Ma TN) cs * a Ld CHINA FAMOUS TRADEMARK CHINA TOP BRAND MDE se Lieb sD eee eid ee Operation and Maintenance Manual for WD615 Engineering Series Diesel Engine Sea oI] fag WEICHAI POWER CO. .LTD:WEICHAI hm ew * om & Me | CHINA FAMOUS TRADEMARK. CHINA TOP BRAND, iat Sie oI TI AS 1 FS BR WEICHAI POWER eeOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL Special Attention @ In order to protect the lawful right and interests of users, it is forbidden to dismantle lead seal of injection pump privately. © Once the injection pump is adjusted or lead seal is dismantled, the guaran- tee from our company will become invalid. @ Injection pump is a precision part, it is forbidden to dismantle by users, or the guarantee from our company will become invalid. © Rotor shaft of supercharger is a precision high - speed rotating part, dis- mantling and impacting are forbidden, or the guarantee from our company will be- come invalid. © There are strict requirements for the torque and turning angle of main bear- ing bolts and connecting rod of diesel engine, loosening and dismantling is forbid- den, or the guarantee from our company will become invalid. © Each time before starting the diesel engine, check whether the coolant is full and whether the lubrication oil is enough. © Connecting rod bolts can be used only oncOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery 6. . The WEICHAL Points for Attention el engine has beenstrictly tested according to the testing specifications when it is delivered from our company. ‘The throttle is limited by lead seal. It is forbidden to remove the lead seal and increase the throttle power at will. Other- wise our company will not be responsible for the three guarantees for the prod- uct; the customer is kindly requested to pay attention to it. . The diesel engine operator must read carefully the operation and maintenance manual, get familiar with the structure of this machine, strictly observe the op- eration and maintenance regulations specified in the manual. . When the customer uses a new engine, it is necessary to perform 50 — hour trial running. . Mier starting the engine from a cold state, do not increase the engine speed suddenly, and do not run the engine at idle speed for a long times After run- ning with heavy load, do not shutdown the engine immediately, after running at idle speed for 5 ~ 10 minutes, and then shutdown the engine. . After shutdown, if the ambient temperature is likely to drop to-below 0 C while the engine is using a coolant without antifreeze additive, it is necessary to drain the water in the water tank and the diesel engine. It is forbidden to run the diesel engine without air filter, so as to prevent the un- filtered air from entering into the cylinder. . When filling the diesel engine with fuel and oil, it is imperative to select the specified brands and use special clean container, and they should be filtered with strainer mesh. Fuel must be precipitated for more than 72 hours. . The check and repair of the components for the electric system should be con- ducted by the personnel who are familiar with electrical knowledge.Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL 9. The preservation period for the diesel engine is | year. If the time exceeds 1 year, the engine should be checked and necessary additional measures should be taken. 10. Feedback of engine quality information Our company practises the system of quality follow - up to WD 615 series diesel engine product and setting up files. When the customers use the prod- ucts, please fill in the cards according to the requirement of the cards and send them back to out company. We will set up contact with the customer ba- sing on the cards.Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL Foreword WD 615 series diesel engine is a high speed diesel engine made in China by adopting the technique introduced from foreign country. ‘This engine possesses the advantages of compact structure, reliable operation, advanced economic and speci fications, rapid starting, simple handling and convenient maintenance. WD615 series diesel engines for engineering machinery are made by out com- pany on the base of digesting and absorbing the advanced technology of foreign country, on the condition that the internal structure and major components of origi- nal Steyr diesel engine for vehicle are remained unchanged or less changed, by making improvements on the combustion system, air inlet and exhaust systems, cooling and lubrication systems, power output and transmission system and the diesel engine supporting, widen the rotating speed range and power application range to meet the requirements of engineering machinery markets at home and a- broad on diesel engine power. ‘This series diesel engine is mainly used on engineer- ing machinery such as loaders, dozers, excavators, and cranes. This manual introduces the key specifications, performance parameter, struc- tural features, operation and maintenance methods and outline of repair for the per- sonal concerned to look up. In order to make WD 615 series diesel engine serve the customers still better and put its efficiency into full play, the customers are expected to thoroughly un= derstand the structure of the diesel engine and grasp the maintenance and operation methods. Service life of the diesel engine will be extended greatly provided that the customer can do a good job in maintenance cording to the regulations. ‘ies of modified models of WD 615 se- ries diesel engine for engineering machinery, there will surely be continuous im- With the continuous increasing of va provement in the structure, Please pay timely attention to the technical information issued by our company, and the customers will not be informed about the altera- tions. To obtain the latest information, the customer (or dealer) may visit www. weichai. com. June, 2007Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL Table of contents Longitudinal and lateral sectional views of WD 615 Series diesel engine External characteristic curve of WD615 series diesel engine for engineering machinei External view of WD 615 series diesel engine for engineering machinery Chapter 1 Technical Survey 1.1 Main Technical Specifications of WD615 Seris Diesel Engine for Engineering Machinery and Its Matched Machine Model and Structure Features “17 a7 1,3 Tightening Tongue and ‘Tightening Method of Heavy Duty Bolts of Dicsel Engine --+ 29 Chapter 2 Fuel, Lubricant, Coolant and Auxiliary Material Used for Diesel Engine «+» 32 Chapter 3 Main Structure of Diesel Engine and Its Replacing and Adjusting Methods «+ 35 3.1 Cylinder block and crankshaft box 3.2 Cylinder head 3.3 Piston 3.4 Link rod 1.2 Fitting Clearance and Abrasion Limit of Main Componentsof Diesel Engine 3.5 Crankshaft -6 Flywheel housing and flywheel 7 Power output device .8 Air intake and exhaust system 9 Valve mechanism 10 Electric equipment <1 Fuel system 12 Lubrication system 13 Cooling system ~ 3 3 3 3 3 3 3 3 3.14 Air compressor + 3 15 Cold starting device + 3.16 Clutch Chapter 4 Installation and Coupling of Diesel Engine -Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL 4.1 Hoisti ng of the diesel engine =-+--+--++ 4.2 Installation of the externally connected systems of the diesel engine -+++++ 5 Chapter 5 Operation requirement and precaution of diesel engine - Chapter 6 Peri lic inspection and technical maintenance work of diesel engine +--+ 79 Chapter 7 Common troubles and remediesOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL Longitudinal sectional view of WD 615 Series diesel engineOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery _ WEICHALOperation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL Me [Nm Me 1200: 1000 800 600 Nefkw] 220 Ne 200 180 = 160 [AW] 20 210 ee 200 1200 1400 1600 1800 2000 2200 Full Load Speed Characteristic Curve of WD615.68GA Diesel EngineOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL Mo (Nm 1000. Me 800 NefkW} 180 600 170 160 150 Ne 140 = 130 120 fe 110 [oskwny 240 100 230 0 220 S 80 210 200 pe erg fgg gt bitty 1000 1200 1400) 1600 1800 2000 2200 fein] Full Load Speed Characteristic Curve of WD615.64G Diesel EngineOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL Me [m) 920 390 Me 860 830 ‘800 70 m0 Ne{kW] 160 40 Ne 120 ® 100 (ew) ij 240 80 230 5 220 210 200 Rea ef ga 1000 1200 1400 1600 1800 2000 2200 sefnin) Full Load Speed Characteristic Curve of WD615.67G3 -28 Diesel EngineOperation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL Me (en) 00) NelKW] 130 Ne = 80 lark] 220 aus 210 205 900 1000 1200 1400 1600 1800 2000 fein] Full Load Speed Characteristic Curve of WD 615. TI -3A Diesel EngineWEICHAL Me Wa Me 110 1009 4 ovo a s00 180 L Xe 10 v0 we ® 19 wane) ao % 210 20 pe 9001000 1100200 1300 10915001600 TO 1800 sain Full Load Speed Characteristic Curve of WD615. 68 GA -1 Diesel EngineBP etig ier lt par 960 Flybe! rear en face 951 4 418 strat ge E Tis. 1 NPT3/8 ting va to ale. A swe‘ Partial View of Air Conprossor Ae inlet Ar cutleg ao a 230 ey i ae Crash center External view and installation diagram of 4D 615,67 G 3-28 type Diesel EngineFE ager utlet pipe os, a me a at Revd Tineriow of rer terme sa pr) View D Year eo fie of pve esses { 2 i Heetiog water oie g D f 5 3165 1 27 351 40 359 x20 Zine Dimensions of ot pressure Sensor port 303 Tse Partial View of Air Coapressor External view and installation diagram of WD615.00 G4 Diesel Engine sue Vater tank outletPartial eof Bie Bnd a ad Fee External view and installation diagram of WD 615. T1-3A Type Diesel EngineOperation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL CHAPTER | TECHNICAL SURVEY OF PRODICT 1.1 Main Specifications, Matching Models and Structural Features of WD615 Series Diesel Engine for Engineering Machinery 1 [syle Jé~yinder, inline, 4~ stoke, water cooled, dry eyinder sleeve, dire injection 2 |Bore/stroke ‘om 126/130 3 Inspiration syle Sapercharging 4 |Rated power ating speed IFNI62KW2200(GB/T6072. 1) 5 | Masi torque _N>mke 843(86) 6 | sn ed ri asa Fal orsamptionnte tre pet - - | 7 Jing eat C/A”) sus _ ~~ Minin fuel consumpin rte 8 Sn napa) S25(158.1) agit 9 il -feleensumption rio. 50.5 Permissible ange of [Long | <0 10 Jnelination (°) at. 225 - Extemal dimensions ur] BETA” Yara wos [PUM 162 | ase | stoners wo fan and water tank are included | _|(Ai ier is rt Advance angle of fuel. supply 12 Vcranshaft tuming angle) al 13 [Supercharger type K29 1905 -2,192,CI90B, CF42 14 JOdter diate feast fan nan] 9670 780 610 i ST loader, Main matching types of vehicles Si 7100 ak 15 T derrick, fork lif] ST oader zis0F = peeocas ‘and agitator truck HAS ko: I employs 8. kW [It employs the oft employs the oil Ieemploys the oit |Mempeys 8: peal 1 eae ea i er, wi oump of off-road ump of off - sump of off-road Jamoant ofthe fan is vehicle, fuel irhiele, fuel ashi, 17% greater than injection pump with [injection pup with 1g [in said ot ed eon, ase Pent [earn Se fe engine ee ann nen cad |PO70 fatty and it land doublestage oil land doublestage oil suokegovemon amd ass 6138 Aywheel [pump. Ituses [pamp. It uses 670 ain Wass housing. ‘The rest of 780 exhaust fan exhaust fan, SAEI R670 exhacat fan, {the structure is the and SAEI flywheel [ywheel housing and} same with 67 G3, housing. RW state, ITsOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL No, 6163 6163-294 [7 {Oi pressure at rated if 17 |eperating conditions I My it pressare at idling 18 ond __ kes Live | 19 [Oil capacity (oil sump) | 2» 20 » 0 20 [Fuel Siter type Double stage carsdge type 21 {Oi fier ype paper eartedge, dual ~ drum in parallel Thennosiat | Open ne ms2 a2 nl (ome temperature" a2 _|| a2 conbvatin) |rempentrec | ® 2 S Mal and type 23] Stater [Power KW) DC self ~ exciting type KB ~24V8, KW Vohage —V Model and type tegrated type of rectification and voltage regulation JPE221 ~28V35A 24] Generator [Power kV Voltage V4 Bore 75mm, sioke 38mm, tos! displacement 168en* operating pressure SOOKPa, 25 | Air compressor meximam pressure 1000KPa, transmission ratio with engine 1.25, pressure lubrica- tion, continuous oper cooling 26 | Remarks 18+Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL No. 6103-3 6703-33 6763 -36 6163-364 f 6 cylinder, inline, 4 — stroke, water — cooling, 7 1 [Type dry cjinder sleeve, diret injection 2 |Bore/stroke wm 126/130 Inspiration syle Sopereharging 4 [ated power = oaing speed TFN1G2KW ~ 2200p GB/TOT2. 1) TEMISW 220m 5 [Maxis torque N+m(hgf-m) 883(86) 855 6 [Retting sped at maxon iwi ‘aes 7 ‘pol = Foe emma nee a ted cpt 7 Viggame Gh) mati) Minion fal consumption rate 8 a et <215(158.1) <215(188.1) 9 Jo fod consumption mio <0.5 <0.5 to | Pemissible lie <2 inclination angle(°) Lat <5 Extemal dimension [1452 «740 x 1140 u LxWxll mm Cir inh eee ore ay [600 «865 2072 (fan and water tank are ince) er kis ack!) [A Her Advance ange of fet suply 3 12) "Cerankshalttuming ange) alr 13) Supercharger type K29 1905 ~2,192, COB, GP42 780 610 16 160 Main match ypes of vehiles at 21506, 1s [iain zis0¢ 21806 msc | yf! ae temple the ot | employs the oi) [temps & KW sup of -roed_ sump of f'-rood_|stater, enount of hile, fil chee, fc neton| wn ofthe fan 7 [pup vih dole |punp wih dauble | greater than tat Sgr fall ~ ape fill ~ of crn! 470 nkegnemor and farnkegnemor and fen. The center |nagtic, 700 Man sti: au uestge cil fintensfed double diane betwoen the fechas fa The mst 16 ‘ ainp. Tess 4780 |sage ol yanp. (fan and he isthe sane with ofthe disc engine fechas fan end 8. | Amante rnd of foransb s change [673 36, TW stator, The [the fn i neeased_ [to 40, ht has te ecter distance |hy 73 as compared [pall ed mechanism een the fan and |vth the comet ft ys 6135 Abe the cls is |e>6N fan, Huss 8 hosing, The nse of changed toi. [TW star the scr ete sane as 671 3. 119+Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL No.) tte 6763 314 6163-33 6163-36 (6163 -36A 17 [Oil presse at rated operating] ren “TI eonditions kPa | 18 [Oi pressure at ile speed KPa 19 Oil quantity (oil sump) 20 20 20 20 [Fuel fier type Double stage carrdge type 21 [oil filter type ne Serew ~in paper eatridge dual ~ drum in parallel Ives (ea apt 1s2 nad na 142 22 faze, coe — bay {combination ely gee, a 2 2 2 Model and type be pe 23] Sater [Power kW self exciting type self exciting RB-24V -8, 1kW RB-24V -8, Voltage V Mel and type 24 | Generator [Power aw] "teat type of rectification and voltage Integrated type of rectification and volage| regulation28V/25A reglation 28 V / 55.4 Voltage V Bore 75mm, travel 38mm, total displacement 168em*, operating pressure 8OOKP-, 25 | Air compressor maximum pressure LO00KPa, transmission ratio with engine is 1.25, pressure lubricac ton, continuous operation and air cooling 26 | Remarks + 20+Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL Nes gaat oc ons, 686 686-2 — 6 ~ cylinder, | | [pe _ dry cylinder sleeve 7 _| 2 |Bore/strke mm 1267 3 [Inspiration type Natur igi Natural inspiration | Mpetcharging —/ — supercharging intercooled imercaled ’ TEN225KW — IFNLI8KW ~2000pm IFN213RW 4 [Rated power ~ rotating speed (GB/T6072.1) 2200rpm (Co) 5 [Maximum torque Nem(kgfom)] 617(63) 611163) 12020123) | 1250(127.6) [Paste te eaten |" 5 25 1390 450 1300 50 1300 +50 Fad nmin ne tel cpt 7 Vogontin erawayigren] <28(175.2) | 250 times, solenoid valve = 1000 times. Control 2 2500 times (6) Under the condition that the ambient temperature is higher than 10°C and lower than 23 °C, though the device participate in the starting, if the driver does not want to use the de- vice under certain circumstances, he can start directly, and the device will stop operation auto- matically, and it will not affect the starting process. 3.16 Clutch ‘The single ~ plate clutch group provides the function of torsional vibration damping and special damping at engine idle, but it mainly funetions as the power output coupling of the diesel engine and gearbox. ‘The diesel engine on which SAEI flywheel and flywheel housing are attached, should be fitted with No. 1 clutch housing (i.e. , SAE 1), the type of the clutch is GF 420, diameter of the driving dise is @ 420 mm, diameter of engine flywheel is @ 484 mm. Diameter of the eire- umference, where the holes of the fastening bolts for connecting the flywheel with the clutch , is © 450 mm. ‘The diesel engine on which SAE2 flywheel and flywheel housing are attached, should be fitted with No.2 elutch housing (i.e. , SAE 2), the type of the clutch is GF 380, diameter of the driving disc is @ 380 mm, diameter of engine flywheel is @ 444 mm. Diameter of the eire- tumference, where the holes of the fastening bolts for connecting the flywheel with the clutch, is, 410 mm, Diesel engine for dozer is generally equipped with special power takeoff unit. Clutch is not listed in the basic acces ory arrangement. “BeOperation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAL Diesel engines for engineering machi re generally matched with torque converter at the output end of flywheel to realize power takeoff. ' ve Vea) (tte i KI Starter electrouagnetic svitend He? pe K I+ Key switeh K 2 Starting button om wo om DL “Indicator Tight " 8 2 D+ - Generator connector li | 1 = Relay I II Relay TT L P ~ Flame preheating plug | DU Soloeead vale . RT ~ Temperature transducer alb, gle a 1 Hi 7" uae was | 3 ha 2 io To f t Bal | 3 sn [2 EH 3 T Ta 42.5 £0.15 a B03 seas a Bret Fig .3 ~34 Blectrie principles and outside view of the electronic control unit 74sOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL CHAPTER 4 INSTALLATION AND COUPLING OF DIESEL ENGINE 4.1 Hoisting of the diesel engine Outside dimensions and weight have been given in the main technical data table, and the hoisting positions are specified in design. ‘The diesel engine can only be hoisted via the hanging ring bolt on the hanging ring clamp or the hanging plate on the main bolt of eylinder head, and no other positions should be used for hoisting. When hoisting, the crankshaft centerline of the ‘engine should be kept level. It is forbidden to hoist aslant or hoist with one side, Lifting and lowing on seat should be slow (see Fig. 4-1). Fig. 4-1 4.2 Installation of the externally connected systems of the diesel engine ‘The exhaust pipe of the diesel engine should be connected to outdoors, the excessive ben- ding for exhaust pipeline should be avoided, and expansion joint should be fitted in the pipe- line, Additional support should be available for the pipeline. ‘The exhaust back pressure should not exceed 6 kPa. @ Rain shield should be used on the exit of exhaust pipe positioned outdoors. To drain out the condensed water in the exhaust pipe smoothly, a drain valve may be fixed at the lowest po sition of the exhaust pipe. © ‘The air inlet positioned outdoors should be fitted with water guard so as to prevent rain from entering the system, © The fuel tank capacity should satisfy 8 hours operation of the diesel engine at nominal load condition. It should be so positioned that its outlet is not lower than the inlet of fuel supply pump of the fuel injection pump. The diameter of the fuel pipe should not be less than 10mm. aiislwOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery CHAPTER 5 OPERATION REQUIREMENT AND PRECAUTION OF DIESEL ENGINE 5.1 The oil used in WD 615 series diesel engine must be CD grade or higher, 5.2 The preservation period of the diesel engine is 1 year. If the time exceeds 1 year, the engine should be checked and necessary additional measures should be taken. 5.3 Depreservation of a new diesel engine Mer opening the packing box, customer should first of all check the amount of the acces- sories as per the packing list, check to see whether there is damage on the surface of the diesel engine, whether the connector are loose, and then do the following: (1) Wipe the anti - rust layer and anti corrosion agent on the exposed parts of the diesel engine. (2) Drain the preservation oil in the fuel filter and in the components of the fuel system (It is permissible to start the engine without draining out the preservation oil. But it is impera- tive to nun the engine at full load only after the preservation oil in the fuel system is completely consumed and normal diesel fuel is supplied). (3) Check whether the water plug and oil plug are in good condition, and check whether the water temperature and oil pressure transducers are complete. ‘Those components that should be prepared by you, must be ready. 5.4 Starting of the diesel engine (1) Preparation before starting Check whether all the parts of the diesel engine are in normal conditions and whether the connections of the diesel engine accessories are reliable, and remedy the abnormal phenomena; Replenish the coolant, fill oil to the specified oil level and add the required fuel quantity. Check whether the connections of the starting system wirings are normal, and whether the battery is sufficiently charged. ‘When everything is normal in the inspection, open the concemed valve of the fuel tank and expel out the air in the fuel system with the hand pump on the fuel supply pump. (2) Starting, in normal temperature Push the handle of the speed governor to a proper position ‘Tum the electric key to ON position, press down the starting button to start the engine. If the engine fails to start up in 5 seconds, release the button immediately. Waite for 1 minute iGOperation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAI performs the second starting. If the engine cannot be started for three successive times, the starting should be stopped till the reason is found out and the fault is remedied. AAs soon as the diesel engine is successfully started, release the button and turn the electric key back to the neutral position. At the same me, wateh the readings of the instruments, es- pecially the oil pressure gauge. When the rotating speed of the diesel engine is 600 pm, the oil pressure should not be lower than 100 kPa. ‘Then let the diesel engine run at 600 ~ 700 rpm for a period of time (the time should be controlled within 10min. ), and check whether the opera- tions of various parts are normal. See to it that cold engine should not run at high speed. (3) Starting of the engine equipped with electronic program control flame preheating unit When the engine water temperature is lower than 23 °C, tum on the electric key switch, the preheating indicator light comes on, the heater plug is energized to warm up. After S0seconds, the prehe ing indicator Light flashes automatically, the heater plug is heated to 850 ~950 °C. Press down the starting button to energize the starter. ‘The solenoid valve opens the fuel passage automatically to supply fuel to the heater plug for performing the flame preheating starting. This device can make the engine start smoothly at the temperature of —25 °C. For the engines used in extremely cold climate districts, special measures should be taken, such as heat preservation of the engine, adoption of low temperature battery, and the use of oil and fuel of particular grades. 5.5 Operation of the diesel engine After starting up, the diesel engine should run at idle speed for a few minutes. ‘Then grad ually raise the rotating speed to 1000 ~ 1200 rpm and then enter partial load operation, ‘The en- gine is allowed to tum at full load operation only when the outlet water temperature is higher than 60°C and the oil temperature is higher than 50°C. Load and rotating speed should be in- creased gradually, and try your best to avoid sudden increment and sudden decrement of load. Warning It is inadvisable for a new engine to run at full ~Ioad at the very beg A ning. It should run at subpower (not more than 80 % of rated power) for about 50 hours to improve the breaking in conditions of the moving parts of the engine, so as to enhance the engine’ reliability and extend its service life. Diesel engine should be matched with engineering machinery of equivalent power. Diesel engine can often operate under the standard operating conditions, but it is inadvisable for it to “TTOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAI operate under high torque operating condition for a long time, otherwise the engine is likely to malfunction, ‘The load should not be too low either. If the rotating speed is too low, on one hand it is not economic, and on the other hand the faults such as blow ~ by oil are likely to oc- cur. During the operation of the diesel engine, pay attention to the variation in instrument read- ing. If there is any abnormal phenomenon, check and remedy it in time. 5.6 Shut down of the diesel engine (1) Normal shutdown Before shutt down, unload it first. Then adjust the fuel supply speed regulating handle to reduce the rotating speed gradually to 600 ~ 1000 rpm and run a few minutes. Then operate the shutdown handle to stop the engine. After shutdown, the electric key should be tured to the middle pi After shutting down the engine in winter or in cold regions, if antifreeze additive is not ion to prevent the reverse current from the battery. added in the coolant, it is imperative to open the drainage valves or water plugs on flank of en- gine body, radiator and on the water inlet pipe to drain the coolant completely, so as to prevent the crack of the engine due to freezi (2) Emergeney shutdown In order to prevent the diesel engine from severe accident under emergency or special con- ditions the emergency engine shutdown should be taken. Under such a condition, at this time, pull back the fuel cutoff handle quickly, besides, the shutdown can also be realized by cutting off the fuel supply pipe of the high pressure fuel pump, blocking up the inlet of air filter or the outlet of muffler. 178+Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL CHAPTE 6 PERIODIC INSPECTION AND TECHNICAL MAINTENANCE WORK OF DIESEL ENGINE Correct maintenance is an important link for ensuring normal and reliable operation of the diesel engine and extending the service life of the engine. ‘The customers should maintain the engine periodically according to the technical maintenance items listed in this section. 6.1 Maintenance period of the diesel engine; The first inspection; The diesel engine operates 30 ~ 50 hours Routine inspection (P); The diesel engine operates every 250 hours Level I maintenance (WD 1) ; The diesel engine operates every 500 hours Level 2 maintenance (WD 2); The diesel engine operates every 1000 hours Level 3 maintenance (WD 3) ; The diesel engine operates every 2000 hours Level 4 maintenance (WD 4) ; 'The diesel engine operates every 4000 hours NOTE: The above maintenance period is calculated on the basis that the diesel engine op- erates 1500 hours each year. If annual operating time is less than $00 hours, its maintenance period is 0.5 times of the above period, and if the annual operating time exceeds 1500 hours, its maintenance period is 1.5 times of the above period. 6.2 Work to be done and articles need to be replaced in the inspection and maintenance Item of operation ‘|p | wor | wo2| wos | wos | linspection| Replace the engine oil (at lest once a year) a [alalalala Water pump (lubricated via grease cup) a [alalalala Replace the oil filter ‘A [Backs time when engine oll is repl [ Check and adjust the air valve clearance rr aAvavata Check the opening pressure of fuel nozzle 7 ala Replace the fuel filter avlalala Clean the fuel pump coarse filter [atalala Check the coolant volume and replenish it a [altalalal[a] Replace the coolant Every 24 months 79+Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL “Tighten the clamps of cooling pipe line Tighten the connectors of the air inlet pipeline hoses and flanges Check air filter maintenance indicator light alalala Clean the air filter dust cup (auto dust exhaus- tion type excluded) Clean the main cart alajlalala air filter When the indicator Replace the main cartridge air filter A Replace the safely cartridge of air fil ‘After the main cartidge Check and tighten the V - belt a l[alalalalta Check the supercharger bearing clearance Check the fuel injection pump in the specialized maintenance center Adjust the idling speed A Technical maintenance items may be increased or reduced appropriately based on the difference of diesel engine models, operating conditions and operation experience. Whatever the maintenance is, the removal, inspection and reassembling must be carried out i a planned ‘way and with steps, the tools should he used reasonably, the force should be applied adequate ly, and the fasteners should be tightened according the tightening torques of the specifications. Surfaces should be clean and coated with anti - rust oil or grease so as to prevent rusting. Pay attention to the relative positions of the removed parts and structural features of the non ~ 1e= movable parts, as well as the fitting gaps and adjusting method. At the same time, it is neces- sary to keep the diesel engine and its accessories clean and complete. For inspection of fuel injector, see the Fig. 6-1. Fig 6 +80Operation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery WEICHAL 6.3 Routine maintenance Following items should be fulfilled in routine maintenance of the diesel engine: (1) Check ftel level in the fuel tank and replenish it according to needs (2) Check oil level in th il sump. Oil level should be up to between the two graduations on the dip stick. Fill it to the specified quantity in ease of shortage. (3) Check whether there are the phenomena of three leakages. Eliminate the oil and fuel leakage, water leakage and air leakage on the sealing surfaces of oil, fuel, water and air pipe- lines. And cheek whether the fasteners are loose. (4) Check whether the instruments are normal, othe: repair or replace them timely. (5) Clean the exterior of the diesel engine and accessories. ‘The relevant maintenance must be carried out for diesel engines that have been parked for more than half a year, such as the re ~ preservation of diesel engine. WEICHAL will provide the maintenance suggestions on the request of the customer. BlOperation and Maintenance Manual of WD6IS Series Diesel Engine for Engineering Machinery WEICHAL CHAPTER 7 COMMON TROUBLES AND REMEDIES 7.1 The diesel engine fails to start Cause Remedy 1. Fuel supply pump strainer mesh or fuel passage such as the hose is blocked Check and clear off the dirt, check cleanli- ness of fuel 2. There is air in the fuel system Deaerate. Check scala and repair of connectors 3. The fuel injection pump is in failure Check the plunger and fuel outlet valve, re- pair orreplace the damaged part 4. Fuel injector is in failure Cheek atomization of the fuel injector, repair angle 5. Air distribution or fuel supply is not correct Check and adjust 6. High presoure fuel pipe is damaged and leaks Repair or replace 7. Insul cylinder snt compression pressure of the 8. Air temperature is too low Cheek the sealability of air valves, sealabili- ty of cylinder gasket and abrasion of piston rings. Repair or replace Add auxiliary starting device 7.2. Engine stops shortly after startup 1. Fuel filter is blocked Remove the filter body, clear off the inside dint and water, , replace the cartridge when necessary 2, Air entered the fuel system Check the sealability of fuel pipe and con- nector, whether the ainbleed screw is tight- ened, expel the remaining air 3. Fuel supply pump does not operate Check the piston and valve of the fuel supply pump, clean and repair 4. Fuel quality is poor, containing too much water Clean the filter, replace the fuel 5. Idle speed is regulated too low Readjust +82Operation and Maintenance Manual of WD615 Series Di iesel Engine for Engineering Machinery 7.3 Insufficient power WEICHAI ler is I. Air intake is blocked (air | biocked) Check the air filter and inlet pipe, clean or replace the eartridge 2, Exhaust back pressure is too high Check the valve timing, whether exhaust pipe is blocked, adjust and repair 3. Supercharger system pressure is in insuf- ficient 4. Supercharger malfunctions 4.1 Air compressor and turbine passage are dirty and blocked Cheek and elimi tions of pipeline nate leakage at the conjui Replace the assembly Clean or replace 4.2 Floating bearing malfunctions 4,3 There is coking and oil sludge in the back gap of turbine and air pump 5. Intercooler is damaged and leaks Replace Clean Replace or repair 6. Fuel passage leaks or is blocked 7. Fuel quality is poor 8. Excessive abrasion of fuel injection pump [or speed govemor 9. Fuel injection pump smokes, limiter dia- phragm is broken Check the sealability of fuel pipe and con- nector, dust of the filter, fuel pipe, repair or clear off ditt, replace cartridge Clean the fuel tank, filtration parts and fuel pipe, replace the fuel _| Repair or replace Replace, repair 10. Smoking limiter air pipe is damaged or leaks Replace 11. Poor atomization of fuel ~ injection noz- ale Check the fuel injection pressure. Fuel i jector coking. Adjust and repair 12. Timing of air distribution or fuel suppl | ying is incorrect Check and adjust 13. High - speed adjustment of speed gover- nor is too low 14. Oil level in the sump is too high 15 Cylinder gasket leaks 16. Piston ring is wom or fractured, exces- sive clearance 0 17. Cylinder sleeve or piston is wom or Is Check the governing charact Check the dip stick and drain the extra oil and adjust Check the compression pressure under hot ‘engine condition, replace the damaged cylin- der gasket Replace the worn parts or overhaul the en- scuffing of eylinder bore _ Overhaul the engine 83+Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery WEICHAI 7.4 Excessive fuel consumption 1. Air intake is blocked (air filter is blocked) Cheek the air filter and inlet pipeline, clear off sia | 2, Exhaust back pressure is too high 3. Fuel quality is poor Check the exhaust pipeline and brake valve, lean Replace the fuel according to the specifica- tion 4. Fuel pipeline is blocked 5. Fuel pipeline leaks Check and repaiz Check and repair 6. Poor atomization of fuel injector Check and adjust or repair 7. Air distribution or fuel supply timing is not correct | Adjust the valve clearance and fuel supply advance angle according to regulations 8 . Cylinder gasket leaks Check the compression pressure 9. Excessive clearance of bearing shell, the engine needs to be overhauled Check and overhaul 10, Piston seizing Replace the cylinder sleeve, piston and pis- ton ving IT, Supercuarger system pressure is insuffi- cient Check and eliminate the leakage at the pipe- line and conjunctions 12, Supercharger malfunctions Check and replace the assembly 13, Intercooler is damaged or leaks Replace or repait 7.5 Black exhaust gas 1. Air inlet is blocked or exhaust back pres- sure is high Clean 2. Fuel quality is poor Clean and replace 3.. Fuel supply or air distribution timing is not correct Adjust according to the specification 4, Poor atomization of fucl ~ injection nozzle 5. Excessive fuel quantity of fuel injection pump Check and repair or replace Check and readjust (by specialized factory ) 6. Supercharger system pressure is insuffi- cient Check and eliminate the leakage in the pipe- line and at conjunctions 7. Supercharger malfunetions Check and replace the assembly 8. Intercooler is damaged and leaks Replace or repair 9. Functioning point of smoking limiter is in- correct Readjust (by speciaOperation and Maintenance Manual of WD615 Series Diesel Engine for Engineering Machinery 7.6 White and blue exhaust gas 1, Fuel quality is poor, containing too much water Replace the fuel 2, Cooling water temperature is too low Check the operating temperature of thermo- stat, replace it if necessary. 3. Air distribution or fuel supply timing not correct Check and adjust 4. Poor atomization of fuel ~ injection nozzle Check and repair 5. Compression pressure is low, combustion 1B is incomplete and piston sei Check the piston rings, eylinder sleeve and cylinder gasket, repair 6. Insufficient running — in of piston rings and cylinder sleeve Continue running ~in 7, Piston ring openings are not staggered Adjust, reassemble 8. Fuel ring of piston malfunctions Replace 9. Fitting clearance between piston and eyl- inder sleeve is too big. Repair, replace 10. Sealing ring of supercharger is wom Cheek, replace LL. Supercharger thrust bearing is worn Check, replace 12. Supercharger return pipeline is blocked Clean or repair 7.7 Oil enrichment at the air inlet and exhaust pipe of the supercharger 1. Sealing of supercharger malfunctions Repair or replace the supercharger 2. Deaerator malfunctions Replace 3. Oil level in the sump is too high, exces- sive oil filled Check and drain a suitable quantity of oil to make it satisfy the regulation 7.8 Rotating speed is unsteady 1. Fuel quality is poor, containing water or wax Clean the fuel system, replace the fuel 2. Air entered the fuel suction pipe [3. Speed govemor weights and spring mal- function Check the sealability of fuel pipe and con- nector, expel the ait; Check and repair (by specialized factory) 4. Inequable fuel supply “Check and adjust (by specialized factory) 5. Unsteady atomization of fuel injection nazale Check and repair 6. Supercharger surges Check and clean the air passage of air com- pressor, eliminate fouling and clear off co- king in the exhaust passage 7, Supercharger bearing is damaged Replace +856WEICHAL 7.9 Oil pressure is too low Operation and Maintenance Manual of WD615 Series 1. Oil level in the sump is too low or shoxt of ‘The pressure regulating valve in main oil duct malfunctions k whether th suction strainer, oil pipeline and joint gasket is blocked or frac- tured 4, Oil brand does not satisfy the stipulations 5. Oil inlet pipe of oil pump leaks Check the oil level and whether there is cil eplenish the oil Check the suetion strainer, pipe joint and fu- el duct for loose of easting Replace the oil according to stipulation, se~ lect oil of suitable brand Check the oil pipe and joint, repair or re- place 6. Water temperature in the cooling system is too high oil temperature is too high Check the cooling system operation and eor- 7. Oil filter resistance is too high 8. Oil cooler is blocked 9. M 10. Bear oil passage is blocked Check and clear off Check and clear off shell clearance is t00 big oF the | Oo. ane sepaie shell is damaged 11, Excessive abrasion of the components, | Check the operating hours of the engine, overhaul is needed. overhaul it, 7.10 Temperature of cooling water is too high 1, Water level in the water tank is too low 2. Water tank is blocked Check whether there is water lea ge and Fe plenish the water Check the water tank, clean or repair 3, Water pump belt is loose 4, Water pump gasket is damaged, water pump impeller is, 5. Thermostat is in failure 6. Water pipe is damaged or air seeps in 7. Oil level in the sump is too low or short of oil ‘Adjust the tension force according to the stipulation Replace Check the water pipes, joints and washers and replace the damaged parts | Check the oil level and check whether there is oil leakage, repair and replenish the oil + 86°7.11 Excessive abrasion of the components Air filter eartvidge is not q is blocked 5. Oil brand does not satisfy the regulation fractured or worn WEICHAL wl replace it with qualified cartridge Check the air inlet pipe, washer and co: necting bush, repair or replace | Check the oil level and cheek whether there | leakage, repair and replenish Clean the oil passage 1g to the specification Replace the oil accord Replace the damaged parts ¢ or piston is worn or seuff- bore Remove and check the piston rings and cyl- inder sleeve, repair or replace 8. Oil filter cartridge is not replaced in time Replace it according to the requirement 9. Excessive abrasion of the components, overhaul is needed. 10. Crankshaft and the mainshaft of the driv- en member are misaligned Check the road mileage of the engine, over- haul it Cheek the n nting bracket, repair 11. Quality of oil in use does not meet the requirement “Employ the oil of specified brand that satis- fies the standa 7.12 Excessive noise 1. Fuel quality is poor 2. ‘Temperature of cooling water is too low Replace the fuel Check the thermostat, ,replace if necessary. 3. Air distribution or fuel supply timing is not correct Check, repair and adjust 4. Poor atomization of fuel ~ injection nozzle Cheek, repair and adjust 5. pump Excessive fuel quantity of fuel injection Check and adjust it (by specialized factory) 6. Shock absoxber is damaged 7. Air valve leaks or improperly adjusted “Check whether there is damage, check the conditions of connecting bolts, and replace “the damaged parts Disassemble and check the air valve 8. Excessive gear elearance or tooth fracture Check and replace the damaged parts 9. Cylinder sleeve or piston is wom or seuff- ing of cyl Cheek and repair or replace 10. Push rod is bent or fracturedWEICHAL Operation and Maintenance Manual of WD61S Series Diesel Engine for Engineering Machinery 13. Excessive clearance of crankshaft thrust bear 14, Main bearing shell are not ¢ saligned 16. Excessive abrasion of the components, en member a overhaul is needed. 15. Crankshaft and the mainshali of the driv- | Replace the thrust plate Check and repair Check the mounting bracket bolts, repair Check the road mileage of the engine, over- haul 17. Supercharger surges 18. Sealing ring of supercharger is fritted Remove the fouling in the air passage of alr compressor and clear off coking in the ex- tp Replace the assembly 19. Supercharger bearing is damaged, rota- ng parts impact and rub against fixed parts Replace the assembly 20. Foreign matter enters the supercharger turbine or the air compressor impeller Replace the assembly 7.13 The starter fails to operate 1. Insufficient charging of the battery Check and charge or replace the battery 2, Poor contact of the connecting wire Clean the circuit, tighten the terminals 3. Fuse is melted Replace the fuse 4. Poor contact of electrie brush 5. The starter itself is shorted Clean the surface of electrie brush or replace it Repair the motor or replace the assembly 7.14 The starter is weak 1, Insufficient voltage of the battery Charge or replace the battery 2. Bearing bush is outwom Replace the assembly Poor contact of electric brush Clean the surface of electrie brush or replace it ‘The commutator is not clean or singed Clear off the oil stains and polish it with em- ery paper or replace the assembly 5. Wire terminal is unsoldered Re = solder it 6. Poor contact of switch Check the switeh and repair 1. ‘The wom elutch slips Adjust the operating torque of the clutch ot place the assembly + 88+Operation and Maintenance Manual of WD615 Series Di iesel Engine for Engineering Machinery WEICHAL 7.15 The generator does not generate power completely 1. Wiring is open or shorted, the connector is loose 2. Coils of the rotor and stator is open , shor- ted or grounded Check the wiring of the generator and amme- ter, repair it. Repair or replace the assembly 3. Rectifier is dai 4, Paper insulation is damaged, wiring is broken Repair 5. Voltage regulated by the regulator is too low Repair 6. Contact points of the regulator are burnt Repair or replace the assembly 7.16 Insufficient charging current from the generator 1, Wiring is open or shorted, the connector is loose Repair 2. Coils of the rotor and stator is partially shorted or open Repair or replace the assembly 3. Generator belt is loose Check and adjust the tension force of the generator belt 4. Reetifying tube of the generator is dam- aged or the contact of electric brush is poor 5. Voltage regulated by the regulator is too low Repair Adjust 6. Wiring of the regulator magnetic field coil or resistor is open Repair or replace 7. Eelectrolyte level of battery is too low, or the battery is too old Fill electrolyte, or replace the battery 7.17 Charging current is unsteady 1. Coils of the rotor or stator is about to be shorted or open Repair or replace 2, Poor contact of electric brush Repair 3. Wiring terminal is loose or in poor contact | Repair 4, Voltage regulator is damaged Repair 5. Voltage is improperly adjusted Check and adjust + 89+Operation and Maintenance Manual of WEICHAI 7.18 Charging current of the generator is WDOIS Series Diesel Engine for Engineering Machinery too high 1. The battery is shorted internally 2. Voltage of the 3. The regulator is poorly grounded 4. Regulator contact mi st netions or is 18 of voltage coil or resistor is ed, W open Repair or replace Repair or replace 7.19 Abnormal noise of the generator generator is improperly mounted 2. ‘The bearing is damaged Repair Replace the beari 3. ‘The rotating part touches the fixed part Repair or replace Replace 5. Stator winding is shorted Repair or replace 90°EU een Di -ele7 NTN 1 Molo Re = Peer, Vat ea OC OCA UAE TOD ee ee a A ee Reon EMIT STRAT een OnE en eae aoe ea Ce UP SC CLC azo UIE Service hotTine: 8008603066 E-mail: weichaieveichai.con Website: tt: //imid.wetchat .con