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WD615欧Ⅱ系列柴油机维修保养手册

-10-

Maintenance Manual for WD615 Series EuroⅡDiesel Engine

表2-3 斯太尔汽车保养制度的机油换油期

Table 2-3 Oil Replacement Period in SteyrVehicle Maintenance System

使用条件
Operating

condition

项目
Item

(WGⅠ)

(WGⅡ)

(WGⅢ)

年行使里程

不到2x10

Annual running mileage

<2×10

年行使里程

不到6x10

Annual running mileage

< 6×10

年行使里程

超过2x10

Annual running mileage

> 6×10

第1次检查

The first inspection

行使1000～1500km时

Running 1000~1500km

行使1500～2000km时

Running 1500~2000km

行使1500～2000km时

Running 1500~2000km

例行检查

Periodical inspection

每隔5000km

Every 500km

每隔1x10

Every 1×10

每隔1.5x10

Every 1.5×10

1级保养

Level 1 maintenance

每隔1x10

Every 1×10

Every 2400h

每隔2x10

Every 2×10

每隔3x10

Every 3×10

2级保养

Level 2 maintenance

每隔2x10

Every 2×10

Every 2400h

每隔4x10

Every 4×10

每隔6x10

Every 6×10

3级保养

Level 3 maintenance

每隔4x10

Every 4×10

Every 2400h

每隔8x10

Every 8×10

每隔12x10

Every 12×10

4级保养

Level 4 maintenance

每隔8x10

Every 8×10

Every 2400h

每隔16x10

Every 16×10

每隔24x10

Every 24×10

Summary of Contents for WD615

Page 1: ...Water cooled X X X Design code for developed diversity model Application code C Marine diesel engine D Diesel engine for generating set G diesel engine for construction machinery T Diesel engine for...

Page 2: ...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 chan...

Page 3: ...eement between Weichai and the customer and as per customer s requirementbefore delivery coolant performance should be checked if the engine has been filled up with coolant The coolant could be remain...

Page 4: ...50S 850 950 25 When the temperature of coolant inside the engine is lower than 23 turn on the electronickey the preheating indicator lighting the heating plug is heated and the preheating indicatorwil...

Page 5: ...ne running at the speed lower than the speed of the biggest torque it is notallowed to continue running on full load over l min 3 5 min After running on full load the engine should run in idling speed...

Page 6: ......

Page 7: ...n 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 or...

Page 8: ...tions with vehicle WG WG WG 2 104 km 600h U n d e r s e v e r e o p e r a t i n g condition e g cold or hot weather high dust content short distance transportation service in construction site and bus...

Page 9: ...ion 5000km 150h Every 5 000km or 150h 1x104 km Every 1 104 km 1 5x104 km Every 1 5 104 km 1 Level 1 maintenance 1x104 km 300h Every 1 104 km or 300h 2x104 km Every 2 104 km 3x104 km Every 3 104 km 2 L...

Page 10: ...1500 2000km 1500 2000km Running 1500 2000km Periodical inspection 5000km Every 500km 1x104 km Every 1 104 km 1 5x104 km Every 1 5 104 km 1 Level 1 maintenance 1x104 km Every 1 104 km Every 2400h 2x10...

Page 11: ...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 T...

Page 12: ...learance Air filter Air intake system Tighten pipe clamps Tighten V belts Inspect and adjust the injection fuel pump on test bench 4 WD 4 Oil Oil filter Fuel filter Coolant Air filter Valve clearance...

Page 13: ...Manual for WD615 Series Euro Diesel Engine 2 3 Maintenance Record Engine number Engine model User name Equipment name Date Running Kilometers hours or interval hours Actual Kilometers Maintenance cont...

Page 14: ......

Page 15: ...ance 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...

Page 16: ...is lower than the lower limit or higher than the upper limit it 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...

Page 17: ...evel Inspect the coolant level through the vitreous view hole if the coolant is not sufficient open the inlet cover and fill into the coolant Note When opening the inlet cover must press down the exha...

Page 18: ...n Check whether the plastic fan is distorted For steel fan check 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...

Page 19: ...ries Euro Diesel 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 cup dismount it and drain off the water an...

Page 20: ...owing contents will be added except daily maintenance items Replacement of the oil and oil filter The oil will be polluted after using the pollution contents is of accordance with the consumption of f...

Page 21: ...gine 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 plug prepare a con...

Page 22: ...5 Series Euro Diesel Engine Tool The special wrench for filter Clean the end surrounding of the filter and remove it Install the new oil filter Note Adjust the seal ring and smear some lubricating oil...

Page 23: ...ro Diesel Engine 32mm Tool 32mm open ended wrench Check and clean the screw thread and seal ring and then install the whorl plug 20L Fill the clean oil up to the upper limit the capacity of the oil su...

Page 24: ...l 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 the upper parts 5 minutes later then check the...

Page 25: ...mm 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...

Page 26: ...arance of exhaust valve is 0 40mm WEVB 0 25mm The Clearance of WEVB systerm is 0 25mm 60 Note When check the clearance of valve the engine should be at the cool condition its temperature is less than...

Page 27: ...rn 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 an...

Page 28: ...embly 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 s...

Page 29: ...offset ring wrench The piston of 1 cylinder is at TDC of the compression stroke A I E Check and adjust the valve clearance as step A I air intake Valve E air exhaust valve Adjust the clearance by gua...

Page 30: ...sel Engine 360 360 Turn the crankshaft 360 by the spanner it can also be turned 360 after marking on the vibration damper B Adjust the valve clearance as step B Loosen the fixing nut of rocker arm adj...

Page 31: ...stall the gasket and cylinder head cover 23N m The tightening torque of bolt is 23N m recommended Check the tension of V belts l0mm Measure the flexibility of the V belt at the middle of its biggest s...

Page 32: ...than l0mm it means the V belt has been loosen the nut for tension pulley needs to be relaxed strain the V belt again and tighten the nut Check whether the rubber pipes of cooling system is aging or c...

Page 33: ...ries Euro Diesel Engine Replace the fuel filter 13mm Tool 13mm open ended wrench Clean the end surrounding of the fuel filter unloosen the upper bolt and disassemble the fuel filter Install the new fu...

Page 34: ...for WD615 Series Euro Diesel 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 t...

Page 35: ...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...

Page 36: ...running at rated speed and full load When the resistance reaches the maximum limit or the indicator light glows the air filter element should be cleaned or replaced as per the maintenance guide from...

Page 37: ...the air filter 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 Nole Don t blow off the air filte...

Page 38: ...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 connecti...

Page 39: ...ust 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 Oi...

Page 40: ...ain 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 noz...

Page 41: ...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 ma...

Page 42: ...ump 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 gaske...

Page 43: ...intenance Manual for WD615 Series Euro Diesel 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 th...

Page 44: ...sh 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...

Page 45: ...o 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 controlli...

Page 46: ......

Page 47: ...time 80N m The second time 250 25 N m 2 Cylinder Head Bolt 24 M1 6 22 Total nos 24 pcs M16 main bolts Tool 22mm sleeve wrench 7 M 12 17 Total nos 7 pcs nuts of M 1 2 auxiliary bolt Tool 17mm sleeve wr...

Page 48: ...e torque is 100N m 90 Step 4 Turn the main bolts 90 as the sequence in above figure 90 Step 5 Turn the auxiliary bolts 90 as the sequence in above figure 90 240 340 N m Step 6 Turn the main bolts 90 a...

Page 49: ...orque of 60N m 180 50 230 280 N m Step 2 Turn these bolts 1 80 5 and the torque range is 230 280 N m Replace those bolts that can not reach required torque range 2 Note The flywheel bolt is only allow...

Page 50: ...ighten these bolts symmetrically with a torque of 60N m 90 100 125 N m Step 2 Turn these bolts 90 and the torque range is 100 125 N m Replace those bolts that can not reach required torque range 242 S...

Page 51: ...tal nos 1 piece M10 bolt Tool 16mm sleeve wrench 60 5 N m Tighten the bolt with a torque of 60 5 N m 242 Coat the thread with LOCTITE 242 THREADLOCKER before tightening 8 Bolt Rocker Arm Support 12 M1...

Page 52: ...m box wrench 1500 15 N m Tighten the boh with a torque of 1500 15 N m 242 Coat the thread with LOCTITE 242 THREADLOCKER before tightening 10 Tight Nut Injection Pump Driving Gear M24x1 5 Total nos 1 p...

Page 53: ...13mm sleeve wrench 35N m Tighten these bohs aymmetrically with a torque of 35N m 242 Coat the thread with LOCTITE 242 THREADLOCKER before tightening 12 Bolt Attaching Damper Pulley and Crankshaft 8 M1...

Page 54: ...inner hexagon wrench 450 5 N m Tighten these bolts in sequence and the torque is 450 5 N m 14 Bolts Exhaust manifold 12 M10 Total nos 12 pcs M 10 bolts 65 80 N m Tighten these bolts symmetrically wit...

Page 55: ...temperature is below 30 you should use No 35 Diesel Fuel 6 2 Lubricant 6 2 1 300PS CD 300PS CF 4 For engines with power of lower and higher than 300PS grade CD and CF 4 oil are recommende respectively...

Page 56: ...nticorrosive agent was contained The customer can replace it with new oil after running 2000km or 50hs 6 3 GB T5671 Grease Fill GB T5671 lithium grease into the grease cup of the water pump 6 4 40 Coo...

Page 57: ...eg Apply to the bolts of exhaust outlet of turbocharger 3 242 LOCTITE 242 glue Blue Apply to thread to seal eg Apply to bolts and thread 4 262 LOCTITE 262 glue Red Apply to thread to lock and seal eg...

Page 58: ...WD615 58 Maintenance Manual for WD615 Series Euro Diesel Engine Note To ensure the proper operation of our diesel engines please use the correct brand fueI and oil as this manuaI described...

Page 59: ...pressure etc Generator The generator is three phase alternator after silicon rectification the current change into direct current 28V 27A 35A 55A Output Voltage 28V DC Current 27A In order to meet cu...

Page 60: ...or 8 1 kW Rotation Direction clockwise View direction face to the output end of the engine 3 9 SAE II 11 SAE1 6I 35 7 5kW 8 1kW 9 3 5 10 11 11 Bosch 3 5 10 11 11 Bosch There are two types of starter...

Page 61: ...re 25 100 Operating Temperature 25 100 0 500kPa Measurement Range 0 500kPa 45 75kPa Alarm Pressure 45 75kPa 6 24V Rated Voltage 6 24V Sensor of water temperature meter 25 120 Operating Temperature 25...

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Page 63: ...acement of Main Components 8 1 Cooling System Replace the V belts 16mm Tool 16mm open ended wrench Loosen the tightening nut of the generator to remove generator belt 16mm Tool 16mm open ended wrench...

Page 64: ...r WD615 Series Euro Diesel Engine 2 Replace the V belts tighten self lock nuts 2 and the nuts of tension bolts again Replace Water Pump 16mm Tool 16mm open ended wrench Loosen the tightening bolts of...

Page 65: ...anual for WD615 Series Euro Diesel Engine 13mm Tool 13mm open ended wrench Loosen the bolt from the generator mounting plate 13mm Tool 13mm open cnded wrench Remove the tightening bolts and hexagon nu...

Page 66: ...WD615 66 Maintenance Manual for WD615 Series Euro Diesel Engine Remove generator 16mm Tool 16mm open ended wrench Loosen the hexagon lock nuts of tension pulley to remove the V belt of water pump...

Page 67: ...tenance Manual for WD615 Series Euro Diesel Engine 6 Tool 6 Screwdriver Loosen the rubber hose clamp of water pipe joint 13mm Tool 13mm sleeve wrench Loosen the bolt of water pipe joint to remove wate...

Page 68: ...WD615 68 Maintenance Manual for WD615 Series Euro Diesel Engine 13mm Tool 13mm open ended wrench 6 Loosen the 6 hexagon nuts attaching water pump and gear case Remove water pump...

Page 69: ...WD615 69 Maintenance Manual for WD615 Series Euro Diesel Engine Clean the seal surface of water pump Replace the seal gasket of water pump...

Page 70: ...ighten 6 hexagon nuts There is a nut in the inner side of water pipe joint 120cm3 Note Fill the Iumen of water pump with 120cm3 general Iithium grease Refill lithium grease with grease cup periodicall...

Page 71: ...intenance Manual for WD615 Series Euro Diesel Engine Install generator 16mm Tool 16mm open ended wrench and pontil M10 Install the V belt and adjust the tensity tighten M10 hexagon lock nuts of tighte...

Page 72: ...nance Manual for WD615 Series Euro Diesel Engine 13mm 16mm Tool 13mm and 16mm open ended wrench Install the V belt of generator and adjust the tensity tighten top nuts of tightening bolts and nuts of...

Page 73: ...he oil cooler core 13mm Tool 13mm 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...

Page 74: ...nce Manual for WD615 Series Euro Diesel Engine 6mm Tool 6mm sleeve wrench 4 M8 Loosen the 4pcs M8 bolts of oil cooler element Remove element of oil cooler and clean the bonding surface of flange of oi...

Page 75: ...o Diesel Engine Replace seal ring of oil cooler element 13mm T o o l 1 3 m m s l e e v e wrench M8 Install the new oil cooler element and tighten the M8 hexagon bolts 242 Note Coat the thread with L O...

Page 76: ...iesel Engine 13mm Tool 13mm 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 Tool 13mm sleeve wrench M8...

Page 77: ...Series Euro Diesel Engine Remove retainer then remove 0il pan 27mm Tool 27mm open ended wrench Remove the release valve of main oil channel When removing the release valve of oil channel move the mal...

Page 78: ...elease valve coat the thread with LOCTITE 242 THREADLOCKER before tightening When installing new release valve move the male end of hexagonal part on valve body 13mm Tool 13mm open ended wrench M8 Ins...

Page 79: ...5 Series Euro Diesel Engine Replace Oil Pump 13mm 16mm Tool 13mm sleeve wrench and 16mm open ended wrench Remove oil pan and suction pipe l0mm Tool l0mm open ended wrench Loosen the mounting plate of...

Page 80: ...Tool 16mm 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 Tool 16mm open ended wrench and 16mm sleeve wrench Loosen the...

Page 81: ...o Diesel 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 fit the damper can be knocked slightly if it is necessary for removing 22mm Tool 22mm open ended wren...

Page 82: ...intenance Manual for WD615 Series Euro Diesel Engine 16mm Tool 16mm sleeve wrench R e m o v e t h e b o l t s o f intermediate gear shaft of oil pump Remove intermediate gear shaft of oil pump with sp...

Page 83: ...WD615 83 Maintenance Manual for WD615 Series Euro Diesel Engine Remove intermediate gear of oil pump 16mm Tool 16mm sleeve wrench Remove the hex head bolts from the hex plug and another hex head bolt...

Page 84: ...WD615 84 Maintenance Manual for WD615 Series Euro Diesel Engine Remove oil pump Clean the seal Surface between crankcase and 0il pump...

Page 85: ...l for WD615 Series Euro Diesel Engine 16mm Tool 16mm sleeve wrench Install new oil pump and gasket tighten the hex head bolts one of them is in the hex head plug Install intermediate gear of oil pump...

Page 86: ...nce Manual for WD615 Series Euro Diesel Engine Install intermediate gear shaft of oil pump 16mm Tool 16mm sleeve wrench Install the bolts of intermediate gear shaft and tighten them 60 5 N m Tightenin...

Page 87: ...WD615 87 Maintenance Manual for WD615 Series Euro Diesel Engine Install damper and pulley 16mm Tool 16mm sleeve wrench Install the bolts of pulley and tighten them 60 5 N m Tightening torque 60 5 N m...

Page 88: ...WD615 88 Maintenance Manual for WD615 Series Euro Diesel Engine 16mm Tool 16mm open ended wrench Install the V belt pulley and adjust the tensity then tighten the hex head lock nuts...

Page 89: ...Replace injection pump 16mm Tool 16mm open ended wrench Remove the joint between the high pressure pipe and injection pump OT Rotate flywheel slowly align the calibrating line of flywheel housing to O...

Page 90: ...tenance Manual for WD615 Series Euro Diesel Engine 16mm Tool 16mm sleeve wrench Remove the screws attaching shaft coupling and driving shaft 16mm 16mm Tool 16mm open ended wrench and 16mm double offse...

Page 91: ...1 Maintenance Manual for WD615 Series Euro Diesel Engine 6 0 5kg Tool 6 screwdriver O 5 kg Open the gap on the angle regulating plate connecting the coupler and the driving shaft Push shaft coupling b...

Page 92: ...r WD615 Series Euro Diesel Engine 8mm Tool 8mm inner hexagon wrench 4 Remove the 4 pcs socket head bolts attaching injection pump and bracket 19mm Tool 19mm open ended wrench Remove all the connecting...

Page 93: ...15 Series Euro Diesel Engine Remove the injection pump and install new injection pump and socket head bolts 8mm Tool 8mm sleeve wrench Tighten socket hexagon bolts of injection pump connect pipeline 4...

Page 94: ...Engine 16mm 16mm Tool 16mm open ended wrench and 10mm double offset ring wrench 242 110N m Install bolts attaching injection pump and shaft coupling coat the thread with LOCTITE 242 T H R E R A D L O...

Page 95: ...pling 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...

Page 96: ...injection pump is aligned with calibration tails of tining adwance unit or flange 16mm Tool 16mm sleeve wrench 242 1500 5 N m Install bolts attaching shaft coupling and driving shaft Coat the thread w...

Page 97: ...o recheck the advance angle of fuel supply remove bolts attaching shaft coupling and driving shaft for readjustment if necessary Replace Injection Pump 17mm Tool 17mm open ended wrench Clean all round...

Page 98: ...WD615 98 Maintenance Manual for WD615 Series Euro Diesel Engine Remove fuel return pipe of the injector 13mm Tool 13mm open ended wrench Loosen bolts of mounting plate then remove mounting plate...

Page 99: ...WD615 99 Maintenance Manual for WD615 Series Euro Diesel Engine Remove injectors Clean seat hole of injector...

Page 100: ...WD615 100 Maintenance Manual for WD615 Series Euro Diesel Engine Replace with new copper washer Replace with new injector and install new rubber seal ring...

Page 101: ...nce Manual for WD615 Series Euro Diesel Engine Install new injector into the seat hole Note It is not allowed to appear any mark of pressing rubber cushion after mounting injector Install the mounting...

Page 102: ...el Engine 13mm Tool l3mm sleeve wrench 25N m Install bolts or hex head nuts of mounting plate Tightening torque 25N m 13mm 17mm Tool 13mm and 17mm open ended wrench Tighten the joint attaching injecto...

Page 103: ...5 Series Euro Diesel Engine 8 4 Air Intake System Replace Turbocharger 6mm Tool 6mm screwdriver Loosen rubber hose clamps from the inlet and outlet of compressor 6mm Tool 6mm screwdriver Loosen hose c...

Page 104: ...s Euro Diesel Engine 6mm Tool 6mm inner hexagon wrench Remove inner head bolts from turbocharger oil inlet sucker raise flange of sucker 16mm Tool 16mm open ended wrench Remove the self locking nuts f...

Page 105: ...intake and exhaust manifolds should be cove red to prevent anything falling into cylinder 6mm Tool 6mm inner hexagon wrench Replace with new gasket for inlet pipe fighten bolts of oil inlet pipe Note...

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Page 107: ...uel 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...

Page 108: ...place the filter element if necessary 2 Air entered into fuel system C h e c k f u e l p i p e a n d s e a l i n g o f t h e connector tighten air venting bolt and drain off the air 3 Supply pump does...

Page 109: ...ter 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 gover nor Repai...

Page 110: ...eaked 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 Leakag...

Page 111: ...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 superchargi...

Page 112: ...fing 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 g...

Page 113: ...re quirements 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 connect...

Page 114: ...oil doesn t conform to specifica tions 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 sy...

Page 115: ...logged 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 thermosta...

Page 116: ...el Engine 9 11 Parts wore quickly 1 1 Filter element of air cleaner is unquali fied or damaged Check and replace filter element 2 2 Air leakage in air intake system Check air intake pipe gasket and co...

Page 117: ...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...

Page 118: ...shed 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 9 13 Sta...

Page 119: ...heck 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 Volt...

Page 120: ...ier 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 b...

Page 121: ...r 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...

Page 122: ...WD615 2007 7...

Page 123: ...tely Once injection pump is adjusted or lead sealing is dismantled the guarantee ceases to be in effect Injection pump is of precision parts it is forbidden to dismantle by user or the guarantee cease...

Page 124: ...re are strict demands on torque and turned angle for main bearing bolts and connecting rod loosening and dismantling is forbidden or the guarantee cease to be in effect Before starting the diesel engi...

Page 125: ...oduct 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 spee...

Page 126: ...f 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...

Page 127: ...l 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...

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Page 129: ...ssels speed 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 custome...

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Page 131: ...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 5...

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Page 133: ...emble 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 equip...

Page 134: ......

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WEICHAI WD615, Usage Instructions

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