WEICHAI WD615 Manual de usuario

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

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:

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℃

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.

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.

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:

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:

● 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

Level 4

maintenance

Every 80,000 km

or 2400 h

Every 160,000

Every 240,000

Operating

Condition

Item

Learning and thinking:

● Oil replacement period in vehicle maintenance system

WG1 WGⅡ WGⅢ

Annual running

mileage<2×104

Annual running

mileage<

6×104 km

Annual running

mileage>

6×104 km

The rst

inspection

Running

1000~1500 km

Running

1,500~2,000

Running

1,500~2,000

Periodical

inspection Every 500 km Every 1×104

Every 1.5×104

Level 1

maintenance

Every 1×104 km

or 300 h

Every 2×104

Every 3×104

Level 2

maintenance

Every 2×104 km

or 600 h

Every 4×104

Every 6×104

Level 3

maintenance

Every 4×104 km

or 1,200 h

Every 8×104

Every 12×104

Level 4

maintenance

Every 8×104 km

or 2,400 h

Every 16×104

Every 24×104

Operating

Condition

Item

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