Escolar Documentos
Profissional Documentos
Cultura Documentos
1.
Usage Instructions
1.1 WD615
The signification of the code of WD615 Series Diesel Engines
W D 6
15
X X
X X
Application code:
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).
--
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
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
--
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
1.5
Starting
Put the power switch and starting key at the starting position
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
turn on the
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
--
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
--
...
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
2.
Maintenance Guide
2.1
Daily Maintenance
Inspection
--
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
210 km
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
-10-
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 V-belts
Periodical inspection
Oil
Oil filter
Tighten V-belts
1
WD1
Oil
Oil filter
Fuel filter
Valve clearance
Air filter
Tighten V-behs
2
WD2
Oil
Oil filter
Fuel filter
Valve clearance
Air filter
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
Tighten V-belts
Valve clearance
Air filter
Tighten V-belt
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
-13-
...
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Maintenance Contents
3.1
Daily Maintenance
Inspect
Leakage
Any unconventionality
-15-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
3
The oil volume tolerance between
the lower limit and the upper limit is
3 liters
-16-
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Maintenance Manual for WD615 Series EuroDiesel Engine
-17-
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Maintenance Manual for WD615 Series EuroDiesel Engine
-18-
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Maintenance Manual for WD615 Series EuroDiesel Engine
-19-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
3.2
Maintencnce items of various
maintenances
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
20L
-21-
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Maintenance Manual for WD615 Series EuroDiesel Engine
-22-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
32mm
Tool:32mm open-endedwrench
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
5min
-24-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
-26-
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.
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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
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
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6# 14mm
Tools6#screwdriver and14mm double
offset ringwrench
A
Step A
-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
-30-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
13mm
Tool:13mm sleeve wrench
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
-32-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-33-
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Maintenance Manual for WD615 Series EuroDiesel Engine
-34-
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
-35-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
7kPa
-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
-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.
-38-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
4
The Main System Flow Chart of Engine
Lubricating system
Cooling 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
-39-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-40-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Lubricating
turbocharger
1
Oil from the main oil
passage
2
Oil inlet of turbocharger
3
The oil outlet of turbocharger
-41-
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
-42-
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
-43-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
4.3
Intake and exhaust system
1
-44-
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
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
-48-
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
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.
-50-
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
-51-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
-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.
2
The bolt for exhaust manifold can
only be used two times
-54-
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
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
-55-
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
-56-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
WD615
Auxiliary Materials List of WD615 Series Diesel Engine
Serial No
Name
Color
Fine
Molybdenum
Powder
Black
Deep
gray
242
LOCTITE 242 glue
Blue
Red
262
LOCTITE 262 glue
510
LOCTITE 510 glue
Red
271
LOCTITE 271 glue
Red
962
LOCTITE 962
Red
Red
-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
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
M5
M6
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
-60-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
16mm
Tool16mm open-ended
wrench
M102
-63-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-64-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
13mm
Tool13mm open-ended wrench
13mm
Tool13mm open cnded wrench
-65-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Remove generator
16mm
Tool16mm open-ended
wrench
-66-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6#
Tool6# Screwdriver
13mm
Tool13mm sleeve wrench
-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
-68-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Clean the seal surface 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
13mm
Tool13mm open-ended wrench
M8
-70-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Install generator
16mm
Tool16mm open-ended
wrench and pontil
M10
-71-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
13mm16mm
-72-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
8.2
Lubricating System
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)
-73-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6mm
Tool6mm sleeve wrench
4M8
-74-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
-76-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Remove retainerthen
remove 0il pan
27mm
Tool27mm open-ended
wrench
-77-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
27mm
Tool27mm open-ended
wrench
242
13mm
Tool:13mm open-ended
wrench
M8
NoteMake sure
packing washer of oil pan
was pressed well
-78-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
16mm
Tool13mm sleeve
wrench and 16mm openended wrench
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
16mm 16mm
Tool16mm open-ended
wrench and 16mm sleeve wrench
-80-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
22mm
Tool22mm open-ended
wrench
-81-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
16mm
Tool16mm sleeve wrench
-82-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
16mm
Tool16mm sleeve wrench
-83-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-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
16mm
Tool16mm sleeve wrench
-86-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
-88-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
83
Fuel Supplying System
OT
-89-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
16mm
Tool16mm sleeve wrench
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
-91-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
8mm
Tool8mm inner hexagon
wrench
4
19mm
Tool19mm open-ended
wrench
-92-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
8mm
Tool8mm sleeve wrench
-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
-95-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
-97-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
13mm
Tool13mm open-ended wrench
-98-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Remove injectors
-99-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-100-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
-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
-102-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
8.4
Air Intake System
Replace Turbocharger
6mm
Tool6mm screwdriver
6mm
Tool6mm screwdriver
-103-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6mm
Tool6mm inner hexagon wrench
16mm
Tool16mm open-ended wrench
-104-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
6mm
Tool6mm inner hexagon wrench
-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
2.
Air entered into the fuel system
3.
Injection pump damaged
4.
Injector damaged
5.
Initial angles of valve gear or fuel delivery
is wrong
6.
High pressure line damaged or leaked
Repair or replace
7.
Insufficient pressure in cylinder
8.
The temperature is too low
-107-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
9.2
Stop soon after starting
1.
Fuel filter clogged
2.
Air entered into fuel system
3.
Supply pump doesn't work
4.
Poor quality of 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
3.
Insufficient pressure in supercharging system
4.
Faults in turbocharger
4.1
Compressor and turbine streets choked up
Clean or replace
4.2
Floating bearing cease to be in effect
Replace
4.3
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
12.
Incorrect timing of valve gear or fuel delivery
13.
High-speed of governor is adjusted too low
14.
Oil level in the oil sump is too high
15.
Leakage in cylinder gaskets
16.
Piston ring broken, the clearance of main bearing is too large
17.
Cylinder liner or piston worn, or piston scuffing
-109-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
9.4
Fuel consumption is too high
1.
Air intake clogged (air cleaner choked)
2.
Exhaust back pressure is too high
3.
Poor quality of fuel
4.
Fuel line choked
5.
Fuel line leaked
6.
Poor atomizing
7.
Incorrect timing of valve gear or fuel delivery
8.
Leakage in cylinder gasket
9.
The clearance of main bearing shell is too large
Engine need to overhaul
10.
Piston scuffing
11.
Insufficient pressure in supercharging system
12.
Faults in turbocharger
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
3.
Incorrect timing of valve gear or fuel supply
4.
Poor atomizing
5.
Excessive injection quantity
()
Check and adjust (by manufacturer)
6.
Insufficient pressure in supercharging system
7.
Faults in turbocharger
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
3.
Incorrect timing of valve gear or fuel delivery
4.
Poor atomizing
5.
Incomplete combustion, scuffing and the
compressed pressure is too low
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
11.
The thrust bearing of turbocharger worn
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
2.
The gas-oil separator cease to be in effect
Replace
3.
Lub-oil level in oil sump is too high
9.8
Uneven engine speed
1.
Poor quality of fuel, mingled with water or wax
2.
Air entered into fuel suction pipe
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
6.
Surge in turbocharger
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
2.
Faults in pressure regulating valve of main oil
passage
3.
4.
Lub-oil doesn't conform to specifications
5.
Intake pipe of oil pump leaked
6.
Water temperature in cooling system and oil
temperature are too high
7.
Excessive resistance of oil filter
8.
Oil cooler choked
9.
Main oil passage choked
10.,
The clearance of bearing is too large or bearing
damaged
,
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
2.
Water tank clogged
Clean or repair
3.
The belt of water pump loosened
4.
Water pump gasket damaged, water pump
impeller worn
5.
Faults in thermostat
Replace it
6.
Water pipe damaged and air entered
7.
The oil level in oil sump is too low
-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
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
3.
Incorrect timing of valve gear or fuel delivery
4.
Poor atomizing
5.
Excessive injection quantity
()
Check and adjust (by manufacturer)
6.
Vibration damper damaged
7.
Leakage in valve or adjusted unsuitably
8.
Excessive gear clearance or tooth broken
9.
Cylinder liner or piston worn, or piston scuffing
10.
Push rod bended or broken
Replace it
11.
Piston rings broken or worn
-117-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
9.13
Starting motor doesn't work
1.
Insufficient charging for battery
2.
Bad contact in connecting wire
3.
Fuse broken
Replace
4.
Bad contact in brush
5.
Short circuit in starting motor
9.14
Starting motor is powerless
1.
Insufficient voltage of battery
Charge or replace
2.
Bearing bush worn
3.
Bad contact in brush
4.
Commutator unclean or sintered
5.
Sealing off at wire end
Reweld
6.
Bad contact for switch
7.
wore clutch slipped
-118-
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
9.15
Generator doesn't work
1.
Wire connecting broken, short circuit, joint
loosened
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
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
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
-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
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
( )
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
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
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
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
Operation Description
2. ---------------------------------7
Maintenance Contents
4. -------------------------------39
Electric System
8. -----------------------------63
WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
Oil coating
()
Fitting (assembly parts)
S K
KUKKO,TSW
Special tools, such as K--- ---,
KUKKO, --- ---, TS--- ---W
Deflating
(loose-proof-fixed) Coat
fluid sealant
Inspecting