WEICHAI WD615 Manuale utente
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 Insufcient Output ………………………………………………………52
3.3.1 Case Description about Insufcient Output (1) ……….……………53
3.3.2 Case Description about Insufcient Output (2) …………………….54
3.3.3 Case Description about Insufcient 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 specication 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 sufcient 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
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