9 GB T18297 16
The power of diesel engine is correct as per GB/T18297 by referring Table
16.
10
Feedback of engine quality information
WD6l5

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

The manufacturer has established quality files for WP615 series diesel
engine. Please fill in the card and post it to uswe will contact with user
according to the card
11
Notice to repairing and replacing parts:
WD6l5
WD6l5

WP615 series diesel engine is of high performance product. Maintenance


should be done in accordance with WP615 series diesel engine parts catalogue
and specifications of maintenance manual. Purchased parts must have approved by us in order to ensure performancereliability and service life

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine


WD615

WD615

http://www.weichai.com,

2007 4

FOREWORD
WD615 series high-speed diesel enslnes are manufactured in China
through introducing advanced technology from Austria With the advantages
of high reliabilitygood economyrapid startingsimple operation and easy
maintenanceit is an ideal power for heavyduty truckshixm7 busses
construction machinerygenerating setsfishing vesselsspeed boats and
so on The new model engines developed by our company have reached over
hundreds to meet the market needs and thus we have goaen a big market share
tm now In order to help customers understand WD615 series diesel engines
well and operate correctlywe especially provide this maintenance manual.
With continuous development, the engine structure will be improved
accordingly. So if there are any differences between your engines and this
manual, please do not hesitate to visit WEICHAI Website: http://www.weicai.
com.You are welcome to offer your comments and recommendations for
further improvement of the products.
April 2007

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine


CONTENTS

Description of Illustration Marks


1. -------------------------------------1

Operation Description
2. ---------------------------------7

Guide for Maintenance


3. -------------------------------------15

Maintenance Contents
4. -------------------------------39

Schematic Diagram of Main Systems


5. -------------------47

Tightening Torque and Tightening Method of Rigid Bolts


6. -----------55

Fuel, Oil, Coolant and Auxiliary Materials


7. -----------------------------------------59

Electric System
8. -----------------------------63

Adjustment and Replacement of Main Parts and Components


9. -------------------------------107

Typical Troubles and Remedy

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine

Description Of The Illustration Marks


()
Dismounting (assembly
parts)

Oil coating

()
Fitting (assembly parts)

S K
KUKKO,TSW
Special tools, such as K--- ---,
KUKKO, --- ---, TS--- ---W

Marking (do before


disassemble, adjust when
assemble)

Pay attention to assembly direction

Filling- full charge (such as


lubricating oil, cooling water
etc.)

Deflating

Draining off (lubricating oil


or cooling water)

Unloosing (such as: unloose clamping


equipment)

(loose-proof-fixed) Coat
fluid sealant

Clamping (such as: reinforcing clamp


equipment)

Accident preventing (marks


for dangerous occasion)

Inspecting-adjusting (such as:


tightening torque, dimension pressure
and clearance)

Replacement when reassembly

Inspecting