Руководство по ремонту двигателя weichai

57,2 Мб

• Год:

  2008

• Страниц:

  698

• Язык:

  русский

• Размер:

  57,2 Мб

• Категории:

Владельцы грузовиков HOWO могут воспользоваться данным каталогом для получения информации о своем автомобиле. Это отличный каталог, который содержит подробные схемы деталей и таблицы с их номерами.

46,5 Мб

• Год:

  2007

• Страниц:

  312

• Язык:

  русский

• Размер:

  46,5 Мб

• Категории:

Отличное руководство для автовладельцев HOWO, которое поможет вам очень быстро отыскать поломку, чтобы заняться ее устранением. К тому же, в руководстве приведено много информации по ремонту и эксплуатации автомобиля.

21,6 Мб

• Год:

  2008

• Страниц:

  66

• Язык:

  русский, английский

• Размер:

  21,6 Мб

• Категории:

Издание предлагает ознакомиться с техническими характеристиками Weichai (Steyr) WD615 – двигателя известного как Steyr (модификационное название) и широко распространенного во всем мире, в том числе и у нас.

42 Мб

• Год:

  2006

• Страниц:

  294

• Язык:

  русский

• Размер:

  42 Мб

• Категории:

Компания HOWO является лидером в сфере производства двигателей для грузовиков. Дизели данной марки широко известны как в ряде азиатских государств, так и в России. Неплохое качество и прекрасная производительность гарантирует двигателям заслуженную популярность.

• Page 1
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Assembly & Disassembly Manual Gas Engine Model: WP6GNA WEICHAI AMERICA CORP.
• Page 2
  Weichai America Corp. Purpose This manual is intended to inform customers on how to assemble and disassemble the Weichai America 6 Liters naturally aspirated engine. This document will be provided to customer so they can incorporate this information into their manuals and service documents.

• Page 3: Table Of Contents

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Table of Contents Disassembly & Assembly of Engine ………………5 1.1 Safety Precautions ………………….5 1.2 Environmental Protection Measures …………….. 5 1.3 Notes for Disassembly and Assembly of Engine …………… 5 Fuel System …………………….

• Page 4
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7.2 Fan Assembly and Disassembly ………………27 7.3 Thermostat Disassembly and Assembly …………….. 28 7.4 Water Pump Assembly and Disassembly …………… 29 Front Cover Components ………………..30 8.1 Torque Vibration Damper and Crankshaft Pulley Assembly and Disassembly ….30 8.2 Gear Housing Assembly and Disassembly …………..
• Page 5
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.4 Assembly and disassembly of crank-rod mechanism……….61 11.5 Assembly and disassembly of piston-rod assembly ……….61 11.6 Assembly and disassembly of crankshaft system ……….65 11.7 Assembly and disassembly of crankshaft bearing shell ……..

• Page 6: Disassembly & Assembly Of Engine

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 1 Disassembly & Assembly of Engine Safety Precautions Please strictly comply with instructions in this manual to safely and properly disassemble and assemble the engine. Environmental Protection Measures Please comply with relevant laws and regulations on environmental protection when handling oil and hydrocarbon waste.

• Page 7: Fuel System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2 Fuel System Fuel System Assembly and Disassembly 2.1.1 Fuel System Exploded View Fig. 2-1 Exploded view of gas supply system 2.1.2 Fuel System Disassembly Procedure 1. Remove ECU.

• Page 8: Lpg Intake System Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. LPG Intake System Assembly and Disassembly 2.2.1 LPG Intake System Exploded View Fig. 2-2 Exploded view of LPG supply system 2.2.2 LPG Intake System Disassembly Procedure 1. Remove the clamps from the gas hose. Separate the hose from the NG intake system.

• Page 9: Ng Shut-Off Valve Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Check the coolant fittings and hoses for leaks. NG Shut-Off Valve Assembly and Disassembly 2.3.1 NG Shut-Off Valve Exploded View Fig. 2-3 Exploded view of electromagnetic valve 2.3.2 NG Shut-Off Valve Disassembly Procedure…

• Page 10: Electronic Pressure Regulator (Epr) Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Electronic Pressure Regulator (EPR) Assembly and Disassembly 2.4.1 EPR Exploded View Fig. 2-4 Exploded view of electronic pressure regulating valve 2.4.2 EPR Disassembly Procedure 1. Remove the socket head bolts and washers bolting the gas pipe joint to the EPR.

• Page 11
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 2-5 Exploded view of mixer Part Name Part Name Part Name Screws Diaphragm Spring Mixer Cover Ring Adjustment Screw Air Fuel Regulator Spring Gasket Valve Diaphragm Screws…
• Page 12
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Reverse the Disassembly Procedure (2.5.2) to assemble the Mixer Diaphragm. 2.5.4 Mixer Diaphragm Inspection and Maintenance If gas flow is insufficient: 1. Rotate the adjustment screw clockwise to increase the flow of gas.

• Page 13: Intake And Exhaust System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3 Intake and Exhaust System Intake and Exhaust System Assembly and Disassembly 3.1.1 Intake and Exhaust System Exploded View Fig. 3-1 Exploded view of intake and exhaust system Fig.

• Page 14
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3.1.2 Intake and Exhaust System Disassembly Procedure 1. Loosen the clamps on the air filter elbow, elbow pipe breather connection, and the mixer hose. Remove the air filter elbow, elbow pipe, and mixer hose.

• Page 15: Intake Manifold Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Intake Manifold Assembly and Disassembly 3.2.1 Intake Manifold Exploded View Fig. 3-3 Exploded view of intake manifold 3.2.2 Intake Manifold Disassembly Procedure 1. Remove the nuts bolting the intake manifold to the engine block. Remove the intake manifold and gaskets.

• Page 16
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 3-4 Exploded view of exhaust manifold 3.3.2 Exhaust Manifold Disassembly Procedure CAUTION: All parts of the exhaust manifold and exhaust elbow will be extremely hot after engine operation.

• Page 17: Ignition System Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Do not reuse exhaust manifold attachment bolts more than twice. 3.3.4 Exhaust Manifold Inspection and Maintenance 1. Check for cracks in the exhaust manifold and deformations in the exhaust elbow flange. Replace the exhaust manifold and exhaust elbow if necessary.

• Page 18: Signal Generator Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 3-6 Exploded view of ignition system 3.4.2 Ignition System Disassembly Steps 1. Unplug the wiring harness connector from the ECU and ignition coil. 2. Remove ignition coil bolts and ignition coils.

• Page 19
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 3-7 Exploded view of signal generator 3.5.2 Signal Generator Disassembly Procedure 1. Remove the connecting bolts of the pump gear and signal generator. 2. Remove the hex nuts between signal generator flange and engine block.

• Page 20: Engine Control Unit (Ecu) Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Engine Control Unit (ECU) Assembly and Disassembly 3.6.1 ECU Exploded View Fig. 3-8 Exploded view of 3.6.2 ECU Disassembly Procedure 1. Remove the fuse box bolts. Remove the fuse box from the bracket.

• Page 21
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. electromagnetic torque. The ring gear mechanism drives the starting engine rotation. The starter motor’s main components are the DC motor, one-way clutch, reduction gear train, electromagnetic switches, and the starter relay. See the dismantled starting system in Fig. 4-1.

• Page 22: Engine Accessory System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 5 Engine Accessory System Engine Accessory System Assembly and Disassembly 5.1.1 Engine Accessory System Exploded View The engine accessory system consists primarily of the belt and alternator. Fig. 5-1 Exploded view of engine accessory system 5.1.2 Engine Accessory System Disassembly…

• Page 23
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 5-2 Exploded view of generator 5.2.2 Alternator Disassembly Procedure 1. Remove the alternator lock nut to loosen the belt if it has not already been removed. Remove the belt from the alternator pulley.

• Page 24: Closed Crankcase Ventilation (Ccv) Breather System Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 6 Closed Crankcase Ventilation (CCV) Breather System Assembly and Disassembly CCV Breather System Assembly and Disassembly 6.1.1 CCV Breather System Exploded View Air Inlet Air Outlet Oil Return Fig.

• Page 25: Ccv Breather Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Hex Nut Rubber Hose Clamp Clamp Formed Hose Bolt Bracket Bolt Oil Return Pipe Hex Bolt Washer 6.1.2 CCV Breather System Disassembly Procedure 1. Loosen the clamps on the air outlet. Remove all air outlet formed and rubber hoses.

• Page 26
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 6-2 Exploded view of CCV breather Fig. 6-3 Schematic diagram of disassembly 6.2.2 CCV Breather Disassembly Open the top cover of the breather by tool or hand. Remove the breather filter element.

• Page 27: Cooling System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7 Cooling System Cooling System Disassembly and Assembly 7.1.1 Cooling System Exploded View The cooling system ensures that the engine can operate at the proper operating temperature. Forced circulation cooling is most effective at keeping the engine within the normal operating temperature range.

• Page 28: Fan Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 7. Remove the middle cushion block of water pump. 7.1.3 Cooling System Assembly Procedure Reverse the Disassembly Procedure (7.1.2) to assemble the Cooling System. Fan Assembly and Disassembly 7.2.1 Fan Exploded View…

• Page 29: Thermostat Disassembly And Assembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Thermostat Disassembly and Assembly 7.3.1 Thermostat Exploded View Fig. 7-3 Exploded view of thermostat 7.3.2 Thermostat Disassembly Procedure 1. Loosen the clamps around the hose connecting the water pipe and thermostat. Remove the hose.

• Page 30: Water Pump Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Water Pump Assembly and Disassembly 7.4.1 Water Pump Exploded View Fig. 7-4 Exploded view of water pump 7.4.2 Water Pump Disassembly Procedure 1. Remove the water pump pulley.

• Page 31: Front Cover Components

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 8 Front Cover Components Torque Vibration Damper and Crankshaft Pulley Assembly and Disassembly 8.1.1 Torque Vibration Damper and Crankshaft Pulley Exploded View Fig. 8-1 Exploded view of damper, pulley, and hub 8.1.2 Torque Vibration Damper and Crankshaft Pulley Disassembly Procedure…

• Page 32: Gear Housing Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Tightening torque: 60~70Nm; Test value: 65~80Nm. 8.1.4 Torque Vibration Damper and Crankshaft Pulley Inspection and Maintenance 1. Check the crankshaft pulley for any damage and distortion. Replace if necessary.

• Page 33
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Bolt Bolt Front Oil Seal Bolt Shaft Bolt Intermediate Oil Fill Plug Shaft Intermediate Gear Washer Plate Stud Bolt Bolt 8.2.2 Gear Housing Disassembly Procedure 1. Remove the intermediate gear.
• Page 34
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-3 Locating pin installation for Gear Housing (2) Apply sealant on the sealing surface of the Gear Housing. Ensure that the sealant is evenly distributed and continuous.

• Page 35: Intermediate Gear Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-5 Gear Housing installation (4) Place the bolts with gaskets in their corresponding holes. Tighten them with a pneumatic impact wrench and an open-end wrench. Key Point 2: Assembling: Oil seals and seal rings should be checked before assembling.

• Page 36
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 8-6 Exploded view of intermediate gear 8.3.2 Intermediate Gear Disassembly Procedure 1. Locate the four M10 bolts to be removed. 2. Remove four bolts and the washer.

• Page 37: Cylinder Heads And Valves

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. or pin-shaft for any wear. Check the oil passage for any blockage. 9 Cylinder Heads and Valves Lifting Lugs Assembly and Disassembly 9.1.1 Lifting Lugs Exploded View Fig. 9-1 Exploded view of lifting lugs 9.1.2 Lifting Lugs Disassembly Procedure…

• Page 38
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 9-2 Exploded view of cylinder head cover 9.2.2 Cylinder Head Cover Disassembly Procedure 1) Loosen the cylinder head cover bolts. Remove the bolts and the washers. 2) Pull the covers up vertically to remove them. Remove all gaskets.

• Page 39: Rocker And Rocker Shaft Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Rocker and Rocker Shaft Assembly and Disassembly 9.3.1 Rocker and Rocker Shaft Exploded View Fig. 9-3 Exploded view of rocker and rocker shaft 9.3.2 Rocker and Rocker Shaft Disassembly Procedure 1.

• Page 40: Tappet And Pushrod Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ⑤ Install valve pushrod, refer to assembly of valve pushrod for details; ① Pre-tighten rocker seat, align rocker adjusting screw socket head to valve pushrod round head, tighten the hexagon bolts to 40~45Nm.

• Page 41
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 9-4 Exploded view of tappet and pushrod 9.4.2 Tappet and Pushrod Disassembly Procedure 1. After removing rockers and rocker shafts, pull the pushrods out vertically. 2. After removing camshaft, directly take out valve tappet, place them orderly;…

• Page 42: Cylinder Heads Assembly And Disassembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2. Ensure that the oil channels of valve tappet and pushrod are smooth. 3. Ensure that the pushrod is not crooked. Check wear condition on the outside surface.

• Page 43
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Remove the cylinder head gasket. If more than one cylinder head gasket needs to be disassembled, mark the cylinder number on the gaskets for reference. 4. Remove the intake and exhaust valve module. Refer to disassembly of valve mechanism (9.6) for details 5.
• Page 44
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Clean the cylinder head, focusing on the combustion chamber surface, valve seat, intake and exhaust valves, and intake and exhaust passages. Remove the carbon deposits and mucilage glue, and check the surface condition.

• Page 45: Assembly And Disassembly Of Valve

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3. Clearance between valve rod and valve guide pipe: Internal surface of valve guide pipe is the contacting surface between valve rod and valve guide pipe, if clearance between valve rod and valve guide pipe exceeds allowed value due to abrasion, then the guide effect will at state, which may affect reliability of the engine.

• Page 46
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 9- 9 Exploded view of valve 9.6.2 Steps to disassemble valve ① Depress valve springs with vale spring compressor or valve overhead plier or other tools, take out valve lock clamp, upper valve spring seat and lower valve spring seat and valve springs orderly;…
• Page 47
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 9.6.4 Inspection and maintenance of valve ① Check whether valve rod and its end faces are worn; ② Check whether valve conical surface is worn or damaged; ③ Check valve conical surface and retainer end faces for carbon deposit;…

• Page 48: Oil & Lubrication System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10 Oil & Lubrication System 10.1 Assembly and disassembly of oil sump. 10.1.1 Exploded view of oil sump. Fig. 10-1 Exploded view of oil sump 10.1.2 Steps to disassemble oil sump.

• Page 49: Disassembly And Assembly Of Engine Oil Strainer

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Apply sealant on fitting surface of engine block and partially apply sealant on oil sump, place sealing gasket on the fitting surface. Lift and place oil sump, be careful and avoid crashing the fitting surface.

• Page 50: Disassembly And Assembly Of Lubricating System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10.3 Disassembly and Assembly of Lubricating System 10.3.1 Exploded View of Lubricating System Fig. 10-3 Exploded view of lubricating system 10.3.2 Steps to Disassemble Lubricating System ① Remove oil sump, refer to disassembly of oil sump for details.

• Page 51
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 10- 4 Exploded view of piston nozzle 10.4.2 Steps to disassemble piston nozzle. ① Remove the hexagon bolt (key point 1) ② Remove the piston nozzle (key point 2) 10.4.3 Steps to assemble piston nozzle…

• Page 52: Disassembly And Assembly Of Engine Oil Pump

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 10.5 Disassembly and Assembly of Engine Oil Pump 10.5.1 Exploded View of Engine Oil Pump Fig. 10-5 Exploded view of engine oil pump 10.5.2 Steps to Disassemble Engine Oil Pump Remove the two hexagon bolts and self-locking nut, take down engine oil pump, as shown in Fig.

• Page 53: Disassembly And Assembly Of Engine Oil Cooler

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 10-6 Exploded view of engine oil filter 10.6.2 Steps to Disassemble Engine Oil Filter Remove the filter with dedicated tool, as shown in Fig. 10-6. 10.6.3 Steps to Assemble Engine Oil Filter 1) Check the O-shape seal ring of engine oil filter before assembling, make sure there is no manufacturing defect and damage, replace the O-ring if necessary.

• Page 54: Disassembly And Assembly Of Main Oil Gallery Pressure Limiting Valve

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 10-7 Exploded view of engine oil cooler 10.7.2 Steps to Disassemble Engine Oil Cooler Loose the connecting bolts and take down the cooler, as shown in Figure 10-7.

• Page 55: Disassembly And Assembly Of Deputy Oil Pressure Limiting Valve

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 10-8 Exploded View of Main Oil Gallery Pressure Limiting Valve 10.8.2 Steps to Disassemble Main Oil Gallery Pressure Limiting Valve Screw off main oil gallery pressure limiting valve, as shown in Fig. 10-8 10.8.3 Steps to Assemble Main Oil Gallery Pressure Limiting Valve…

• Page 56: Crank-Rod Mechanism

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 10-9 Exploded view of deputy oil pressure limiting valve 10.9.2 Steps to Disassemble Deputy Oil Pressure Limiting Valve Screw off and take down deputy oil pressure limiting valve, as shown in Fig. 10-9.

• Page 57
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 11-1 Exploded view of flywheel housing 11.1.2 Steps to disassemble flywheel housing ① Remove fixing bolts of flywheel housing (Key point 1). ② Remove speed sensor ③…

• Page 58: Assembly And Disassembly Of Flywheel And Ring Gear

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. flywheel housing and engine block. Bolts and tools: M10-10.9 hexagon bolts (×12), M12-10.9 hexagon bolts (×6), 17mm and 19mm socket spanner. Step 1: Preassemble the bolts Step 2: Follow the sequence of arrow to tighten the M10 bolts, tighten torque for M10 bolts is 80~85Nm.

• Page 59
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 11 — 2 Exploded view of flywheel and ring gear 11.2.2 Steps to disassemble flywheel and ring gear Disassembling steps are contrary to assembling ones. 11.2.3 Steps to assemble flywheel and ring gear.

• Page 60: Assembly And Disassembly Of Front Oil Seal And Rear Oil Seal

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ③ Check whether flywheel ring gear is damaged. 11.3 Assembly and disassembly of front oil seal and rear oil seal 11.3.1 Exploded view of front oil seal and rear oil seal.

• Page 61
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Assembling 1) Clean the junction surface and install 2 pins into engine body. 2) Apply sealant on the junction surface of rear oil seal cover. 3) Apply oil on surface of crankshaft flange, assemble rear oil seal and tighten bolt. Bolt tightening sequence is: 1-2-6-7-3-4-5-8-9-10。…

• Page 62: Assembly And Disassembly Of Crank-Rod Mechanism

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.4 Assembly and disassembly of crank-rod mechanism. 11.4.1 Exploded view of crank-rod mechanism. Fig. 11-5 Exploded view of crank-rod mechanism 11.4.2 Steps to disassemble crank-rod mechanism ① Check before disassembling. Check connecting rod axial backlash, check tightening torque of connecting rod bolts;…

• Page 63
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig.11-6 Schematic diagram of piston-rod assembly Fig. 11-7 Exploded view of piston-rod assembly 11.5.2 Steps to disassemble piston-rod assembly 1) Check before disassembling. Check connecting rod axial backlash, check tightening torque of connecting rod bolts;…
• Page 64
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 2) Tilt and lay the engine on its side, rotate the flywheel until the to-be removed piston is in BDC, and then remove connecting rod bolts and cap;…
• Page 65
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 120° to that of the first compression ring, and opening direction of oil ring should be 120° to both that of first compression ring and second compression ring, also should be perpendicular to piston pin center line.

• Page 66: Assembly And Disassembly Of Crankshaft System

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.5.4 Inspection and maintenance of piston-rod assembly 1) Check whether there is crack on combustor throat fillet and piston pin boss; Check piston skirt and piston head for cylinder scoring phenomenon; Check wear condition of piston pin hole.

• Page 67
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ② Take down crankshaft and flywheel, remove front and rear thrust plates and flywheel bearing. Remove oil seals; place the crankshaft on bracket (for long time storage, the crankshaft should be placed vertical);…
• Page 68
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ⑨ Press lower bearing shell and lower thrust plate (the side with oil groove should face crankshaft) into crankcase and assemble the crankshaft. ⑩ Apply clean lubricating oil on crankcase bolt bearing surface and main bearing bolt thread.

• Page 69: Assembly And Disassembly Of Crankshaft Bearing Shell

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.7 Assembly and disassembly of crankshaft bearing shell 11.7.1 Exploded view of crankshaft bearing shell Fig. 11- 11 Exploded view of crankshaft bearing shell 11.7.2 Steps to disassemble crankshaft bearing shell Push the shells out with hand, and mark the removed shells (should be corresponded with holes on engine block and crankcase).

• Page 70: Assembly And Disassembly Of Thrust Plates

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.8 Assembly and disassembly of thrust plates. 11.8.1 Exploded view of thrust plates. Fig. 11- 12 Exploded view of thrust plates 11.8.2 Steps to disassemble thrust plates ①…

• Page 71: Assembly And Disassembly Of Camshaft

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 11.9 Assembly and disassembly of camshaft 11.9.1 Exploded view of camshaft Fig. 11- 13 Exploded view of camshaft 11.9.2 Steps to disassemble camshaft Disassembling steps are contrary to assembling ones.

• Page 72
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. ④ Install gaskets, flange, washers and hexagon bolts on camshaft threaded end. Measure the axial clearance of camshaft, which should be 0.1~0.29mm, if the clearance is too small, check whether there is burr between camshaft and sector plate.

• Page 73: Engine Block Assembly

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Rotate crankshaft to check whether 0 tick of each gear is normally engaged. 11.9.4 Inspection and maintenance of camshaft ① Check whether there is wear trace on cam face that contacting tappet, check main journal for seizure and abrasion.

• Page 74
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Cup pulg Camshaft bushing Stud Camshaft Camshaft bushing Cup plug bushing Cylinder liner Dipstick O seal ring Plug O seal ring Stud Seal plug Cup plug Stud Rivet washer 12.1.2 Steps to disassemble engine block:…
• Page 75
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. a. Pre-tighten to 30N.m b. turn 120°±4° c. turn 120°±4° again. The figure below show the tightening sequence of cylinder head bolt in every cylinder head. (3) The tightening sequence of cylinder head is:…

• Page 76: Steps To Assemble And Disassemble Engine Block Module

  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Place cylinder sleeve vertically on engine block, install seal rings on the sleeve and engine block and then assemble the sleeve, knock it to the right place evenly with nylon rod.

• Page 77
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. Fig. 12-2 Exploded view of engine block 12.2.2 step to disassemble Engine Block Module (1) Remove main bearing bolts (key point 1); (2) Remove main bearing caps (key point 2);…
• Page 78
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. For 6-cylinder engine, 14 M14－10.9 main bearing bolts are used to fix the bearings. As shown in Fig. 4-3, start with middle bearings, do the tightening work from middle to two ends evenly, follow the procedures below: Firstly pre-tighten each bolt to 70Nm, and tighten the bolts for further 90°±4°.
• Page 79
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 13 APPENDIX A Appendix A: Torsional Torque and Tightening Method for Main Bolts and Nuts Bolts Bolts Specification Tightening torque(N·m) Inspect value (N·m) Intake manifold bolt 45～50 40～60 Exhaust manifold bolt 45～50…
• Page 80
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 14 APPENDIX B Appendix B: Tolerance Clearance for Main Parts of Gas Engine (Reference value) Items Theoretical value (mm) Main bearing clearance 0.05～0.11 Connecting rod bearing clearance 0.045～0.09 Crankshaft axial clearance 0.04～0.25…
• Page 81
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 15 APPENDIX C Appendix C: The Evaluation Criteria for Main Friction Wear of Gas Engine (Reference value) Wear limit Clearance limit Parts life (mm) (mm) (hours) Closed clearance of the first (top) ring 1.70…
• Page 82
  WEICHAI & PSI SERVICE MANUALS AVAILABLE ONLINE AT FLYPARTSGUY.COM Weichai America Corp. 3100 Golf Road Rolling Meadows, IL 60008 http://www.WeichaiAmerica.com/…

• Page 1
  Service Manual for WD10 Mechanical Pump Series Engine Service Manual for WD10 Diesel Engine…
• Page 3
  Service Manual for WD10 Diesel Engine WD10 China II series diesel engine (China II emission standard)
• Page 4
   Please add fuel of specified brand at a normal gas station, Weichai Power shares no responsibility for fuel system damage caused by inferior fuel, and the “three guarantees” we committed shall automatically become invalid.
• Page 5
  This manual briefly introduced the technical parameters, structural features, operation and maintenance methods, and overhaul tips of WD10 diesel engine, for users to refer to; provided service technologies of diesel engine to help serviceman profoundly understand disassembly and assembly methods of the engine, also laid a solid technical foundation for serviceman to do troubleshooting.

• Page 6: Table Of Contents

  Service Manual for WD10 Diesel Engine CONTENTS Usage Instructions for Diesel Engine …………..1 11 External View of Diesel Engine …………….1 12 Diesel Engine Model Composition and Significance ……….3 13 Diesel Engine Main Technical Parameters …………. 3 14 Unseal of Diesel engine ………………5 15 Lifting of Diesel Engine ………………

• Page 7
  Service Manual for WD10 Diesel Engine Diagnosis and Troubleshooting of Diesel Engine Common Faults ….. 21 31 Diagnostic Methods ………………..21 32 Fault Causes and Elimination Methods …………..22 321 Diesel Engine Couldn’t Be Started ………….. 22 322 Diesel Engine Stops Soon after Starting …………23 323 Underpower ………………..
• Page 8
  Service Manual for WD10 Diesel Engine 422 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover Shield ………………….38 423 Disassembly, Inspection, Maintenance and Assembly of Water Outlet Pipe ……………………………………………………………………………39 424 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator ……………………………………………………………………………41 425 Disassembly, Inspection, Maintenance and Assembly of Hanger Plates ..42 426 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover ..
• Page 9
  Service Manual for WD10 Diesel Engine 453 Disassembly, Inspection, Maintenance and Assembly of Rocker and Rocker Shaft ………………….79 454 Disassembly, Inspection, Maintenance and Assembly of Valve Tappet and Pushrod ………………….82 455 Disassembly, Inspection, Maintenance and Assembly of Valve ….83 456 Disassembly, Inspection, Maintenance and Assembly of Intermediate Gear ……………………………………………………………………………85…
• Page 10
  Service Manual for WD10 Diesel Engine 497 Disassembly, Inspection, Maintenance and Assembly of Main Oil Gallery Pressure Limiting Valve …………….111 498 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler Bypass Valve ………………..112 499 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer ………………………………………………………………………….113…

• Page 11: Usage Instructions For Diesel Engine

  Service Manual for WD10 Diesel Engine 1 Usage Instructions for Diesel Engine 11 External View of Diesel Engine…

• Page 12
  Service Manual for WD10 Diesel Engine…

• Page 13: Diesel Engine Model Composition And Significance

  Power code Application code Product series code 13 Diesel Engine Main Technical Parameters Table 1-1 Main Technical Parameters of WD10 China II series diesel engine Water-cooling, 4-stroke, brake with build-in air Engine type bleeding valve, in-line, direct injection, supercharged and intercooling…

• Page 14
  (° ) side Crankshaft rotating direction (View from free Clockwise end) Table 1-2 Main Technical Parameters of WD10 China II series diesel engine Unit WD10 engine G240E211 G220E221 G210E211 G210E241 G200E251 G175E251 Engine model G220E211 220E231 G210E221 G175E231 G200E251 G156E261 Water-cooling, 4-stroke, brake with build-in air bleeding valve, —…

• Page 15: Unseal Of Diesel Engine

  Service Manual for WD10 Diesel Engine Minimum fuel consumption under g/(kWh) full load Cold start—with aid White smoke Light After 20s idling≤15% discharge obscuration Noise at 1m dB(A) <104 service life 800,000 14 Unseal of Diesel engine After opened the engine packing container, the user should firstly check the engine and its…

• Page 16: Lifting Of Diesel Engine

  Service Manual for WD10 Diesel Engine 15 Lifting of Diesel Engine Keep the center line of engine crankshaft horizontal during lifting, tilting or unilateral lifting is strictly forbidden. Keep the lifting-up and putting-down process slowly (refer to Fig. 1-1). Correct Wrong Fig.

• Page 17: Start The Engine

  Service Manual for WD10 Diesel Engine on instrument panel or check the fuel tank. (3) Check engine oil level Engine oil level should between the bottom scale and top scale on oil dipstick, add engine oil through oil filling port if necessary.

• Page 18
  Service Manual for WD10 Diesel Engine (5) Parameters and check points that should always be noticed during normal use: Engine oil pressure (main gallery) 350~500kPa. Engine oil temperature in oil sump <110 Coolant outlet temperature 80+5 C, should not exceed 93 ≤550…

• Page 19: Maintenance Guidelines For Diesel Engine

  15W/40CF-4 or 5W/40CF-4 engine oil. If ambient temperature is higher than -15 C, select 15W/40CF-4 engine oil and 5W/40CF-4 is applicable for ambient temperature lower than -15 (Weichai dedicated engine oil is recommended, and only choose Weichai dedicated engine oil for the first replacement). Table 2-1 Lubricating oil brand option list…

• Page 20: Lubrication Of Tensioning Wheel

  Service Manual for WD10 Diesel Engine 213 Lubrication of Tensioning Wheel Apply general purpose lithium lubricating grease for lubrication of tensioning wheel (refer to GB/T5671-1995) 214 Antifreeze Additive in Engine Cooling System The adopted antifreeze additive is ethylene glycol, and it is allowed to replace it with domestic long-acting antifreeze additive with reliable quality, refer to related description for specific application method.

• Page 21: Auxiliary Materials

  Service Manual for WD10 Diesel Engine We can get that required antifreeze additive for -20 C is 13.5L Difference value between -30 C and -20 C is 4L For the difference value 4L, another 50% of that is required and necessary, because of before adding antifreeze additive, a part of coolant must be drained out, and antifreeze additive in this part of coolant will be drained out too.

• Page 22: Daily Maintenance

  Service Manual for WD10 Diesel Engine Used for the seal Loctite 277 between core and Other bowl type plugs hole Used to seal top end － Loctite 270 face cylinder Pushrod bush Cylinder cover cover Fitting surface between cylinder block and…

• Page 23: Check Engine Oil Level

  Service Manual for WD10 Diesel Engine Expansion water tank Fig. 2-3 Expansion water tank 222 Check Engine Oil Level Check whether engine oil level is between the bottom scale and top scale on oil dipstick. Under no circumstances should the engine be started if the oil level is lower than the bottom scale (L) or higher than the top scale (H).

• Page 24: Check Fuel Level

  Service Manual for WD10 Diesel Engine 223 Check Fuel Level Check fuel level gauge on instrument panel and add fuel timely. 224 Check “Three Leakages” Check engine appearance for water leakage, air leakage and oil leakage. 225 Check Fan Visually check whether fan blades are damaged, and whether connecting bolts are tightened.

• Page 25: Check Whether Running Sound Is Normal

  Service Manual for WD10 Diesel Engine 228 Check Whether Running Sound is Normal 229 Check Whether Rotating Speed and Vibration are Normal 23 Periodic Maintenance  Replace engine oil Screw off oil drain plug on the bottom of oil sump to drain all engine oil out and then screw on the plug, refer to Fig.

• Page 26
  (3) Measure the clearance between rocker and valve rod upper surface with feeler gauge. Required intake valve clearance for WD10 diesel engine is 0.3mm; while that for exhaust valve is 0.4mm. If the clearance is too large or too small, you can rotate the adjusting screw to adjust until the clearance meets the requirements.

• Page 27: Replace Fuel Filter Element

  Service Manual for WD10 Diesel Engine ATTENTION: In the adjusting process, you should rotate the bolt assembly 2 until the feeler gauge is gently infibulated, so that valve rocker piston 5 can be pushed to the bottom and no clearance between piston and piston hole bottom.

• Page 28
  Service Manual for WD10 Diesel Engine Fig. 2-11 Deflating of coarse filter Drain water in water collector: ATTENTION: When water collector is full or spinning coarse filter is replaced, it is required to drain the water in water collector out.
• Page 29
  Service Manual for WD10 Diesel Engine  Install the screw with hand and tighten it with tool.  If the collector needs to be used on a new spinning filter, check it for damage first.  Install the collector with torque wrench, tightening torque is 20Nm.

• Page 30: Maintenance For Long-Term Storage

  Service Manual for WD10 Diesel Engine infiltration of dust and impurities will lead to premature wear of engine. Remove the filter element from air filter, pat its end faces gently to clean the dust on it, blow it with compressed air reversely (from inside to outside) is also feasible.

• Page 31: Diagnosis And Troubleshooting Of Diesel Engine Common Faults

  3 Diagnosis and Troubleshooting of Diesel Engine Common Faults WD10 China II series diesel engine is designed and manufactured under strict quality guarantee system, each delivered engine has passed specified tests. Since diesel engine is precision machinery, guarantee for long-term reliable service is inseparable from correct maintenance. Causes for diesel engine early failure are as follows: …

• Page 32: Fault Causes And Elimination Methods

  Service Manual for WD10 Diesel Engine ATTENTION: Diesel engine fault cause determination is an extremely careful job. Before basically be sure about the cause, it’s not allowed to disassemble the engine casually, otherwise instead of eliminating the fault, some severe trouble may occur due to improper reassembling.

• Page 33: Diesel Engine Stops Soon After Starting

  Service Manual for WD10 Diesel Engine 322 Diesel Engine Stops Soon after Starting Disassemble the filter body to clear up the water 1. Blockage of fuel filter and dirt, replace the filter element if necessary. Expel the air and check airtightness of joints, check 2.

• Page 34: Large Fuel Consumption

  Service Manual for WD10 Diesel Engine 12. Incorrect valve or injection timing Check and adjust it. 13. Governor high-speed regulating Check the speed control characteristic and adjust. performance is poor Check oil dipstick and drain redundant engine oil 14. High engine oil level in oil sump out.

• Page 35: Engine Gives Off Black Smoke

  Service Manual for WD10 Diesel Engine 325 Engine Gives off Black Smoke 1. Blockage of intake pipe or high exhaust Clean it up. back pressure 2. Inferior fuel Clean and replace. Adjust valve clearance and fuel supply advance 3. Incorrect valve or injection timing angle according related requirements.

• Page 36: Turbocharger Intake Port And Intake Pipe Are Accumulated With Engine Oil

  Service Manual for WD10 Diesel Engine 327 Turbocharger Intake Port and Intake Pipe Are Accumulated with Engine Oil 1. Turbocharger sealing failure Repair or replace the turbocharger. 2. Oil-gas separator failure Replace. Check oil dipstick and drain redundant engine oil 3.

• Page 37: 3210 High Cooling Water Temperature

  Service Manual for WD10 Diesel Engine 7. Large filtering resistance of engine oil Replace filter element. filter 8. Blockage of engine oil cooler Check and clean. 9. Blockage of main oil gallery Check and clean. 10. Large bearing shell clearance, Check and replace.

• Page 38: 3212 Excessive Noise

  Service Manual for WD10 Diesel Engine 9. Severe wear of parts, overhaul needs to Check working hour of engine, overhaul the engine. be done 10. Crankshaft and the follower main shaft Check the installing support, repair. are not concentric 11. The applied engine oil quality fails to Choose specified engine oil brand.

• Page 39: 3214 Underpowered Starter Motor

  Service Manual for WD10 Diesel Engine 3214 Underpowered Starter Motor 1. Undercharged battery Check, recharge or replace the battery. 2. Bearing sleeve wear Replace the assembly. 3. Bad contact of electric brush Clean the brush or replace it. Wipe out oil dirt and polish it with abrasive paper or 4.

• Page 40: 3217 Unstable Charging Voltage

  Service Manual for WD10 Diesel Engine 3217 Unstable Charging Voltage 1. Rotor coil or stator coil is about to in Repair or replace. open circuit or short circuit 2. Bad contact of electric brush Repair. 3. Loose terminals, bad contact Repair.

• Page 41: Disassembly & Assembly Of Diesel Engine

  Service Manual for WD10 Diesel Engine 4 Disassembly & Assembly of Diesel Engine 41 Overview Please comply with instructions in this manual strictly to disassemble and assemble the engine and pay special attention to operations which danger signs and safety signs are involved in this manual, in order to ensure personal safety and avoid accidents.

• Page 42: Safety Signs

  Service Manual for WD10 Diesel Engine Safety information described in this manual cannot cover all safety precautions, if the procedures or actions that are not recommended in this manual are used, you must ensure the safety of the operator and machine.

• Page 43: Recommended Tools

  Service Manual for WD10 Diesel Engine 413 Recommended Tools Signs Information 2.5mm hexagon wrench 5mm hexagon wrench 8mm socket Slotted screw driver Dedicated tool 10mm slotted hexagon wrench If the methods or tools that are not recommended in this manual are used, you must ensure safety to avoid life risk to yourself or other people, in the meantime make sure the operating, maintenance and repair methods wouldn’t bring damage to the engine or potential safety hazard.

• Page 44: Environmental Protection Measures

  Any violation of instructions in this manual may result in serious accident, even death. Weichai Power cannot foresee all potential dangers. Similarly, the rules and instructions in this manual cannot cover everything.

• Page 45: Explode View Of The Whole Engine

  Service Manual for WD10 Diesel Engine 417 Explode View of the Whole Engine Turbocharger Cylinder cover shield Cylinder cover Oil-gas separator Exhaust pipe Water outlet pipe Thermostat Intake pipe Cylinder Block Pushrod Valve Engine oil Tappet cooler cap Camshaft Engine oil filter…

• Page 46: Cylinder Cover Assembly

  Service Manual for WD10 Diesel Engine 42 Cylinder Cover Assembly 421 Disassembly and Assembly of Cylinder Cover Assembly 4211 Exploded View of Cylinder Cover Assembly Cylinder cover is located on top of cylinder block, combustion chamber is jointly formed by cylinder cover and piston head.

• Page 47
  Service Manual for WD10 Diesel Engine (6) Disconnect EVB oil pipe and pipe joint; (7) Disconnect injector wiring harness, remove injector oil return pipe and high pressure fuel pipe, refer to disassembly of fuel system for details; (8) Remove the injector, refer to disassembly of fuel system for details;…

• Page 48: Disassembly, Inspection, Maintenance And Assembly Of Cylinder Cover Shield

  Service Manual for WD10 Diesel Engine 422 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover Shield 4221 Exploded View of Cylinder Cover Shield Cylinder cover shield bolt Cylinder cover shield Cylinder cover shield gasket Fig. 4-3 Exploded view of cylinder cover shield 4222 Steps to Disassemble Cylinder Cover Shield (1) Screw off cylinder cover shield bolts orderly;…

• Page 49: Disassembly, Inspection, Maintenance And Assembly Of Water Outlet Pipe

  Service Manual for WD10 Diesel Engine Check whether there is manufacturing defect, usage defect or damage on cylinder cover shield gaskets and cylinder cover before assembling. (2) Clean up cylinder cover upper surface and assemble cylinder cover shield gaskets orderly.

• Page 50
  Service Manual for WD10 Diesel Engine 4233 Inspection and Maintenance of Water Pipe (1) Check whether there is water leakage trace on the pipe before disassembling; check the pipe for damage like crack and corrosion, a cracked pipe should be replaced, for corrosion that may affect reliability of the pipe, the cause should be analyzed and corroded pipe should be replaced.

• Page 51: Disassembly, Inspection, Maintenance And Assembly Of Oil-Gas Separator

  Service Manual for WD10 Diesel Engine 424 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator 4241 Exploded View of Oil-Gas Separator Front hanger plate Fixing bolt Oil-gas separator Oil-gas separator outlet pipe Flange and gasket Clamp Oil-gas separator oil return pipe…

• Page 52: Disassembly, Inspection, Maintenance And Assembly Of Hanger Plates

  Service Manual for WD10 Diesel Engine 4244 Steps to Assemble Oil-Gas Separator Assembling steps are contrary to disassembling ones. Do not mix up the rubber hoses and hoses joints (refer to Fig. 4-5), connect each hose to the engine properly.

• Page 53: Disassembly, Inspection, Maintenance And Assembly Of Cylinder Cover

  Service Manual for WD10 Diesel Engine 4254 Steps to Assemble Hanger Plates Firstly distinguish the front hanger plate and rear hanger plate, front hanger plate should be installed on front end of engine (fan end), and rear hanger plate should be installed on rear end of engine (flywheel end), fasten the plates with M12 hexagon bolts (as shown in Fig.

• Page 54
  Service Manual for WD10 Diesel Engine details). Besides, for engine with EVB oil pipe, the pipe need to be remove too. Disassembling of other parts is as follows: (1) Remove cylinder cover auxiliary nuts, and take down the clamp blocks, there are two kinds of clamp blocks: one is installed between two adjacent cylinder covers, the other is installed on two sides;…
• Page 55
  Service Manual for WD10 Diesel Engine Fig. 4-8 Depth micrometer Refer to Table 4-1 for valve recession requirements. If valve recession exceeds allowed range, check wear condition of valve and valve seat, replace the valve with a new one to determine wear condition of valve seat by measuring the valve recession again, if the valve recession still exceeds allowed range, the cylinder cover must be replaced to ensure reliability of diesel engine.
• Page 56
  Service Manual for WD10 Diesel Engine (7) Check the disassembled cylinder cover gaskets for visible damage and analyze the cause, cylinder cover gaskets are disposable, and should be replaced once removed. (8) Check whether valve rod seal cartridge rubber lip is damaged, whether the spring is in failure and whether there is other abnormal phenomenon before disassembling, seal cartridge should be replaced once removed.
• Page 57
  Service Manual for WD10 Diesel Engine 2) Rub-up cylinder sleeve inner wall and apply clean engine oil on the wall; Clean up upper surface of cylinder block, and place cylinder gaskets correctly by aligning the holes; 3) Check and make sure the holes on cylinder cover gasket are correctly aligned to holes on cylinder block.
• Page 58
  Service Manual for WD10 Diesel Engine 2) Check and make sure cylinder cover air passage and water passage are free of foreign matter; Check and make sure the cylinder is free of foreign matter, cylinder cover gasket and cylinder cover undersurface are clean;…
• Page 59
  Service Manual for WD10 Diesel Engine 6) Tighten cylinder cover main bolts with torque wrench orderly to 200Nm and mark the bolts; 7) Tighten each cylinder cover auxiliary nut for further 90° with torque wrench orderly and mark the new position of the nuts;…
• Page 60
  Service Manual for WD10 Diesel Engine Fig. 4-17 Assembly of cylinder cover main bolts Fan side Flywheel side Fig. 4-18 Tighten number 22~45 cylinder cover main bolts…

• Page 61: Engine Block Assembly

  Service Manual for WD10 Diesel Engine 43 Engine Block Assembly 431 Disassembly, Inspection, Maintenance and Assembly of Engine Block Assembly 4311 Exploded View of Engine Block Assembly Engine block module Cylinder sleeve Cylinder cover auxiliary bolt Elastic cylindrical pin Pre-glued set screw…

• Page 62
  Service Manual for WD10 Diesel Engine Compound gasket Main oil gallery rear plug Bowl shape plug Rivet Seal ring Main bearing bolt Fig. 4-20 Exploded view of engine block assembly 4312 Steps to Disassemble Engine Block Assembly (1) Remove crankcase fastening bolts (key point 1);…
• Page 63
  Service Manual for WD10 Diesel Engine Key point 2: Assembling: Apply clean lubricating oil on crankcase bearing surface and thread of main bearing bolts, and then tighten them according to following order: Tightening torque 265± 25Nm Key point 3: Assembling: Tighten cylinder cover auxiliary bolts according to the following order, cylinder cover auxiliary bolts are allowed to use twice at most.

• Page 64: Disassembly, Inspection, Maintenance And Assembly Of Engine Block Module

  Service Manual for WD10 Diesel Engine 432 Disassembly, Inspection, Maintenance and Assembly of Engine Block Module 4321 Exploded View of Engine Block Module Cylinder Bowl shape plug Bowl shape plug block Camshaft sleeve Cylindrical pin with Crankcase internal thread Oil dipstick pipe head…

• Page 65
  Service Manual for WD10 Diesel Engine 4322 Steps to Disassemble Engine Block Module (1) Remove cylindrical pins (with internal thread); (2) Remove camshaft sleeve (key pint 1); (3) Remove main bearing bolts and crankcase fastening bolts (refer to 431); (4) Remove crankcase (key point 2);…

• Page 66: Disassembly, Inspection, Maintenance And Assembly Of Engine

  Service Manual for WD10 Diesel Engine 433 Disassembly, Inspection, Maintenance and Assembly of Engine Front Cover 4331 Exploded View of Engine Front Cover Engine front cover Hexagon flange toothed bolt Seal ring Fig. 4-22 Exploded view of engine front cover 4332 Steps to Disassemble Engine Front Cover (1) Remove engine front cover fastening bolts (key point 1);…

• Page 67: Disassembly, Inspection, Maintenance And Assembly Of Gear Housing

  Service Manual for WD10 Diesel Engine 4334 Steps to Assemble Engine Front Cover Assembling steps are contrary to disassembling ones. 434 Disassembly, Inspection, Maintenance and Assembly of Gear Housing 4341 Exploded View of Gear Housing Timing gear housing Seal ring…

• Page 68
  Service Manual for WD10 Diesel Engine 4343 Inspection and Maintenance of Gear Housing Key point 1: Assembling: Tighten gear housing fastening bolts according to the following order crosswise. Tightening torque 44~58Nm Fig. 4-24 Key point 2: Assembling: Check whether seal ring is damaged, replace it if so. When assembling, seal ring should be applied with oil and fully pressed into seal groove, protect the ring in this process.

• Page 69: Disassembly, Inspection, Maintenance And Assembly Of Flywheel Housing

  Service Manual for WD10 Diesel Engine 435 Disassembly, Inspection, Maintenance and Assembly of Flywheel Housing 4351 Exploded View of Flywheel Housing Stud Spring washer 1-type Flywheel housing hexagon bolt Flywheel housing bolt Monitoring window cap Hexagon bolt Cylindrical pin Fig. 4-25 Exploded view of flywheel housing 4352 Steps to Disassemble Flywheel Housing (7) Remove fastening bolts of flywheel housing (key point 1);…

• Page 70: Disassembly, Inspection, Maintenance And Assembly Of Oil Sump

  Service Manual for WD10 Diesel Engine Fig. 4-26 Key point 2: Assembling: Apply sealant on fitting surfaces of flywheel housing and engine block, pay attention not to crash flywheel housing during lifting. 4354 Steps to Assemble Flywheel Housing Assembling steps are contrary to disassembling ones.

• Page 71
  Service Manual for WD10 Diesel Engine 4362 Steps to Disassemble Oil Sump (1) Turn over the engine to keep oil sump upward (key point 1); (2) Remove oil sump fastening bolts (key point 2); (3) Remove oil sump support blocks;…

• Page 72: Disassembly, Inspection, Maintenance And Assembly Of Piston Nozzle

  Service Manual for WD10 Diesel Engine 437 Disassembly, Inspection, Maintenance and Assembly of Piston Nozzle 4371 Exploded View of Piston Nozzle Hollow bolt Seal gasket Nozzle assembly Elastic cylindrical pin Fig. 4-29 Exploded view of piston nozzle 4372 Steps to Disassemble Piston Nozzle (1) Remove the hollow bolt (key point 1);…

• Page 73: Disassembly, Inspection, Maintenance And Assembly Of Thrust Plates

  Service Manual for WD10 Diesel Engine 4374 Steps to Assemble Piston Nozzle Assembling steps are contrary to disassembling ones. 438 Disassembly, Inspection, Maintenance and Assembly of Thrust Plates 4381 Exploded View of Thrust Plates Upper thrust plate Lower thrust plate Fig.

• Page 74: Disassembly, Inspection, Maintenance And Assembly Of Front And Rear Oil Seals

  Service Manual for WD10 Diesel Engine side with oil groove should be outward. 4384 Steps to Assemble Thrust Plates (1) Install crankshaft; (2) Install upper thrust plates (without lug); (3) Install lower thrust plates (key point 1). 439 Disassembly, Inspection, Maintenance and Assembly of Front and…

• Page 75
  Service Manual for WD10 Diesel Engine tool. Disassembling: Removed oil seals should not be reused. 4394 Steps to Assemble Front and Rear Oil Seals (1) Install crankcase; (2) Install rear oil seal; (3) Install gear housing; (4) Install front oil seal.

• Page 76: Crank-Rod Mechanism

  Service Manual for WD10 Diesel Engine 44 Crank-Rod Mechanism 441 Disassembly and Assembly of Crank-Rod Mechanism 4411 Exploded View of Crank-Rod Mechanism Main bearing bolt Main bearing shell Crankcase Crankshaft Connecting rod big end cap Crankshaft Flywheel ring gear timing gear…

• Page 77: Disassembly, Inspection, Maintenance And Assembly Of Piston-Rod Assembly

  Service Manual for WD10 Diesel Engine 442 Disassembly, Inspection, Maintenance and Assembly of Piston-Rod Assembly 4421 Exploded View of Piston-Rod Assembly Crankshaft Piston-rod assembly Fig. 4-33 Schematic diagram of piston-rod assembly First compression ring Second compression ring Piston pin Oil ring…

• Page 78
  Service Manual for WD10 Diesel Engine 4422 Steps to Disassemble Piston-Rod Assembly (1) Remove circlip on two sides of piston with internal circlip plier and push piston pin out, take down the connecting rod body. Number the piston pins, connecting rod bodies and place them orderly.
• Page 79
  Service Manual for WD10 Diesel Engine (5) Adjust opening direction of each ring: The opening direction of first compression ring should be 30° to piston pin center line, opening direction of the second compression ring should be 120° to that of the first compression ring, and opening direction of oil ring should be 120° to both that of first compression ring and second compression ring, also should be perpendicular to piston pin center line.

• Page 80: Disassembly, Inspection, Maintenance And Assembly Of Crankshaft

  Service Manual for WD10 Diesel Engine 443 Disassembly, Inspection, Maintenance and Assembly of Crankshaft 4431 Exploded View of Crankshaft Main bearing bolt Crankcase Crankshaft Flywheel ring gear Flywheel Main bearing shell Bearing Crankshaft timing gear Baffle ring Damper Pulley Flywheel bolt…

• Page 81
  Service Manual for WD10 Diesel Engine (6) Check wear condition of crankshaft journal, check bend and distortion condition of crankshaft. 4434 Steps to Assemble Crankshaft (1) Clean up cylinder bottom holes. (2) Press main bearing upper shells into cylinder bottom holes and clean up scraped foreign matter.

• Page 82: Disassembly, Inspection, Maintenance And Assembly Of Flywheel And Ring Gear

  Service Manual for WD10 Diesel Engine (11) Firstly pre-tighten each bolt with low-torque pneumatic impact wrench, and then tighten each bolt to 80Nm orderly, thirdly the torque should reach 250~280Nm. Assembly of crank shaft is finished. 444 Disassembly, Inspection, Maintenance and Assembly of Flywheel and…

• Page 83
  Service Manual for WD10 Diesel Engine 4444 Steps to Assemble Flywheel and Ring Gear (1) Fix the flywheel ring gear on flywheel with bolts; (2) Knock the pin into crankshaft rear end fully. (3) After inserting flywheel guide rod into crankshaft threaded hole, install flywheel and pre-tighten the bolts diagonally.

• Page 84: Disassembly, Inspection, Maintenance And Assembly Of Damper And Crankshaft Pulley

  Service Manual for WD10 Diesel Engine 445 Disassembly, Inspection, Maintenance and Assembly of Damper and Crankshaft Pulley 4451 Exploded View of Damper and Crankshaft Pulley Crankshaft timing gear Flange Crankshaft Damper Crankshaft pulley Pulley bolt Fig. 4-39 Exploded view of damper and crankshaft pulley 4452 Steps to Disassemble Damper and Crankshaft Pulley Screw off pulley bolts and then take down pulley and damper orderly.

• Page 85: Disassembly, Inspection, Maintenance And Assembly Of Crankshaft Bearing Shell

  Service Manual for WD10 Diesel Engine 446 Disassembly, Inspection, Maintenance and Assembly of Crankshaft Bearing Shell 4461 Exploded View of Crankshaft Bearing Shell Main bearing upper shell Crankshaft Main bearing lower shell Fig. 4-40 Exploded view of crankshaft bearing shell…

• Page 86: Valve Mechanism

  Service Manual for WD10 Diesel Engine 45 Valve Mechanism 451 Disassembly and Assembly of Valve Mechanism 4511 Exploded View of Valve Mechanism Adjusting nut Hexagon screw Intake rocker Supporting arm Adjusting screw Adjusting bolt assembly Valve lock clamp Adjusting nut…

• Page 87: Disassembly, Inspection, Maintenance And Assembly Of Camshaft

  Service Manual for WD10 Diesel Engine (3) Install valve tappet and pushrod, refer to assembly of valve tappet and pushrod for details; (4) Assemble intake and exhaust valves, refer to assembly of valves for details; (5) Install rocker and rocker shaft, refer to assembly of rocker and rocker shaft for details;…

• Page 88
  Service Manual for WD10 Diesel Engine abrasion. (2) Measure camshaft main journal circular run-out. Maximum allowed Camshaft Measured value circular run-out The second main journal (Between cylinder 1 and 0.04 cylinder 2) The third main journal (Between cylinder 2 and 0.05…

• Page 89: Disassembly, Inspection, Maintenance And Assembly Of Rocker And Rocker Shaft

  Service Manual for WD10 Diesel Engine (5) Turn the engine anticlockwise (view from timing gear housing end) until cylinder 1 and 6 reach TDC. At this point, piston upper end should be aligned to cylinder block upper surface. (6) Draw a straight line across flywheel housing and flywheel, install the dial and adjust it until 0°…

• Page 90
  Service Manual for WD10 Diesel Engine 4532 Steps to Disassemble Rocker and Rocker Shaft (1) Rotate crankshaft to check whether rocker is flexible. (2) Measure each valve clearance, and check the change of valve clearance. (3) If the rocker is not flexible or too big valve clearance, loosen hexagon nut and then take down the supporting arm, rocker shaft, intake and exhaust rocker assembly, mark them to prevent confusion.
• Page 91
  Service Manual for WD10 Diesel Engine valve clearance: As shown in Fig. 4-44, firstly loose the adjusting bolt 2, and then adjust valve clearance adjusting screw on pushrod end 10 without compressing exhaust valve rocker sealing surface until total valve clearance is 0.4mm, and then tighten adjusting nut. (ATTENTION:…

• Page 92: Disassembly, Inspection, Maintenance And Assembly Of Valve Tappet And Pushrod

  Service Manual for WD10 Diesel Engine 3) Rotate the engine for 360° , so that cylinder 6 can be in compression TDC, adjust intake valve clearance of No. 6, 5, 3 cylinder and exhaust valve clearance of No. 6, 4, 2 cylinder, and EVB valve clearance.

• Page 93: Disassembly, Inspection, Maintenance And Assembly Of Valve

  Service Manual for WD10 Diesel Engine (4) Check whether pushrod two ends are worn; (5) Check whether valve tappet surface and undersurface are worn; (6) Check whether valve tappet inner socket head is worn. 4544 Steps to Assemble Valve Tappet and Pushrod (1) Check valve tappets and pushrods, replace them if necessary.

• Page 94
  Service Manual for WD10 Diesel Engine 4552 Steps to Disassemble Valve (1) Depress valve springs with vale spring compressor or valve overhead plier or other tools, take out valve lock clamp, upper valve spring seat and lower valve spring seat and valve springs orderly;…

• Page 95: Disassembly, Inspection, Maintenance And Assembly Of Intermediate Gear

  Service Manual for WD10 Diesel Engine 456 Disassembly, Inspection, Maintenance and Assembly of Intermediate Gear 4561 Exploded View of Intermediate Gear Sleeve Intermediate gear shaft Gasket Bolt Intermediate gear Fig. 4-49 Exploded view of intermediate gear 4562 Steps to Disassemble Intermediate Gear (1) Remove air compressor, refer to disassembly of engine accessory system for details;…

• Page 96
  Service Manual for WD10 Diesel Engine 4564 Steps to Assemble Intermediate Gear (1) Install engine oil pump, crankshaft and engine oil pump intermediate gear module orderly; (2) Install gear housing. Before assembling gear housing, put intermediate gear shaft into intermediate gear assembly (intermediate gear and sleeve). For intermediate gear the end with “V”…

• Page 97: Intake And Exhaust System

  Service Manual for WD10 Diesel Engine 46 Intake and Exhaust System 461 Disassembly and Assembly of Intake and Exhaust System 4611 Exploded View of Intake and Exhaust System Intake pipe Turbocharger Exhaust pipe Fig. 4-50 Exploded view of valve intake and exhaust system 4612 Steps to Disassemble Intake and Exhaust System (1) Loosen air filter fixing bolts and hose clamps, take down air filter and hoses.

• Page 98: Disassembly, Inspection, Maintenance And Assembly Of Intake Pipe

  Service Manual for WD10 Diesel Engine 462 Disassembly, Inspection, Maintenance and Assembly of Intake Pipe 4621 Exploded View of Intake Pipe Stud Intake pipe end Intake pipe gasket cover gasket Intake pipe Intake pipe end cover Intake heater Intake heater…

• Page 99: Disassembly, Inspection, Maintenance And Assembly Of Exhaust Pipe

  Service Manual for WD10 Diesel Engine 463 Disassembly, Inspection, Maintenance and Assembly of Exhaust Pipe 4631 Exploded View of Intake Pipe Front exhaust pipe Exhaust pipe seal ring Exhaust pipe bolt Exhaust pipe gasket Rear exhaust pipe Exhaust pipe heat shield bolt…

• Page 100: Disassembly, Inspection, Maintenance And Assembly Of Turbocharger System

  Service Manual for WD10 Diesel Engine (2) Exhaust pipe bolts should be applied with molybdenum disulfide, recommended tightening torque for exhaust pipe fixing bolts is 65~80Nm. Exhaust pipe bolts cannot be reused more than twice. 464 Disassembly, Inspection, Maintenance and Assembly of Turbocharger…

• Page 101
  Service Manual for WD10 Diesel Engine Press measuring head of dial indicator against compressor end, push and pull the shaft axially and record value difference of the indicator. As shown in Fig. 4-54. Required range is 0.088~0.118mm, if exceeds this range, then it indicates that thrust bearing plate or thrust plate and bearing is worn, you must find out the cause and eliminate the problem.
• Page 102
  Service Manual for WD10 Diesel Engine (1) Check whether the pipe connection between turbocharger and engine is loose, eliminate the problem in time. (2) Check turbocharger for air leakage and oil leakage, eliminate the fault in time. (3) Check whether turbocharger fastening screws are loose, eliminate the problem timely.

• Page 103: Fuel System

  Service Manual for WD10 Diesel Engine 47 Fuel System 471 Disassembly and Assembly of Fuel System 4711 Exploded View of Fuel System Fig. 4-56 Exploded view of fuel system 4712 Steps to Disassemble Fuel System (1) Remove low pressure fuel pipe module;…

• Page 104: Disassembly, Inspection, Maintenance And Assembly Of Fuel Injection Pump

  Service Manual for WD10 Diesel Engine 472 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump 4721 Exploded View of Fuel Injection Pump Fig. 4-57 Exploded view of fuel injection pump 4722 Steps to Disassemble Fuel Injection Pump (1) Screw off the hexagon nuts that connecting fuel injection pump flange and gear housing;…

• Page 105
  Service Manual for WD10 Diesel Engine 4724 Steps to Assemble Fuel Injection Pump (1) Install fuel injection pump flange, apply a small amount of lubricating oil on pump rubber ring; (2) Screw on the hexagon bolts to connect fuel injection pump and the flange;…

• Page 106: Disassembly, Inspection, Maintenance And Assembly Of High Pressure Fuel Pipes

  Service Manual for WD10 Diesel Engine 473 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel Pipes 4731 Exploded View of High Pressure Fuel Pipes Fig. 4-59 Exploded view of high pressure fuel pipes 4732 Steps to Disassemble High Pressure Fuel Pipes (1) Remove high pressure fuel pipe support;…

• Page 107: Disassembly, Inspection, Maintenance And Assembly Of Fuel Injector

  Service Manual for WD10 Diesel Engine 474 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector 4741 Exploded View of Fuel Injector Fig. 4-60 Exploded view of fuel injector 4742 Steps to Disassemble Fuel Injector (1) Remove the hexagon bolts that used to fix injector pressing block;…

• Page 108
  Service Manual for WD10 Diesel Engine (2) All kinds of protective caps only need to be removed before assembling; (3) Place the injector into cylinder cover and tighten injector clamping bolt to 3Nm; (4) Loose injector clamping bolt until axial force posed on injector is 0kN;…

• Page 109: Cooling System

  Service Manual for WD10 Diesel Engine 48 Cooling System 481 Disassembly and Assembly of Cooling System 4811 Exploded View of Cooling System The function of cooling system is to ensure diesel engine can continuously work at proper temperature. Forced circulation cooling offers the best guarantee to keep the engine in normal operating temperature, which mainly consists of water pump, fan, expansion water tank, water tank and thermostat.

• Page 110: Disassembly, Inspection, Maintenance And Assembly Of Fan

  Service Manual for WD10 Diesel Engine (4) Remove generator, generator support, crankshaft pulley and damper. (5) Remove thermostat, refer to disassembly of thermostat for details. (6) Remove air compressor and hydraulic pump. (7) Remove pipe joints of water pump and take down the pump, refer to disassembly of water pump for details.

• Page 111: Disassembly, Inspection, Maintenance And Assembly Of Water Pump

  Service Manual for WD10 Diesel Engine 4823 Inspection and Maintenance of Fan Check fan, fan clutch, fan connecting plate and water pump pulley for crack and damage. 4824 Steps to Assemble Fan (1) Before the assembly, check fan, fan clutch, fan connecting plate and hexagon flange bolts, make sure there is no manufacturing and use defect and damage.

• Page 112
  Service Manual for WD10 Diesel Engine (4) Remove the hexagon flange nuts; (5) Remove the studs; (6) Remove the water pump and take down pump gaskets. 4833 Inspection and Maintenance of Water Pump (1) Check pipe joint and pipe joint module for blockage and crack damage, replace if necessary.

• Page 113: Disassembly, Inspection, Maintenance And Assembly Of Thermostat

  Service Manual for WD10 Diesel Engine 484 Disassembly, Inspection, Maintenance and Assembly of Thermostat 4841 Exploded View of Thermostat Clamp Cooling water Cooling water pipe adapter pipe adapter Clamp Thermostat Block cap Fig. 4-64 Exploded view of thermostat 4842 Steps to Disassemble Thermostat As shown in Fig.

• Page 114
  Service Manual for WD10 Diesel Engine 4844 Steps to Assemble Thermostat (1) Before the assembly, check the clamps, cooling water adapters, thermostat and thermostat cap, make sure there is no manufacturing and use defect and damage. (2) Clean up cooling water outlet pipe and water pump outlet pipe.

• Page 115: Lubricating System

  Service Manual for WD10 Diesel Engine 49 Lubricating System 491 Disassembly and Assembly of Lubricating System 4911 Exploded View of Lubricating System Hexagon plug Hollow bolt Crankshaft pulley and damper Engine oil cooler Oil strainer Engine oil pump Hexagon bolt…

• Page 116: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Pump

  Service Manual for WD10 Diesel Engine (10) Remove engine oil cooler bypass valve. 4913 Steps to Assemble Lubricating System Assembling steps are contrary to disassembling ones. 492 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump 4921 Exploded View of Engine Oil Pump…

• Page 117: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Pump Intermediate Gear

  Service Manual for WD10 Diesel Engine (4) Install engine oil pump. (5) Install and tighten the two toothed hexagon bolts. 493 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump Intermediate Gear 4931 Exploded View of Engine Oil Pump Intermediate Gear…

• Page 118: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Filter

  Service Manual for WD10 Diesel Engine (2) Clean up the fitting surface between crankcase and engine oil pump intermediate gear module. (3) Install the seal ring in intermediate gear. (4) Install engine oil pump intermediate gear (convex side face inward).

• Page 119: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Cooler Cap

  Service Manual for WD10 Diesel Engine no manufacturing and use defect and damage. (2) Clean up the fitting surface between engine oil filter assembly and engine block. (3) Install engine oil filter seat gasket and filter assembly. (4) Install the wave spring washers and bolts, tighten the bolts.

• Page 120: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Cooler

  Service Manual for WD10 Diesel Engine 4954 Steps to Assemble Engine Oil Cooler Cap (1) Check the cooler cap and gasket before assembling, make sure there is no manufacturing defect and damage. (2) Clean up the fitting surface between engine oil cooler cap and engine block, install cooler cap gasket.

• Page 121: Disassembly, Inspection, Maintenance And Assembly Of Main Oil Gallery Pressure Limiting Valve

  Service Manual for WD10 Diesel Engine (2) Clean up the fitting surface between engine oil cooler and engine block. (3) Install the seal rings and engine oil cooler. (4) Install the wave spring washers and the bolts, tighten the bolts.

• Page 122: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Cooler Bypass Valve

  Service Manual for WD10 Diesel Engine (3) Apply sealant on the valve thread. (4) Install the valve and tighten it. 498 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler Bypass Valve 4981 Exploded View of Engine Oil Cooler Bypass Valve…

• Page 123: Disassembly, Inspection, Maintenance And Assembly Of Engine Oil Strainer

  Service Manual for WD10 Diesel Engine (2) Clean up engine oil cooler bypass valve and valve fitting hole on engine block. (3) Install safety valve, safety valve spring and compound gasket orderly. (4) Install the hexagon plug and tighten it.

• Page 124: Starting System

  Service Manual for WD10 Diesel Engine 410 Starting System 4101 Disassembly and Assembly of Starting System 41011 Exploded View of Starting System 4 Ring gear 2 Stud 3 Hexagon nut 1 Starter motor Fig. 4-74 Exploded view of starting system 41012 Steps to Disassemble Starting System (1) Remove the starter motor;…

• Page 125
  Service Manual for WD10 Diesel Engine 41023 Inspection and Maintenance of Starter Motor Check the starter motor gear for damage, replace it if necessary. 41024 Steps to Assemble Starter Motor Assembling steps are contrary to disassembling ones.

• Page 126: Engine Accessory System

  Service Manual for WD10 Diesel Engine 411 Engine Accessory System 4111 Disassembly and Assembly of Engine Accessory System 41111 Exploded View of Engine Accessory System 1 Air compressor water inlet pipe module 2 Air compressor oil inlet pipe module 3 Hydraulic pump module…

• Page 127
  Service Manual for WD10 Diesel Engine Fig. 4-76 Disassembly of steering pump Disassembly of air compressor and its pipelines (1) Remove air compressor intake pipe, water inlet pipe, water outlet pipe and oil inlet pipe. (2) Remove the three hexagon flange bearing surface toothed bolts of air compressor, and then take air compressor out, remove the O-shape seal ring in the meantime.
• Page 128
  Service Manual for WD10 Diesel Engine Fig. 4-78 Disassembly of A/C compressor Disassembly of generator module (1) Screw off generator draw-in nut, remove connecting bolt and nut of draw-in block, take down the block and gasket. (2) Remove generator the other end fixing bolt, rotate the generator to remove the poly V-belt, take down the fixing bolt and generator, as shown in Fig.
• Page 129
  Service Manual for WD10 Diesel Engine 41113 Steps to Assemble Engine Accessory System Assembly of generator module (1) Place the generator on generator support, loose-fit it on the support and draw-in rod with fixing bolts. (2) Install generator poly V-belt.
• Page 130
  Service Manual for WD10 Diesel Engine Fig. 4-81 Assembly of A/C compressor (2) Install A/C compressor V-belt. (3) Adjust the location of compressor and tension the V-belt with the draw-in rod, tighten compressor fixing bolts and nuts, as shown in Fig. 4-81.
• Page 131
  Service Manual for WD10 Diesel Engine Fig. 4-82 Assembly of air compressor and its pipelines Assembly of steering pump (1) Make sure steering pump main axis is perpendicular to engine timing gear housing fitting surface, and push the pump (with a sealing gasket) into the mounting hole gently, ensure the…

• Page 132: 4112 Disassembly, Inspection, Maintenance And Assembly Of Generator

  Service Manual for WD10 Diesel Engine 4112 Disassembly, Inspection, Maintenance and Assembly of Generator 41121 Exploded View of Generator 1 V-belt 2 Poly V-belt 3 Generator 4 Draw-in block Fig. 4-84 Exploded view of generator 41122 Steps to Disassemble Generator (1) Remove A/C compressor draw-in bolt and disassemble A/C compressor V-belt (refer to disassembly of A/C compressor for details).

• Page 133
  Service Manual for WD10 Diesel Engine (3) Remove generator poly V-belt (8PK) (4) Screw off draw-bolt block bolt, remove the block Draw-in block (5) Remove generator M10 studs (6) Assembling steps are contrary to disassembling ones ATTENTION: The disassembly of generator should be performed by professional personnel.
• Page 134
  Service Manual for WD10 Diesel Engine Turn on the machine power switch and connect test lamp to generator B+ terminal and E (negative) terminal. It means there is no voltage in B+ terminal, Is the test lamp on? the wire to battery positive is in failure.
• Page 135
  Service Manual for WD10 Diesel Engine (2) Charging system fault diagnosis and troubleshooting a) No charging Fault 1: No charging Phenomenon Fault detection Troubleshooting a. Check whether there is voltage between (1) Turn on a. Check charging charging indicator and ground, if no starting key, indicator lamp.
• Page 136
  Service Manual for WD10 Diesel Engine a. If B+ terminal to ground voltage is zero, then check generator to battery positive and negative circuits for breakover. b. If B+ terminal to ground voltage is obviously lower than battery voltage, then…
• Page 137
  Service Manual for WD10 Diesel Engine Fault 2: Low charging voltage Phenomenon Fault detection Troubleshooting Measure generator B+ terminal voltage, which should be within 27.8~28.4V, if the voltage is normal, then it means voltmeter failure or voltmeter sampling point is in fault, repair or replace.
• Page 138
  Service Manual for WD10 Diesel Engine c) High charging voltage Fault 3: High charging voltage Phenomenon Fault detection Troubleshooting a. Measure generator B+ terminal voltage, a. Check whether which should be within 27.8~28.4V, if the voltmeter is damaged. voltage is normal, then it means voltmeter b.
• Page 139
  Service Manual for WD10 Diesel Engine e) Generator produces abnormal sound Fault 5: Generator produces abnormal sound Phenomenon Fault detection Troubleshooting a. Generator fixed support is a. Improve generator fixed deformed or interfered with support installation other parts. strength adjust b.

• Page 140: 4113 Disassembly, Inspection, Maintenance And Assembly Of A/C Compressor

  Service Manual for WD10 Diesel Engine 4113 Disassembly, Inspection, Maintenance and Assembly of A/C Compressor 41131 Exploded View of A/C Compressor 1 V-belt 2 A/C compressor 3 Draw-in block Fig. 4-86 Exploded view of A/C compressor 41132 Steps to Disassemble A/C Compressor Disassembly of A/C compressor (1) Installation position of A/C compressor.

• Page 141
  Service Manual for WD10 Diesel Engine (3) Remove the V-belt. (2) Remove compressor fastening nut, stud and spacer block. Spacer block (5) Remove the other compressor fastening nut and stud, disassembly of A/C compressor is done. 41133 Inspection and Maintenance of A/C Compressor…
• Page 142
  Service Manual for WD10 Diesel Engine The belt is too tight, which leads to Adjust the belt tension, it is suitable if the belt is vibration of A/C compressor depressed 10~14mm after loading 10kg force. Misalignment of pulley shafts, or the…
• Page 143
  Service Manual for WD10 Diesel Engine 2) Before assembling the compressor, turn over the compressor all around for 2~3 times, so that lubricating oil in the compressor can be evenly distributed. After assembling compressor and its pipelines, rotate the compressor by hand for 10 circles at least.
• Page 144
  Service Manual for WD10 Diesel Engine deformed fins with nipper plier carefully. 14) Adjust the belt tension periodically. A freshly installed belt should be adjust to required tension, adjust the belt tension again after 30min run-in period. 15) Pay attention to anti-loose and cleanliness of electric connectors.
• Page 145
  Service Manual for WD10 Diesel Engine 1) Visual inspection method 2) Soap-suds inspection method Refrigerant and freezing engine oil are mutually Apply the to-be inspected part with soap-studs, soluble, so there must be oil trace at the leaking bubble will occur if there is leakage.
• Page 146
  Service Manual for WD10 Diesel Engine 5) Positive pressure inspection method 6) Negative pressure inspection method After maintenance but before filling refrigerant, Pump the system into a vacuum, and check add a small amount of gaseous refrigerant and vacuum gauge after a while, if vacuum degree inflate the system with nitrogen to 1.4~1.5MPa,…

• Page 147: 4114 Disassembly, Inspection, Maintenance And Assembly Of Air Compressor

  Service Manual for WD10 Diesel Engine 4114 Disassembly, Inspection, Maintenance and Assembly of Air Compressor 41141 Exploded View of Air Compressor 1 Hollow bolt 2 Combined sealing washer 3 Air compressor water inlet pipe 4 Combined sealing washer 5 O-shape seal ring…

• Page 148
  Service Manual for WD10 Diesel Engine 41142 Steps to Disassemble Air Compressor (1) Remove air compressor intake pipe, water inlet pipe, water outlet pipe and oil inlet pipe. (2) Remove the three hexagon flange bearing surface toothed bolts and take down the compressor and O-shape seal ring.
• Page 149
  Service Manual for WD10 Diesel Engine 1) Air pressure gauge failure. 2) The transmission belt between air compressor and engine is loose and slipping; pipe from air compressor to gasholder is fractured or air leakage in the joints. 3) Oil-water separator, pipeline or air filter is blocked due to too much deposit sediment.
• Page 150
  Service Manual for WD10 Diesel Engine 4) Insufficient cooling of air compressor. 5) Too much unclean matter in gasholder. 6) Long-running of air compressor. 7) High pressure in engine crankcase. High engine oil pressure. 9) Deteriorated engine oil. 10) Defective air compressor.
• Page 151
  Service Manual for WD10 Diesel Engine 3) Check measure wear condition and fitting condition of air compressor cylinder sleeve, piston and piston ring, severely worn parts should be replaced. 4) For compressor air cooling parts, please: Clean up accumulated oil dirt, soot and other dirty materials on cooling fin.
• Page 152
  Service Manual for WD10 Diesel Engine worn or damaged, whether connecting rod bolts are loose; check whether air compressor main oil gallery is unblocked; replace the severely worn or damaged bearing shells, sleeve and main bearing shell; tighten connecting rod bolts to 35Nm~40Nm; unblock the main oil gallery with compressed air.
• Page 153
  Service Manual for WD10 Diesel Engine Check and adjust bearing shell clearance. (6) Air compressor leaking oil Fault phenomenon: Lubricating oil oozes from air compressor housing. Possible causes: 1) Oil seal has fallen off or oil seal is damaged. 2) Main shaft is loose.
• Page 154
  Service Manual for WD10 Diesel Engine Troubleshooting: 1) Check relief valve module when unloading intake, clean the jammed valve or replace valid parts. Check unloading valve module when unloading exhaust, clean the jammed/blocked valve or replace valid parts. 2) Check brake system, replace unserviceable parts.
• Page 155
  Service Manual for WD10 Diesel Engine Fig. 4-90 Assembly of air compressor pipelines…

• Page 156: 4115 Disassembly, Inspection, Maintenance And Assembly Of Steering Pump

  Service Manual for WD10 Diesel Engine 4115 Disassembly, Inspection, Maintenance and Assembly of Steering Pump 41151 Exploded View of Steering Pump 1 Hexagon bolt (× 2, not the same) 2 Spring washer 3 Steering pump 4 Sealing gasket 5 Steering pump fitting hole Fig.

• Page 157
  Service Manual for WD10 Diesel Engine (2) Remove steering pump fastening bolts and spring washers, take down the pump and sealing gasket. 41153 Inspection and Maintenance of Steering Pump Three typical fault of steering pump are: leaking oil, hard steering and abnormal noise. Besides, faults like steering pump gear teeth collision, steering pump shaft breakage and steering pump housing cracking are also involved.
• Page 158
  Service Manual for WD10 Diesel Engine (2) Hard steering Fault phenomenon: The steering wheel is hard to turn, or cannot be turned when engine is running but can be turned when engine is shut down, or hard to turn at engine idle speed but easy to turn when engine is speed up.
• Page 159
  Service Manual for WD10 Diesel Engine 4) If the steering wheel is easy to turn at low oil temperature, but hard to turn after oil temperature raised, we divided this fault into two kinds: a) Easy steering after cold start, but hard to steer after the vehicle is warmed up: The problem indicates that the pump and steering gear is in good condition.
• Page 160
  Service Manual for WD10 Diesel Engine 3) Poor cleanliness of steering system, leads to overwear and ablation of steering pump stator and rotor module, and produces noise. 4) Blockage, twisting or huge deformation of oil pipe results in poor oil supply, or poor system matching leads to resonance.
• Page 161
  Service Manual for WD10 Diesel Engine 41154 Steps to Assemble Steering Pump (1) Installation specifications of steering pump Check before assembling the pump: 1) Oil paint on steering pump oil inlet and outlet holes should be removed completely. 2) Do not apply sealant on steering pump flange face if an O-shape ring is used for sealing.
• Page 162
  Service Manual for WD10 Diesel Engine surface, and push the pump (with a sealing gasket) into the mounting hole gently, ensure the helical gears are normally engaged and steering pump flange face should be parallel with the fitting surface, loose-fit the pump with two M10 hexagon bolts and wave spring washers, and tighten the bolts diagonally with 16mm open end wrench (or double offset ring spanner) to 50~60Nm, make sure not to damage the sealing gasket in this process.