WEICHAI WD615 User manual

Contents
Chapter I Maintenance for WD615/WD10/WD618/WD12 Diesel Engines ...1
1.1 Daily Maintenance………………………………………………………....3
1.2 Periodic Maintenance………………………………………………….......5
1.3 Maintenance Interval ……………………………………………………...6
1.4 Maintenance Contents …………………………………………….……10
1.5 Replacement of Oil and Oil Filter ……………………………….……..13
1.6 Replace Fuel Filter ……………………………………………….…….16
1.7 Check Air Filter Element …………………………………………….…...17
1.8 Check and Adjust Valve Clearance ……………………………….……19
1.9 Check and Adjust Fuel Supply Advance Angle …………………….….24
Chapter II Key Points about Assembling or Disassembling WD615 Diesel
Engines ………………………………………………..……………………..26
2.1 Assemble Injection Nozzle, Camshaft and Cylinder Liner……………26
2.1.1 Assemble Injection Nozzle …………………………………………..26
2.1.2 Assemble Camshaft …………………………………………………..26
2.1.3 Assemble Cylinder Liner ………………………………………….…27
2.2 Pre-assemble & Assemble Crankshaft …………………………………29
2.2.1 Assembling Steps (1) ……………………………………………..….29
2.2.2 Assembling Steps (2) ……………………………………………...…30
2.3 Assemble Cylinder Body ………………………………………..……..31
2.4 Pre-assemble & Assemble Connecting Stick and Piston ……………32
2.5 The Assembly of the Timing Gear Housing …………………………...36
2.6 The Assembly of Flywheel Housing and Flywheel ……………………39
2.6.1 The Assembly of Flywheel Housing ………………………………...39
2.6.2 The Assembly of Flywheel ………………………………………..…39
2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear…………40
2.8 Tightening Torque and Tightening Method of Main Bolts of Diesel
Engine ……………………………………...………………………………....42
Chapter III Introduction of Fault Case for WD615/618 Diesel Engine …44
3.1 Diesel Engine Starts Hard …………………………………………….…44
3.1.1 Case Description about Diesel Engine Cannot Be Started (1) ……46

3.1.2 Case Description about Diesel Engine Cannot Be Started (2) ……48
3.2 Stop Soon after Starting ………………………………………..……..50
3.3 Insufcient Output ………………………………………………………52
3.3.1 Case Description about Insufcient Output (1) ……….……………53
3.3.2 Case Description about Insufcient Output (2) …………………….54
3.3.3 Case Description about Insufcient Output (3) ………………...…..55
3.4 Fuel Consumption Is Too High ………………………………………….57
3.5 Black Smoke Exhaust …………………………………………………...59
3.6 Oil Is Gathered in Inlet and Exhaust Vents of Turbocharger and Inlet
and Exhaust Pipe ……………………………………………………….….…62
3.7 Lub-oil Pressure Is Too Low …………………………………….………65
3.7.1 Case Description about Lub-oil Pressure Is Too Low (1) . … … … .66
3.7.2 Case Description about Lub-oil Pressure Is Too Low (2) …………..67
3.8 Cooling Water Temperature Is Too High …………………….……..…70
3.9 The Oil Mixed with the Water …………………………………………..73

1
Chapter I Maintenance for WD615/WD10/WD618/WD12
Diesel Engines
● Operators of diesel engines must carefully read Operation and
Maintenance Manual, and well understand the structure of diesel
engines, strictly comply with the operation and maintenance stipulated in
the Operation and Maintenance manual.
● Based on the maintenance requirements stipulated in the manual,
please periodically inspect diesel engines and replace oil in accordance
with work condition.
Proper maintenance can effectively prolong service life of
diesel engines, decrease trouble rate and reduce cost.
● Maintenance contents :
Replace fuel lter element and oil lter element;
Clean and check air lter element. Replace it every 5 times
of cleaning.
● Maintenance interval:
Maintenance should be done in time at service stations
authorized by Weichai Power according to the following
requirements:

2
Recommend CF-4 oil to be used in Weichai Power diesel
engine series. High quality oil is allowed to replace low quality oil.
The specication of common oil is as follows:
Please use right oil according to ambient temperature,
otherwise, engine trouble can occur.
Viscosity grade 0W-30 5W-30 10W-30 15W-40 20W-50
Applied
temperature
-40～30℃-30～35℃-25～35℃-20～40℃-15～50℃

3
1.1 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 xed well;
● Check whether the water or oil is leaking;
● Check whether the charging indicator light is in order;
● Inspect sufcient grease;
● Inspect whether oil pressure and water temperature are in normal
condition;
● Inspect that exhaust temperature, sound and vibration are normal
condition;
● Inspect rotary speed is stable.

4
When water temperature is too high, please check:
①the tension of water pump belt
②the tension of fan belt
③thermosta
Before starting the engine one
should check coolant level, and
check whether the cooling system is
leaking.
Check whether water
temperature is at the required range
or not when the engine is running.
Diagram of water
temperature in cab
The normal water temperature
is 80~95℃above sea-level to
3000 altitude.

5
1.2 Periodic Maintenance
Regular maintenance should be done as per the following table. If
the operating condition is heavy dust content or the engine running on
starting- stopping frequently, the regular maintenance period should be
shortened accordingly．
Learning and thinking:

6
1.3 Maintenance Interval
(WG I ) (WG II ) (WG III )
Under tough 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,
re bridge vehicle), annual
running mileage of the vehicle
less than 20,000 km or annual
operated time less than 600 h.
Annual running
mileage of the
vehicle less
than 60,000
km, for short- or
medium-distance
transportation
(for goods).
Annual running
mileage of the
vehicle more
than 60,000 km
for long distance
transportation.
Learning and thinking:

7
● The rst inspection, routine inspection and maintenance interval
WG1 WGⅡ WGⅢ
2x104 km
Annual running
mileage
<20,000 km
6x104 km
Annual running
mileage
<60,000 km
6x104 km
Annual running
mileage
<60,000 km
The rst
inspection
Running
1,000~1,500 km
or 30~50 h
Running
1,500~2,000 km
Running
1,500~2,000 km
Periodical
inspection
Every 5,000 km
or 150 h Every 10,000 km Every 15,000 km
Level 1
maintenance
Every 10,000 km
or 300 h Every 20,000 km Every 30,000 km
Level 2
maintenance
Every 20,000 km
or 600 h Every 40,000 km Every 60,000 km
Level 3
maintenance
Every 40,000 km
or 1200 h Every 80,000 km Every 120,000
km
Level 4
maintenance
Every 80,000 km
or 2400 h
Every 160,000
km
Every 240,000
km
Operating
Condition
Item
Learning and thinking:

8
● Oil replacement period in vehicle maintenance system
WG1 WGⅡ WGⅢ
Annual running
mileage<2×104
km
Annual running
mileage<
6×104 km
Annual running
mileage>
6×104 km
The rst
inspection
Running
1000~1500 km
Running
1,500~2,000
km
Running
1,500~2,000
km
Periodical
inspection Every 500 km Every 1×104
km
Every 1.5×104
km
Level 1
maintenance
Every 1×104 km
or 300 h
Every 2×104
km
Every 3×104
km
Level 2
maintenance
Every 2×104 km
or 600 h
Every 4×104
km
Every 6×104
km
Level 3
maintenance
Every 4×104 km
or 1,200 h
Every 8×104
km
Every 12×104
km
Level 4
maintenance
Every 8×104 km
or 2,400 h
Every 16×104
km
Every 24×104
km
Operating
Condition
Item

9
● Maintenance items
Items Replacement Adjustment Inspection
●WD 3
●Oil
●Oil lter
●Fuel lter
●Coolant
●Air lter
●Valve
clearance
●Air lter
●Air intake system
●Tighten pipe clamps
●Tighten V-belts
●Inspect and adjust the
injection fuel pump on test
bench
Items Replacement Adjustment Inspection
●WD 4
●Oil
●Oil lter
●Fuel lter
●Coolant
●Air lter
●Valve
clearance
●Air lter
●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
Learning and thinking:

10
1.4 Maintenance Contents
Daily maintenance
● Preventive maintenance should be done every day in order to
understand the engine's condition.
● Before starting the engine one should check the oil level, coolant
level and the fuel level.
● Inspect the oil level height
● When the oil level is lower than the lower limit or higher than the
upper limit，it is not allowed to start the engine
● After the engine stopped, inspect
the oil level at least 5 minutes later
in order to ensure the oil can ow back
to the oil sump．
※ The oil volume tolerance
between
the lower limit and the upper limit
is 3 liters．

11
● Inspect the coolant level
● Inspect the coolant level through the vitreous
view hole，if the coolant is not sufcient, open the
inlet cover and ll into the coolant.
※ Note: When opening the inlet
cover, one must press down the
exhaust button rstly to prevent
hot coolant from injuring people
● Inspect the fuel level
● Inspect the fan
● Check whether the plastic fan is
distorted. For steel fan, check
whether the rivet loosened and the
vane is curved to ensure reliable
running

12
● Inspect the V-belts
● Inspect the V-belts with your eyes
to nd if there is any crack or scratchon
the V-belts. Replace them if necessary.
● Drain off the water and deposit from the small lter cup tted on the
fuel delivery pump.
● Unscrew the bottom bolt of the small lter cup，dismount it and
drain off the water and deposit，then re-install the cup again

13
1.5 Replacement of Oil and Oil Filter.
Maintenance items of various maintenances
● Replacement of the oil and oil lter
※ Note: The replacement interval of
oil under proper using condition cannot
beyond 250 h(10,000 Kilometers)
● Tool: 32 mm open-ended wrench
● Remove the whorl plug，prepare a
container to collect 20 L of oil．
※ Note：The oil should be drained off
when it is hot．Hot oil can injure people.

14
● Tool: The special wrench for lter
● Clean the end surrounding of the lter, and remove it
● Install the new oil lter
● Note：Adjust the seal ring and smear some lubricating oil on it
while tting the oil lter．
● Tool: 32 mm open-ended wrench
● Check and clean the screw thread and seal ring, and then install
the whorl plug.
● Fill the clean oil up to the upper limit the capacity of the oil sump is 20 L．

15
● Run the engine at idling speed and check the filter to find
whether it leaks or not
● Stop the engine and make the oil run into the sump from the
upper parts 5 minutes later, then check the oil level, ll oil up to the
upper limit if necessary．

16
1.6 Replace Fuel Filter
● Tool：13 mm open-ended wrench
● Clean the end surrounding of the fuel lter, unloosen the upper bolt
and disassemble the fuel lter.
● Install the new fuel pre-lter element and lter element
● Install the replaced fuel lter on the bracket and tighten the bolt.
● Drain off the air from the fuel delivery pipe and fuel lter.
● Open the fuel draining bolt of the inlet of injection pump.

17
1.7 Check Air Filter Element
Press the fuel delivery pump plug till the fuel drained off from the
draining bolt outlet does not contain air, then tighten the bolt．
● Check the air intake system.
● Check whether the air intake rubber pipes are aging or cracked,
the steel wire hoop is loosening．If it is necessary, tighten or replace the
parts to ensure good sealing performance．

18
● The max air intake resistance of the engine is 7 kpa. Air intake
resistance must be checked when
diesel engines run at rated speed
and in full load. When the resistance
reaches the max. limit permitted,
one should clean or replace air lter
element as per relevant requirements
from suppliers.
Note：It is not allowed to
use the engine without air filter，
otherwise the dust and impurity will
cause early wearing of the engine.
● Remove the filter core
from the air lter element and
beat the side of the element
lightly to make dust fall down,
or blow the element backward
(blow back from inside to
outside) by compressed air．
Note：
● Don't blow off the
air ltering paper.
● Don't clean the air
filtering paper by water
and oil.
● Don't beat the core
forcibly．