WEICHAI WD615 User Manual

Contents
Chapter I Maintenance for WD615/WD10/WD618/WD12 Diesel Engines
...1
1.1 Daily Maintenance………………………………………………………....3
1.2 Periodic Maintenance………………………………………………….......5
1.3 Maintenance Interval ……………………………………………………...6
1.4 Maintenance Contents …………………………………………….……10
1.5 Replacement of Oil and Oil Filter ……………………………….……..13
1.6 Replace Fuel Filter ……………………………………………….…….16
1.7 Check Air Filter Element …………………………………………….…...17
1.8 Check and Adjust Valve Clearance ……………………………….……19
1.9 Check and Adjust Fuel Supply Advance Angle …………………….….24
Chapter II Key Points about Assembling or Disassembling WD615 Diesel
Engines
………………………………………………..……………………..26
2.1 Assemble Injection Nozzle, Camshaft and Cylinder Liner……………26
2.1.1 Assemble Injection Nozzle …………………………………………..26
2.1.2 Assemble Camshaft …………………………………………………..26
2.1.3 Assemble Cylinder Liner ………………………………………….…27
2.2 Pre-assemble & Assemble Crankshaft …………………………………29
2.2.1 Assembling Steps (1) ……………………………………………..….29
2.2.2 Assembling Steps (2) ……………………………………………...…30
2.3 Assemble Cylinder Body ………………………………………..……..31
2.4 Pre-assemble & Assemble Connecting Stick and Piston ……………32
2.5 The Assembly of the Timing Gear Housing …………………………...36
2.6 The Assembly of Flywheel Housing and Flywheel ……………………39
2.6.1 The Assembly of Flywheel Housing ………………………………...39
2.6.2 The Assembly of Flywheel ………………………………………..…39
2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear…………40
2.8 Tightening Torque and Tightening Method of Main Bolts of Diesel
Engine ……………………………………...………………………………....42
Chapter III Introduction of Fault Case for WD615/618 Diesel Engine
…44
3.1 Diesel Engine Starts Hard …………………………………………….…44
3.1.1 Case Description about Diesel Engine Cannot Be Started (1) ……46

WEICHAI WD615 Specifications

General

Brand	WEICHAI
Model	WD615
Category	Engine
Language	English

Summary

Chapter I Maintenance for WD615/WD10/WD618/WD12 Diesel Engines

1.1 Daily Maintenance

Essential daily checks for engine health and readiness, covering fluid levels, belts, and indicators.

1.2 Periodic Maintenance

Scheduled maintenance tasks to ensure long-term engine performance and reliability.

1.3 Maintenance Interval

Guidelines for determining maintenance intervals based on operating conditions and usage.

1.4 Maintenance Contents

Specific procedures and checks included in routine engine maintenance activities.

1.5 Replacement of Oil and Oil Filter

Step-by-step guide for replacing engine oil and the oil filter element.

1.6 Replace Fuel Filter

Instructions for safely removing and installing a new fuel filter.

1.7 Check Air Filter Element

Inspection process for the air filter element to ensure clean air intake.

1.8 Check and Adjust Valve Clearance

Steps for checking and adjusting valve clearance for optimal engine operation.

1.9 Adjustment of Fuel Supply Advance Angle

Method for adjusting the fuel supply advance angle for correct engine timing.

Chapter II Key Points about Assembling or Disassembling WD615 Diesel Engines

2.1 Assemble Injection Nozzle, Camshaft and Cylinder Liner

Procedures for assembling injection nozzles, camshaft, and cylinder liners.

2.2 Pre-assemble & Assemble Crankshaft

Detailed steps for pre-assembly and assembly of the crankshaft.

2.3 Assemble Cylinder Body

Instructions for assembling the main cylinder body components.

2.4 Pre-assemble & Assemble Connecting Stick and Piston

Guide for pre-assembling and assembling pistons and connecting rods.

2.5 The Assembly of the Timing Gear Housing

Procedures for assembling the timing gear housing.

2.6 The Assembly of Flywheel Housing and Flywheel

Steps for assembling the flywheel housing and flywheel.

2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear

Procedures for assembling front oil seal and camshaft timing gear.

2.8 Tightening Torque and Tightening Method of Main Bolts of Diesel Engine

Specifications for tightening main engine bolts and their methods.

Chapter III Introduction of Fault Case for WD615/618 Diesel Engine

3.1 Diesel Engine Starts Hard

Diagnosis and steps for addressing issues with engine starting.

3.2 Stop Soon after Starting

Procedures for diagnosing and resolving engine shutdown shortly after starting.

3.3 Insufficient Output

Steps for identifying and fixing causes of reduced engine output.

3.4 Fuel Consumption Is Too High

Diagnosis and remedies for excessive diesel fuel consumption.

3.5 Black Smoke Exhaust

Identifying causes and solutions for black smoke emissions from the engine.

3.6 Oil Is Gathered in Inlet and Exhaust Vents of Turbocharger and Inlet and Exhaust Pipe.

Diagnosing and fixing oil accumulation in turbocharger and pipe vents.

3.7 Lubricant-oil Pressure Is Too Low.

Steps to diagnose and resolve low lubricant oil pressure issues.

3.8 Cooling Water Temperature Is Too High.

Procedures for identifying and resolving high engine cooling water temperature.

3.9 The Oil Mixed with the Water

Diagnosing and fixing issues where oil and water are mixed.