Maintain and Repair WD615 Diesel Engine

WD615
Maintenance Manual for WD615 Series EuroDiesel Engine
1.
Usage Instructions
1.1 WD615
The signification of the code of WD615 Series Diesel Engines
W D 6
15
X X
X X
Design code for developed

diversity model
Application code:
Basic product code
Single cylinder displacement
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).
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WD615
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
First oil 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 change perild is
1,500-2,000km
Perform daily maintenance work as specified in this manual.
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
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
Inspect the coolant level
Inspect the fuel level
Inspect the lubricating oil level
1.5
Starting
Put the power switch and starting key at the starting position
Put the gearlever at empty gear-matching position

(
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WD615
)
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
Low temperature starting
With electronic control flame preheating device

-23 50S
850-950
-25
When the temperature of coolant inside the engine is lower than-23
turn on the
electronickeythe preheating indicator lightingthe heating plug is heatedand the preheating

indicatorwill be automatically flickered after 50SWhen the heating plug is heated to
850-950 pressdown the start buttonconnect the starterthe electromagnetic valve will
be automaticallyopenedand the heating plug will be provided with fuel to proceed flame
preheatingand theengine can be easily started under-25
With low temperature auxiliary starting device

50
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
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WD615
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
Engine'S running stop
Put the hand-accelerograph of injection pump at zero positionstop the engineand

readjust the hand-accelerograph
1-2min
NoteThe engine should run in idling speed for 1-2 minutes before stopped
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WD615
2.
Maintenance Guide
2.1
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 fixed well;

;
Check whether the water or oil is leaking;
;
Check whether the charging indicator light is in order;
;
Inspect sufficient grease;
;
Inspect toil pressure and water temperature are normal condition
;
Inspect that exhaust temperature, sound and vibration are normal condition
Inspect rotary speed is stable.
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WD615
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
Annual running mileage of the
Annual running mileage of the
vehicle more than 6104km for
vehicle less than 610 4km,,
long distance transportation.
210 km
for short- or medium-distance
600h
transportation (for goods).
Under severe 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, fire
bridge vehicle), annual running
mileage of the vehicle less than
210 4km or annual operated
time less than 600h.
--
(WG)
WD615
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
2-3
Table 2-3 Oil Replacement Period in SteyrVehicle Maintenance System
(WG)
(WG)
(WG)
2x104km
Annual running mileage
<2104 km
6x104km
< 6104 km
2x104km
> 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-
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2.2.2
Maintenance Items
Items

Replacement

Adjustment

Inspection
1
The 1st
inspection
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
Tighten pipe clamps
Tighten V-behs
2
WD2
Oil
Oil filter
Fuel filter
Valve clearance
Air filter
Air intake system
Tighten pipe clamps
Tighten V-belts
-11-
WD615
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
Air intake system
Tighten pipe clamps
Tighten V-belts
Inspect and adjust the

injection
fuel pump on test
bench
Valve clearance
Air filter
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
WD615
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-
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WD615
Maintenance 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 the fuel level.
Inspect
Leakage
Fast wearing parts
Any unconventionality
-15-
WD615
Inspect the oil level height
When the oil level is lower than the

lower limit or higher than the upper
limitit 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 can flow
back to the oil sump
3
The oil volume tolerance between
the lower limit and the upper limit is
3 liters
-16-
WD615
Inspect the coolant level
Inspect the coolant level through the

vitreous view holeif the coolant is
not sufficientopen the inlet cover
and fill into the coolant.
Note:When opening the inlet

covermust press down the
exhaust button firstly to prevent
hot coolant from injuring people.
Inspect the fuel level
-17-
WD615
Inspect the fan
Check whether the plastic fan is

distorted.For steel fancheck
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 find if there is any crack or
scratch on the V-beltsReplace
them if necessary
-18-
WD615
Drain off the water and deposit from

the small filtercup fitted on the fuel
delivery pump.
Unscrew the bottom bolt of the

small filter cupdismount it and
drain off the water and deposit
then re-install the cup again
-19-
WD615
3.2
Maintencnce items of various
maintenances
The following contents will

be added except daily maintenance
items
Replacement of the oil and oil

filter
The oil will be polluted after

usingthe pollution contents is of
accordance with the consumption of
fuel and oil
250h(1 )
Note:The replacement period
of oil under proper using
condition cannot beyond 250h
(10,000Kilometers)
-20-
WD615
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 plugprepare a

container tocollect 20L of oil
NoteHot oil can injure people.
-21-
WD615
Tool:The special wrench for filter
Clean the end surrounding of the

filterand remove it
Install the new oil filter

,
-
NoteAdjust the seal ringand

smear some lubricating oil on it
while fitting the oil filter
-22-
WD615
32mm
Tool:32mm open-endedwrench
Check and clean the screw thread

and seal ringand then install the
whorl plug .
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
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 theupper parts
5 minutes laterthen check the oil
levelfill oil up to the upper limit if
necessary
-24-
WD615
Check and adjust the valve

clearance
13mm
Tool1 3mm 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 the
position of TDC of compression
stroke of 1st cylinder(the intake and
exhaust valve of 1st cylinder are
dosed)
-25-
WD615
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
Note:When check the clearance

of valvethe engine should
be at the cool conditionits
temperature is less than 60.
When the clearance guage
glides between the top of valve
rod and rocker arm and can be
felt retarded and stickythe
measuring result is proper
-26-
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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.
-27-
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1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
1. Valve clearance adjusting nut
2. Regulating bolt assembly
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 screw 11. Hexagonal bolt 12. Support arm
2 0.4mm
-28-
30.25mm
Fig. 2 Total Valve Clearance of Cold-State
Fig. 3 End Valve Clearance of Cold-State
Exhaust Valve 0.4mm
Exhaust Valve 0.25mm
WD615
6# 14mm
Tools6#screwdriver and14mm double
offset ringwrench
A
Step A
The piston of 1 cylinder is atTDC of

the compressionstroke
A
(I E )
Check and adjust the valveclearance
as step A(I-airintake Valve E-air
exhaustvalve)
Adjust the clearance by guage and

tighten the fixing nut ofrocker arm
re-check theclearance till it meets the
requirement
-29-
WD615
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
Loosen the fixing nut of rocker

armadjust the c|earance by guage
then tighten the nut again.
-30-
WD615
13mm
Tool:13mm sleeve wrench
Install the gasket and cylinder

head cover
23Nm(
)
The tightening torque of bolt is
23Nm(recommended)
Check the tension of V-belts
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-
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16mm
16mm open-ended wrench
l0mm
If the flexibility is more than

l0mmit means the V-belt has
been loosenthe nut for tension
pulley needs to be relaxedstrain
the Vbelt again and tighten the
nut
Check whether the rubber pipes of

cooling system is aging or cracked
the steel wire hoop is loosening
If it is necessarytighten or replace
the parts to ensure good sealing
pertormance.
-32-
WD615
Replace the fuel filter

13mm
Tool13mm open-ended wrench

Clean the end surrounding of the

fuel filterunloosen the upper bolt
and disassemble the fuel filter.
Install the new fuel pre-fiher

element and filter element
-33-
WD615
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 the

inlet of injection pump.
-34-
WD615
,
Press the fuel delivery pumpplug
till the fuel drained off from the
draining bolt outlet does not contain
airthen tighten the bolt
Check the air intake system
Check whether the air intake rubber

pipes are aging or crackedthe
steel wire hoop is looseningIf
it is necessary tighten or replace
the parts to ensure good sealing
performance
-35-
WD615
Check the air filter element
7kPa
The maximum air intake resistance

of the engine should be less than
7kpait should be checked while
the engine running at rated speed
and full load When the resistance
reaches the maximum limit or the
indicator light glowsthe air
filter element should be cleaned
or replaced as per the maintenance
guide from the manufacture.
Notelt is not allowed to use

the engine without air filter
otherwise the dust and impurity
will cause early wearing of the
engine.
-36-
1
Paper foltering element
2
Blanketry sofety futering
element
WD615
( )
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
Don't blow off the airfiltering

paper
Don't clean the air filtering

paper by water and oil
Don't beat the core forcibly
-37-
WD615
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.
Pack the engine if transportation is necessary.
-38-
WD615
4
The Main System Flow Chart of Engine
Lubricating system
Cooling system
Intake and exhaust 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
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
Lubricating for main moving parts

1
The oil flowing from the oil
cooler
2
Main oil passage
3
Oil to the main 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 nozzle to cool piston
10
Camshaft beating
11
Lubricating air compressor
through the oil from sub-passage
12
Lubricating fuel injection pump
through the oil from sub-passage
-40-
WD615
Lubricating 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 main oil
passage
2
Oil inlet of turbocharger
3
The oil outlet of turbocharger
-41-
WD615
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
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
4.3
Intake and exhaust system
1
The fresh 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 engine supplied
without intercooler when
delivering out of our company)
4
Intake manifold
5
Intake valve
-44-
WD615
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
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
Following such tightening sequence

30Nm
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
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
Tool22mm sleeve wrench
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
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
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
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
242
Smear the thread with LOCTITE 242 THREADLOCKER before tightening
3
The bolt for intermediate gear shaft can only be used three times.
Bolt for Intermediate

Gear Shaft
-50-
WD615
7
BoltOil Pump Idler
Gear Shaft
M10 16mm
T0tal nos1 piece M10 bolt
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
18mm
100Nm
Tighten these bolts with a torque
of 100Nm
-51-
WD615
Hex head Bolt Binding Coupling

and Injection Pump
M14x15
Total nos1 piece M14x15 bolt
18mm
Tool18mm box wrench
1500+15Nm
Tighten the boh with a torque
of 1500+15Nm
242
Coat the thread with LOCTITE 242
THREADLOCKER before tightening
10
Tight NutInjection Pump Driving
Gear M24x1.5
Total nos:1 piece M24x1.5 nut
36mm
450~500Nm
Tighten the nut with a torque 0f
450~500Nm
242
Coat the thread with LOCTlTE 242
THREADLOCKER beforetightening
-52-
WD615
l 1
Bohs|Camshaft Gear
4M8
13mm
35Nm
Tighten these bohs aymmetrically
with a torque of 35Nm
242
Coat the thread with LOCTITE
242 THREADLOCKER before
tightening
12
BoltAttaching Damper Pulley and

Crankshaft
8M10
16mm
Tool16ram sleeve wrench
60+5Nm
Tighten these bolts symmetrically with
a torque 0f 60+5 Nm
-53-
WD615
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.
Note:Coat the thread and bearing

surface with Molybdenum disulfide Lube
before tightenin
2
The bolt for exhaust manifold can
only be used two times
-54-
WD615
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
you should use No.-20 Diesel FuelIf the
temperature is below-30you should use No.-35 Diesel Fuel
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
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
LOCTITE 510242271277262 sealing glue and cohesive material can be used

during tne process of mounting and repalnng
6.5.2
Fine molybdenum powder
6.5.3
Please reference the following table for detailed application of auxiliary materials
-56-
WD615
WD615
Auxiliary Materials List of WD615 Series Diesel Engine
Serial No
Name
Color
Purpose and Application
Fine
Molybdenum
Powder
Black
Apply to smooth surface of metal to prevent biting.
egApply to exterior surface of cylinder liner.
To prevent adhesion of parts under higher

temperature
egApply to the bolts of exhaust outlet

of turbocharger
Molybdenum disulphide ointment

Lube
Deep
gray
242
LOCTITE 242 glue
Blue
Apply to thread to seal
egApply to bolts and thread
Red
Apply to thread to lock and seal
egApply to auxiliary bolts of cylinder

head
262
LOCTITE 262 glue
510
LOCTITE 510 glue
Red
Apply to surface of metal to seal
egApply to bond surface of"cylinder

block and crankcase
271
LOCTITE 271 glue
Red
Apply to surface of metal to seal
egApply to oil channel plug
962
LOCTITE 962
Red
Sealing of plug and hole
egApply to the water reservoir plug of

cylinder block
Lithium grease glue
Red
Grease for Water Pump
-57-
WD615
NoteTo ensure the proper operation of our diesel enginesplease use the
correct brand fueI and oil as this manuaI described
-58-
WD615
7
Electrical Appliance
This section consists of generatorstartersensor of water temperature indicator

induction plug of oil pressureetc
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
Connection Pole
D+
M4
D+connect to Charging(electri6cation)Indicating Lampthe screw specificationM4

W
M5
Wconnect to Speed Measuring Motorthe screw specificationM5

B+
M6
B+connect to the positive electrode of batterygenerator shell is groundedthe screw

specificationM6
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
Extemal Connection Pole

30 M10
30 connect to the positive electrode of batterythe screw specificationM10
3 1 M10
3 1 grounding the screw specificationM10
50 M6
50 connect to the electromagnetic switch the screw specificationM6
-60-
WD615
Induction plug of oil pressure

-25~100
Operating Temperature-25~100
0~500kPa
Measurement Range0~500kPa
45~75kPa
Alarm Pressure45~75kPa
6~24V
Rated Voltage6~24V
Sensor of water temperature meter

-25~120
Operating Temperature-25 120
6~24V
Rated Voltage6~24V
Battery
2x12V 135Ah 165Ah 195Ah
212V 135Ah or 165Ah or 195Ah
-61-
...
WD615
8
Adjustment and Replacement of Main Components
8.1
Cooling System
Replace the V-belts

16mm
Tool16mm open-ended
wrench
Loosen the tightening nut of

the generator to remove
generator belt
16mm
Tool16mm open-ended
wrench
M102
Loosen the M10 self-lock nut

(2)of tension pulleyremove
the V-beh of water pump
-63-
WD615
Replace the V-beltstighten

self-lock nuts (2)and the nuts
of tension bolts again
Replace Water Pump

16mm
Loosen the tightening bolts of

generator to remove the V beIt
-64-
WD615
13mm
Loosen the bolt from the generator

mounting plate
13mm
Tool13mm open cnded wrench
Remove the tightening bolts and

hexagon nuts attaching gear case
-65-
WD615
Remove generator
16mm
Tool16mm open-ended
wrench
Loosen the hexagon lock nuts of

tension pulley to remove the V-belt of
water pump
-66-
WD615
6#
Tool6# Screwdriver
Loosen the rubber hose clamp

of water pipe joint
13mm
Loosen the bolt of water pipe

joint to remove water pipe joint
-67-
WD615
13mm
Tool13mm open-ended
wrench
6
Loosen the 6 hexagon nuts
attaching water pump and gear
case
Remove water pump
-68-
WD615

Clean the seal surface of
water pump
Replace the seal gasket of

water pump
-69-
WD615
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
NoteFill the Iumen of water

pump with 120cm3 general
Iithium greaseRefill lithium
grease with grease cup
periodically
13mm
M8
Install the water pipe jointtighten

two M8 bolts of water pipe joint
then i nstall the rubber hose
-70-
WD615
Install generator
16mm
Tool16mm open-ended
wrench and pontil
M10
Install the V-belt and

adjust the tensity, tighten M10
hexagon lock nuts of tightening
pulley
-71-
WD615
13mm16mm
Tool13mm and 16mm

open-ended wrench
Install the V-belt of

generator and adjust the tensity
tighten top nuts of tightening
bolts and nuts of mounting
plate.
-72-
WD615
8.2
Lubricating System
Replace the oil cooler core

13mm
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 cooler cover

and seal surface of the cylinder
block,replace with new gasket of oil
cooler cover.
-73-
WD615
6mm
4M8
Loosen the 4pcs M8 bolts

of oil cooler element.
Remove element of oil

cooler and clean the bonding
surface of flange of oil cooler
element.
-74-
WD615
Replace seal ring of oil

cooler element.
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
13mm
Tool13mm 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
Tool13mm sleeve
wrench
M8
Loosen all peripheral

M8 hex head bolts of oil
pan.
-76-
WD615
Remove retainerthen
remove 0il pan
27mm
Tool27mm open-ended
wrench
Remove the release valve

of main oil channel
When removing the release

valve of oil channel,move the
male end of hexagonal part on
valve body.
-77-
WD615
27mm
Tool27mm open-ended
wrench
242
Install new release valve

coat the thread with LOCTITE
242 THREADLOCKER before
tightening
When installing new

release valvemove the male
end of hexagonal part on valve
body
13mm
Tool:13mm open-ended
wrench
M8
Install oil pan and tighten

the M8 hex head bolts
NoteMake sure
packing washer of oil pan
was pressed well
-78-
WD615
Replace Oil Pump

13mm
16mm
Tool13mm sleeve
wrench and 16mm openended wrench
Remove oil pan and

suction pipe.
l0mm
Tooll0mm open-ended
wrench
( )
Loosen the mounting
plate of oil suction pipe(twostage oil pump)
-79-
WD615
16mm (
)
Tool16mm 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
Tool16mm open-ended
wrench and 16mm sleeve wrench
Loosen the hex head bolts

of tension pulley and the bolts of
crankshaft pulley
-80-
WD615
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 fitthe
damper can be knocked slightly
if it is necessary for removing
22mm
Tool22mm open-ended
wrench
Remove the hex head plug

screws of gear case
-81-
WD615
16mm
Remove the bolts of

intermediate gear shaft of oil
pump.
Remove intermediate gear

shaft of oil pump with special
tool
-82-
WD615
Remove intermediate gear of

oil pump
16mm
Remove the hex head bolts

from the hex plug and another hex
head bolt
-83-
WD615
Remove oil pump
Clean the seal Surface between

crankcase and 0il pump
-84-
WD615
16mm
(
)
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
Install intermediate gear shaft

of oil pump
16mm
Install the bolts of intermediate

gear shaft and tighten them
60+5Nm
Tightening torque60+5Nm
-86-
WD615
Install damper and pulley
16mm
,
Install the bolts of pulley and
tighten them
60+5Nm
Tightening torque605Nm
-87-
WD615
16mm
Tool16mm open-ended
wrench
Install the Vbelt pulley

and adjust the tensitythen
tighten the hex head lock nuts
-88-
WD615
83
Fuel Supplying System
Replace injection pump

16mm
Tool16mm open-ended
wrench
Remove the joint between the

high pressure pipe and injection
pump
OT
Rotate flywheel slowlyalign

the calibrating line of flywheel
housing toOTcalibrating line
to fix the position of TDC of
compression stroke of the first
cylinder
-89-
WD615
16mm
Remove the screws attaching

shaft coupling and driving shaft
16mm 16mm
Tool16mm open-ended
wrench and 16mm double offset
ring wrench
-90-
WD615
6# 0.5kg
Tool6# screwdriver O.5 kg
Open the gap on the angle

regulating plate connecting the
coupler and the driving shaft.
Push shaft coupling backward
-91-
WD615
8mm
Tool8mm inner hexagon
wrench
4
Remove the 4 pcs socket head

bolts attaching injection pump and
bracket
19mm
Tool19mm open-ended
wrench
Remove all the connecting

pipes from the injection pump.
-92-
WD615
Remove the injection pump

and install new injection pump and
socket head bolts
8mm

Tighten socket hexagon bolts

of injection pumpconnect pipeline.
45+5Nm
Tightening torque
45+5Nm
-93-
WD615
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
Rotate shaft coupling 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
reference fuel system mating list for
fuel supply advance angle of each
cylinder)
-95-
WD615
The calibration tails of injection

pump is aligned with calibration tails
of tining adwance unit(or flange).
16mm

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
Rotate flywheel to recheck

the advance angle of fuel supply
remove bolts attaching shaft
coupling and driving shaft for
readjustment if necessary
Replace Injection Pump

17mm
Tool17mm open-ended
wrench
Clean all round of the injector

remove the joint attaching high
pressure fuel pipe and injector
-97-
WD615
Remove fuel return pipe of the

injector
13mm
Loosen bolts of mounting plate

then remove mounting plate
-98-
WD615
Remove injectors
Clean seat hole of injector
-99-
WD615
Replace with new copper washer
Replace with new injector and

install new rubber seal ring
-100-
WD615
Install new injector into the seat

hole.
NoteIt is not allowed to appear

any mark of pressing rubber
cushion after mounting injector
Install the mounting plate of

injector.
-101-
WD615
13mm
Tooll3mm sleeve wrench
25Nm
Install bolts or hex head nuts
of mounting plateTightening
torque25Nm
13mm 17mm
Tool13mm and 17mm open ended

wrench
Tighten the joint attaching injector

and high pressure fuel pipeinstall
fuel return pipe
-102-
WD615
8.4
Air Intake System
Replace Turbocharger
6mm
Tool6mm screwdriver
Loosen rubber hose clamps from the

inlet and outlet of compressor
6mm
Tool6mm screwdriver
Loosen hose clamp from

turbocharger oil retum pipe
-103-
WD615
6mm
Remove inner head bolts from

turbocharger oil inlet sucker, raise
flange of sucker
16mm
Remove the self-locking nuts

from exhaust manifold to remove
turbocharger
-104-
WD615
Replace with new tu rbocharger
NoteIf the turbocharger is not

replaced immediatelythe intake
and exhaust manifolds should
be cove red to prevent anything
falling into cylinder
6mm
Replace with new gasket for

inlet pipe,fighten bolts of oil inlet
pipe.
NoteMake sure to adjust the

gasket oil hole and tu rbocharger
flange oil holeadd some clean
oil and rotate turbo impeller to Iet
oil flow into bearing Case
-105-
WD615
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
Clear away the dirt and check if the fuel is clean
2.
Air entered into the fuel system
Drain off the air, check the sealing of the

connector and repair it
3.
Injection pump damaged
Check plunger, fuel 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
6.
High pressure line damaged or leaked
Repair or replace
7.
Insufficient pressure in cylinder
Check the sealing of the valve and cylinder gasket

and the wear of the piston ring. Repair or replace
them
8.
The temperature is too low
With the addition of start-assist device
-107-
WD615
9.2
Stop soon after starting
1.
Fuel filter clogged
Dismantle and clean away dirt and water, replace

the filter element if necessary
2.
Air entered into fuel system
Check fuel pipe and sealing of the

connector,tighten air venting bolt, and drain off
the air
3.
Supply pump doesn't work
Check piston and valve of supply pump, clean

and repair
4.
Poor quality of fuel
Clean fuel filter and renew fuel
5.
Idling speed is too low
Readjust it
-108-
WD615
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
Check the valve-timing and exhaust pipe, adjust and repair
3.
Insufficient pressure in supercharging system
Check and block up the leakage of pipeline
4.
Faults in turbocharger
Replace the turbocharger assembly
4.1
Compressor and turbine streets choked up
Clean or replace
4.2
Floating bearing cease to be in effect
Replace
4.3
Carbon deposit or greasy filth in clearance of turbine and

Clean
compressor back
5.
Intercooler damaged
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.
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
Check the injecting pressure, clean away the carbon deposit in

nozzle, adjust and repair in-jector
12.
Incorrect timing of valve gear or fuel delivery
Check and adjust it
13.
High-speed of governor is adjusted too low
Check the speed-governing and adjust
14.
Oil level in the oil sump is too high
Check the oil-dipstick, and drain off unnecessary oil
15.
Leakage in cylinder gaskets
Check the compressed pressure at hot state, replace cylinder

gaskets
16.
Piston ring broken, the clearance of main bearing is too large
Replace worn parts or overhaul the engine
17.
Cylinder liner or piston worn, or piston scuffing
Overhaul the engine
-109-
WD615
9.4
Fuel consumption is too high
1.
Air intake clogged (air cleaner choked)
Check air cleaner and air intake pipe, then

clean them
2.
Exhaust back pressure is too high
Check exhaust pipe and brake valve, then clean

them
3.
Renew the fuel according to requirements
4.
Fuel line choked
Check and repair
5.
Fuel line leaked
Check and repair
6.
Poor atomizing
Check, adjust and repair
7.
Adjust valve clearance and injection ad-vance

angle according to requirements
8.
Leakage in cylinder gasket
Check compressed pressure
9.
The clearance of main bearing shell is too large
Engine need to overhaul
Check and overhaul
10.
Piston scuffing
Replace cylinder liner, piston and piston ring
11.
Check and block up the leakage of pipeline
12.
Check and replace
13.
Intercooler damaged or leaked
Replace or repair
-110-
WD615
9.5
Black smoke exhaust
1.
Air intake isn't free or exhaust back pressure is
too high
Clean
2.
Clean and renew
3.
Incorrect timing of valve gear 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.
Check and block up the leakage of pipeline and

connector
7.
Check and replace
8.
Intercooler damaged or leaked
Replace or repair
9.
Incorrect working point of smoke-limiter
()
Readjust ( by manufacturer)
-111-
WD615
9.6
White, blue smoke exhaust
1.
Poor quality of fuel, contains water
Renew fuel
2.
Temperature of cooling water is too low
Check working temperature of thermostat, replace

if necessary
3.
Check and adjust
4.
Poor atomizing
Check and repair
5.
Incomplete combustion, scuffing 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 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
Check and replace
11.
The thrust bearing of turbocharger worn
Check and replace
12.
The oil return pipe of turbocharger choked.
Clean or repair
-112-
WD615
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
Repair or replace turbocharger
2.
The gas-oil separator cease to be in effect
Replace
3.
Lub-oil level in oil sump is too high
Drain off unnecessary oil according to requirements
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 connector,

drain off air
3.
Faults in flyweight of governor and speed
governing spring
()
Check and repair (by manufacturer)
4.
Uneven fuel delivery
()
5.
Unstable atomizing
Check and repair
6.
Surge in turbocharger
Check, Wash compressor streets, clean a-way the

carbon deposit from exhaust passage
7.
Bearing of turbocharger damaged
Replace it
-113-
WD615
9.9
Lub-oil pressure is too low
1.
Oil level in oil sump is too low
Check oil leakage, add oil
2.
Faults in pressure regulating valve of main oil
passage
Check valve, clean and repair
3.
Strainer, oil pipes, connector gasket

choked or broken
Check strainer and connector , check if there is

any sponge in oil passage, repair
4.
Lub-oil doesn't conform to specifications
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 system and oil
temperature are too high
Check cooling system, and correct it
7.
Excessive resistance of oil filter
Renew the filter element
8.
Oil cooler choked
Check and clean
9.
Main oil passage choked
Check and clean
10.,
The clearance of bearing is too large or bearing
damaged
Check and replace
11.,11. Excessive wear of

parts, need to over-haul
,
Check the working time of the engine, over haul
-114-
WD615
9.10
Cooling water temperature is too high
1.
Water level in water tank is too low
Check water leakage, add water
2.
Water tank clogged
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 thermostat
Replace it
6.
Water pipe damaged and air entered
Check the water pipe, connector and gasket.

Renew the damaged parts
7.
The oil level in oil sump is too low
Check oil leakage, repair and add oil
-115-
WD615
9.11
Parts wore quickly
1.1. Filter element
of air cleaner is unqualified or damaged
Check and replace filter

element
2.2. Air leakage in air intake

system
Check air intake pipe, gasket and connecting sleeve, repair or replace
3.
4.
5.
6.
7.
8.
9.
10.
11.
-116-
WD615
9.12
Noise is too high
1.
Renew fuel
2.
Temp of cooling water is too low
Check thermostat, replace it if necessary
3.
Check, repair and adjust
4.
Poor atomizing
Check, repair and adjust
5.
Excessive injection quantity
()
6.
Vibration damper damaged
Check connecting bolt and replace damaged parts
7.
Leakage in valve or adjusted unsuitably
Dismantle and check valve, readjust it
8.
Excessive gear clearance or tooth broken
Check and replace damaged parts
9.
Cylinder liner or piston worn, or piston scuffing
Check and repair, or replace
10.
Push rod bended or broken
Replace it
11.
Piston rings broken or worn
Check and replace damaged parts
-117-
WD615
9.13
Starting motor doesn't work
1.
Insufficient charging for battery
Check, charge or replace
2.
Bad contact in connecting wire
Check up circuit, tighten terminal
3.
Fuse broken
Replace
4.
Bad contact in brush
Clean brush surface or replace brush
5.
Short circuit in starting motor
Check and repair it, or replace the motor

assembly
9.14
Starting motor is powerless
1.
Insufficient voltage of battery
Charge or replace
2.
Bearing bush worn
Replace bearing assembly
3.
Clean brush surface or replace brush
4.
Commutator unclean or sintered
Clean away the dirt and furbished 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
-118-
WD615
9.15
Generator doesn't work
1.
Wire connecting broken, short circuit, joint
loosened
Check 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.
Voltage regulated by regulator is too low
Repair
6.
Contact of regulator fused
Repair or replace
-119-
WD615
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
Check and adjust tension
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
Add electrolyte or renew battery
9.17
Uneven charging current
1.
Coil of rotator or stator will short or break
Repair or replace
2.
Repair
3.
Terminal loosened and bad contact
Repair
4.
Voltage regulator damaged
Repair
5.
Incorrect regulated voltage
Check and regulate
-120-
WD615
9.18
Generator over-charged
1.
Shorted in battery
Repair or replace
2.
Voltage of regulator is too high
Repair 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 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
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

( )
The rotator of turbocharger is a high speed rotating component. It is

prohibited to allow any moving objects (such as hands, tools, cotton yarn) to
approach the inlet of supercharger for prevention of the people from injury
or of machine from damage. No one other than the professional maintenance
personnel on supercharger or professional maintenance station authorized by
WD615
Weichai is entitled to dismantle the rotator assembly;

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

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
After the engine is stopped, if the environmental temperature is lower than
WD615
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
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
WP615 series diesel engine is of high performance product. Maintenance

should be done in accordance with WP615 series diesel engine parts catalogue
and specifications of maintenance manual. Purchased parts must have approved by us in order to ensure performancereliability and service life
WD615

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

CONTENTS
Description of Illustration Marks

1. -------------------------------------1
Operation Description
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. -----------------------------------------59
Electric System
8. -----------------------------63
Adjustment and Replacement of Main Parts and Components

9. -------------------------------107
Typical Troubles and Remedy
WD615
Description Of The Illustration Marks

()
Dismounting (assembly
parts)
Oil coating
()
Fitting (assembly parts)
S K
KUKKO,TSW
Special tools, such as K--- ---,
KUKKO, --- ---, TS--- ---W
Marking (do before

disassemble, adjust when
assemble)
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

equipment)
(loose-proof-fixed) Coat
fluid sealant
Clamping (such as: reinforcing clamp

equipment)
Accident preventing (marks

for dangerous occasion)
Inspecting-adjusting (such as:

tightening torque, dimension pressure
and clearance)
Replacement when reassembly
Inspecting

Maintain and Repair WD615 Diesel Engine

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WD615

Maintenance Manual for WD615 Series EuroDiesel Engine

Design code for developed

Basic product code

Single cylinder displacement

First oil change period:

Perform daily maintenance work as specified in this manual.

Inspect the coolant level

Inspect the fuel level

Inspect the lubricating oil level

Put the gearlever at empty gear-matching position

Low temperature starting

With electronic control flame preheating device

electronickeythe preheating indicator lightingthe heating plug is heatedand the preheating

With low temperature auxiliary starting device

Engine'S running stop

Put the hand-accelerograph of injection pump at zero positionstop the engineand

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 fixed well;

Inspect rotary speed is stable.

Annual running mileage of the

Annual running mileage of the

vehicle more than 6104km for

vehicle less than 610 4km,,

long distance transportation.

for short- or medium-distance

transportation (for goods).

Under severe operating

Tighten pipe clamps

Air intake system

Tighten pipe clamps

Air intake system

Tighten pipe clamps

Air intake system

Tighten pipe clamps

Inspect and adjust the

Air intake system

Tighten pipe clamps

Check the bearing

Inspect and adjust the

Preventive maintenance should be

Before starting the engine

Fast wearing parts

Inspect the oil level height

When the oil level is lower than the

After the engine stopped inspect

Inspect the coolant level

Inspect the coolant level through the

Note:When opening the inlet

Inspect the fuel level

Inspect the fan

Check whether the plastic fan is

Inspect the V-belts

Inspect the V-belts with your

Drain off the water and deposit from

Unscrew the bottom bolt of the

The following contents will

Replacement of the oil and oil

The oil will be polluted after