Wd10 Workshop Manual 20162
Wd10 Workshop Manual 20162
Wd10 Workshop Manual 20162
Special Tips
Operators must carefully read Diesel Engine Instruction Manual before operating, all technical
operations and maintenance regulations specified in the manual must be strictly complied with.
Turbocharger rotor is precision high-speed rotating component, unauthorized disassembling
and crashing is strictly prohibited, otherwise the three guarantees we committed shall
automatically become invalid.
Various bolts like diesel engine main bearing bolts and connecting rod bolts have strict torque
requirements and tightening angle requirements, users are not allowed to loosen or remove the
bolts casually; connecting rod bolts are disposable bolts, do not reuse them, otherwise the
three guarantees we committed shall automatically become invalid.
The added engine oil or diesel oil, whose brand must complied with requirements specified in
operation and maintenance manual, moreover, all oil must be filtered with specialized clean
filter, fuel must be subsided for more than 72 hours before adding; Before operating the
machine each time, check and ensure coolant level and engine oil level meet the requirements.
It is forbidden to run the diesel engine without an air filter to prevent unfiltered air entering into
cylinders.
Test-run a new machine for 50 hours (run-in period) before putting it into operation.
Increase the engine rotating speed slowly after cold starting, neither increase the speed abruptly
or long-term idling is proper; After heavy load running, do not stop the engine immediately
(peculiar circumstance exception), you should run it at low speed for 5~10 minutes before
shutting down;
After parking, if the ambient temperature is likely to be lower than 0oC and there is unused
coolant in the machine, please be sure to drain the coolant in water tank and diesel engine out;
To prevent rusting, the diesel engine is sealed with oil before delivery, seal period for common
diesel engine before unpacking is one year, for new diesel engine that has been sealed for more
than one year should be inspected and taken additional measures.
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.
Please overhaul and maintenance the engine at the service station specified by Weichai Power,
and only used Weichai Power specified spare parts for replacement, otherwise Weichai Power
shares no responsibility for damage caused by using unauthorized parts.
Service Manual for WD10 Diesel Engine
Preface
As an advanced high-speed diesel engine, WD10 is a newly-developed product of Weichai Power
Company Limited based on bran-new design concept, which meets China II emission standard.
WD10 diesel engine has the features of compact structure, reliable service, excellent dynamic
property and economic efficiency, rapid start, easy operation and convenient maintenance. WD10
can achieve advanced emissions target, definitely an ideal engine for heavy vehicles.
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. Please carefully read this manual to make the best use of it. With development of
product, some structures may be improved, so there might be a slight difference between technical
specifications and graphic descriptions in this manual and the real machine in use, users should pay
attention to the differences despite our company will continuously do the complements in the
successive versions.
SDLG
Technology Department
June 2014
Service Manual for WD10 Diesel Engine
CONTENTS
1 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 ......................................................................................... 6
16 Installation of Engine .............................................................................................. 6
17 Preparation before Starting Engine......................................................................... 6
18 Start the Engine....................................................................................................... 7
19 Run the Engine ....................................................................................................... 7
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Service Manual for WD10 Diesel Engine
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Service Manual for WD10 Diesel Engine
WD10 G XXX E2 XX
Variant code
Emission standard
Power code
Application code
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
Cylinder diameter/Stroke 126/130
Displacement (L) 9.726
Compression ratio 17:1
Ignition order 1-5-3-6-2-4
Fuel injection equipment Mechanical pump
Intake valve 0.3; Exhaust valve 0.4; EVB system
Valve clearance in cold state
0.25
Intake valve open BTDC 34~39
Valve timing (Valve clearance: when intake Intake valve closed ABDC 61~67
valve 0.3, exhaust valve 0.4) Exhaust valve open BBDC 76~81
Exhaust valve open ATDC 26~31
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Service Manual for WD10 Diesel Engine
Allowed longitudinal
Front/Rear Long-term 10/10 Short-term 30/30
inclination ()
Exhaust pipe
Allowed transverse
side/Injection pump Long-term 45/15 Short-term 45/30
inclination ()
side
Crankshaft rotating direction (View from free
Clockwise
end)
Table 1-2 Main Technical Parameters of WD10 China II series diesel engine
Fuel consumption
g/(kWh) 217
rate at rated power
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Service Manual for WD10 Diesel Engine
Minimum fuel
consumption under g/(kWh) 196
full load
o
Cold startwith aid C -25
White smoke Light
After 20s idling15%
discharge obscuration
Noise at 1m dB(A) <104
After opened the engine packing container, the user should firstly check the engine and its
accessories according to the packing list, check whether engine appearance is damaged and whether
connections are loose, and then perform the following work:
(1) Wipe up the antirust coat and anticorrosive agent on exposed surface of the engine.
(2) Drain seal fuel in fuel filter and parts of fuel system out (Its also allowed to start the engine
without draining seal fuel in fuel system, but only can the engine be loaded after all seal fuel
are consumed and normal diesel fuel is supplied in place).
ATTENTION: The users also need to pay attention to that storage life for diesel engine
before unpacking is one year, for new diesel engine that has been stored for more than
one year should be inspected and taken additional measures:
Rotate the flywheel and spray solvent into engine intake tube, until all seal fuel in cylinders
is expelled.
Spray solvent into turbocharger intake and exhaust vent, until all seal fuel there is expelled.
According to the service agreement with customer, we are obliged to add specified engine
oil to engine without oil in oil sump; while for engine that has been filled with engine oil
(with running-in accelerant) before being delivered, we suggest you replace the engine oil
after run-in period (2000km or 50h).
According to the service agreement with customer, for engine that has been filled with
coolant before delivery under customers requirements, the coolant performance should be
checked after unpacking, if the coolant is subjected to -30oC or -35oC, its PH should be 7~8
(neutral) and hardness value should be 5~15d [9~15f (hardness)], otherwise, drain the old
coolant and out and refill coolant with antifreeze additive.
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Service Manual for WD10 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
16 Installation of Engine
For installation, please ensure the center line of engine crankshaft and input shaft axis of
transmission (transmission box, gearbox or generator) are coaxial. And make sure the crankshaft is
not subjected to additional axial force caused by assembly.
(1) Turn on the power switch and insert the electric lock key, put gear shifting handle in neutral,
then begin to start the engine.
(2) Depress the clutch pedal and accelerator pedal, and then turn the electric lock key to start the
engine. If the engine failed to start in 5~10s, then restart it 1min later. But if failed three times
in a row, you should stop trying, find out the cause and eliminate it. After the engine is started,
pay attention to all readings of gauges on instrument panel and keep the engine run idly, at this
point engine oil pressure gauge should indicate pressure immediately. Do not run the cold
engine at high speed, keep the engine run idly for a while to warm the engine up but idling time
should not be too long.
(3) Use starting aid to start the engine in cold weather. By controlling the relay to put heating
equipment into work, the engine can be successfully started in -30oC environment.
19 Run the Engine
(1) After the engine is started, firstly let it run idly for several minutes, and then increase the speed
to 1000~1200r/min and partially load the engine. Do not run the engine in full load and high
speed unless coolant temperature is higher than 60oC and engine oil temperature is higher than
50oC. The load and speed should be increased gradually, try not to load or unload abruptly.
(2) In the 60h run-in period (First 3000km), the engine is only suitable for moderate duty work and
under, and no towing operation.
(3) Slow down when traveling on a slope, and long-term high torque operation is inadvisable. It is
also inappropriate to keep the engine at low speed and low load, otherwise failure like
lubricating oil carry-over may occur.
(4) It is allowed to run the engine at rated power and rated speed for normal use, but only no more
than 20min is allowed for overload running (105% rated speed or 110% rated power). Only
idling for 1~2min after unloading should the engine be shut down.
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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 <110oC.
Coolant outlet temperature 80+5oC, should not exceed 93oC
Turbine-rear exhaust temperature 550oC;
Intake air temperature after intercooler 50~55oC.
Check the exhaust gas color to determine working quality of injector and load condition, if the
color is seriously bad, stop the engine for inspection.
ATTENTION: When the engine is in operation, check it for water leakage, air leakage
and oil leakage, and stop the engine immediately for troubleshooting.
(6) Following diesel engine features should be fully aware by operator:
1) The engine consumes less fuel when output torque is large, and fuel consumption rises as
engine speed increases.
2) Output torque reaches the best value at intermediate speed range (1200~1600r/min).
3) Engine output power increases as rotating speed gets faster, and reaches rated power at
rated speed.
(7) Notes for running the engine in cold environment:
1) Fuel oil: Choose different brands of diesel fuel based on ambient temperature.
2) Engine oil: Choose engine oil of different viscosity according to season.
3) Coolant: Antifreeze additive is required for cooling system, choose different brands and
different proportion based on ambient temperature.
4) Starting: Use starting aid to start the engine in winter. Load and speed up the engine only
after oil pressure and water temperature get normal.
5) Storage battery: Be sure to check electrolyte level, viscosity and unit voltage before winter
comes. If the engine needs to be stored in cold weather for long term, be sure to take down
the battery and put it in warm environment.
6) Stop: For shutting down the engine in cold weather, you should firstly unload it and run it
idly for 1~2min, stop the engine after all temperature drops down. Notice that coolant with
antifreeze additive mustnt be drained out after stop. For coolant without antifreeze
additive, it must be drained out to prevent frost cracking the engine, open the water drain
valve or cap on engine block, engine oil cooler, radiator and water inlet pipe to drain the
coolant out.
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Service Manual for WD10 Diesel Engine
Diesel engine oil capacity: 23L, engine oil level is subjected to the marks on oil dipstick (there
might slight differences between different models).
Selection of engine oil: To ensure safety and reliable operation of your diesel engine, please choose
15W/40CF-4 or 5W/40CF-4 engine oil. If ambient temperature is higher than -15oC, select
15W/40CF-4 engine oil and 5W/40CF-4 is applicable for ambient temperature lower than -15oC
(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
Ambient Ambient
Multi-grade oil
temperature temperature
ATTENTION: It is not allowed to apply CE, CD, CC, CB, and CA grade engine oil to WP10
China II series diesel engine. Replace the filter along with the engine oil replacement.
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Service Manual for WD10 Diesel Engine
Apply general purpose lithium lubricating grease for lubrication of tensioning wheel (refer to
GB/T5671-1995)
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. The following two long-acting antifreeze additives in china are recommended:
JFL336# Long-acting antifreeze additive
FD30# Long-acting antifreeze additive
It's important to note that long-acting antifreeze additive should be replaced periodically according
to related requirements.
Calculation of antifreeze additive (for reference)
Coolant amount: 40L (for an engine with radiator)
Current application temperature of coolant: -20oC
Required minimum anti-freezing temperature: -30oC
Calculation method: Find the point of coolant amount 40L on x-coordinate, and draw a vertical
line through this point, and point 1 and 2 are the intersections between the vertical line and -20oC
oblique line, -30oC oblique line respectively. (As shown in Fig. 2-1)
Minimum anti-freezing temperature
2
4
Amount of antifreeze additive (L)
6
8
10
12
14 13.5
16
18 17.5
20
22
24
26
28
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
Coolant amount (L)
Fig. 2-1 Antifreeze additive calculation map
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Service Manual for WD10 Diesel Engine
Additional
Brand Main application Application position list remarks
Apply on thread to
Loctite 262 lock, seal and Cylinder cover auxiliary bolt
prevent loose
Anti-loosing and
Loctite 271 Bowl type plug used to block oil hole
fastening
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Service Manual for WD10 Diesel Engine
22 Daily Maintenance
Check the coolant level through the glass window, Open the filler cap to add coolant if it is
insufficient.
ATTENTION: Press down exhaust button in advance before open the filler cap to avoid
injury caused by hot coolant.
Expansion water
tank
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).
Oil level checking should be done at least 5min later after engine stopped, in order to let engine oil
have enough time to return to oil sump.
Engine oil level difference between L and H: 3L
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Service Manual for WD10 Diesel Engine
Check fuel level gauge on instrument panel and add fuel timely.
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.
The belt is automatically taken-up by a tightening wheel, user can check the tension of the belt by
pressing it with hand.
Normal exhaust gas color is light gray. Find out the cause and eliminate it if the color is abnormal.
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Service Manual for WD10 Diesel Engine
23 Periodic Maintenance
Fig. 2-7 Engine oil filling port Fig. 2-8 Oil drain plug
ATTENTION: Discarded oil should be put in prescribe location and container for recycling
and reusing.
Replace engine oil filter and filter element
(1) Screw off the old engine oil filter;
(2) Fill up the new filter with clean engine oil;
(3) Coat the new filter rubber gasket with oil before installing, and then tighten the filter by hand;
(4) After the rubber gasket touched the base, tighten the filter for another 3/4~1 circle to seal it up.
(5) Check whether there is oil leakage after engine started.
Check and adjust intake and exhaust valve clearance
(1) Firstly make sure the engine is in cold state, and then rotate the flywheel positively with
external force until cylinder 1, 6 get to TDC, at this point mark (notch groove) on flywheel is
aligned to the pointer on sightglass cover plate.
(2) Remove the valve rocker shield on cylinder cover, to determine whether it is cylinder 1 or
cylinder 6 in compression stroke (for cylinder in compression stroke, there is clearance between
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Service Manual for WD10 Diesel Engine
Adjusting
screw
Cold-state intake valve clearance is 0.3mm Cold-state Exhaust valve clearance is 0.4mm
Fig. 2-9 Intake and exhaust valve clearance
(4) After checking cylinder 1 or cylinder 6, rotate the flywheel positively with external force for
another 360to let cylinder 6 or 1 in power stroke, check and adjust other valves.
Table 2-4
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6
Intake and
Cylinder 1 in Intake Exhaust Intake Exhaust Cannot be
exhaust
compression stroke valve valve valve valve adjusted
valves
Intake and
Cylinder 6 in Cannot be Exhaust Intake Exhaust Intake
exhaust
compression stroke adjusted valve valve valve valve
valves
For exhaust valve equipped with EVB auxiliary braking device, follow the steps below to adjust its
clearance:
(1) Rotate the flywheel until the piston is in compression stroke TDC.
(2) Loosen bolt assembly 2.
(3) Adjust valve clearance adjusting screw on pushrod end 10 without compressing exhaust valve
rocker sealing surface until the total valve clearance is 0.4mm, and then tighten bolt assembly 2.
(ATTENTION: In the adjusting process, you should rotate the valve clearance adjusting
screw 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).
(4) Loosen bolt assembly 2.
(5) Adjust bolt assembly 2, and insert a 0.25mm feeler gauge between bolt 2 and valve bridge, and
tighten lockup nut at last.
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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.
11 Hexagon bolt 12 Supporting arm
1 Adjusting nut
2 Bolt
3 Valve-rocker assembly
4 Steel ball
10 Pushrod end
5 Valve-rocker piston
6 Piston spring
7 Roller pin
9 Rocker seat
8 Ball valve spring
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Service Manual for WD10 Diesel Engine
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Service Manual for WD10 Diesel Engine
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Service Manual for WD10 Diesel Engine
241 Cleaning
(1) Drain all engine oil out after warming up the engine and clean engine oil filter, add slushing oil
into engine oil sump;
(2) Drain all fuel in fuel system out, and add slushing oil instead to protect the fuel circuit;
(3) Drain cooling water out, and add coolant with antirust agent instead;
(4) Run engine idly for 15~25min;
(5) Drain all kinds of oil and fluid in the engine out, including engine oil, fuel, coolant and urea
solution;
(6) Perform the protection on other parts.
242 Protection
To prevent humid air and impurities infiltrating into the engine, all open ports (import and export of
oil, air and water) should be sealed up with caps or plastic cloth, and also seal up the whole engine
with anti-rust film.
ATTENTION: Additional packaging is required for transporting.
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Service Manual for WD10 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:
Violation of operating regulations, poor management and improper applications;
Fail to maintain the machine according to requirements or even no maintenance;
Ill manufactured accessories, fake and inferior accessories will greatly shorten the life of
engine.
Unsuitable or unqualified fuel and lubricating oil brand.
31 Diagnostic Methods
Common diagnostic methods for diesel engine failure:
Observation method: Check the exhaust gas color for fault diagnosis (Fig. 3-1).
Auscultatory method: Determine the location, type and degree of the trouble according the
abnormal noise produced by the engine (Fig. 3-2).
ATTENTION:
1. Diesel engine fault cause determination is an extremely careful job. Before basically be
sure about the cause, its not allowed to disassemble the engine casually, otherwise instead
of eliminating the fault, some severe trouble may occur due to improper reassembling.
2. For key components, such as high pressure oil pump and turbocharger, only dedicated
instruments and equipment are not enough to perform proper maintenance and
inspection, an experienced serviceman is indispensable. So users without proper
experience and tools are not allowed to disassemble and adjust the engine casually.
1. Blockage of fuel pump oil inlet filter Check and clean up the dirt, and check the
screen or hoses in the circuit cleanliness of the fuel.
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Service Manual for WD10 Diesel Engine
323 Underpower
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Service Manual for WD10 Diesel Engine
1. Blockage of intake pipe Check air filter and intake pipe, clean them up.
11. Underpressure of supercharging system Check and eliminate leakage in pipes and joints.
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Service Manual for WD10 Diesel Engine
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Service Manual for WD10 Diesel Engine
327 Turbocharger Intake Port and Intake Pipe Are Accumulated with
Engine Oil
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Service Manual for WD10 Diesel Engine
1. Low cooling water level in water tank Check for water leakage, add water.
3. Loose water pump belt Tension the belt according to related requirements.
4. Damaged water pump gasket, wear of
Check and repair or replace.
water pump impeller
5. Thermostat failure Replace.
Check water pipe, pipe joints and gaskets, replace
6. Damage of water pipe, air infiltrated in.
damaged parts.
7. Low engine oil level in oil sump, lack of Check engine oil level and leakage, repair and fill
engine oil oil.
1. Unqualified or damaged air filter element Check and replace with qualified air filter element.
Check intake pipe, gaskets and pipe joints, repair or
2. Short circuit of intake system
replace.
3. Low engine oil level in oil sump, lack of Check engine oil level and leakage, repair and fill
engine oil oil.
4. Blockage of oil gallery Clean.
Replace engine oil according to related
5. Wrong engine oil brand
requirements, choose suitable engine oil brand.
6. Breakage or wear of piston ring Replace damaged parts.
7. Wear of piston or cylinder sleeve, or Overhaul piston and cylinder sleeve, repair or
scuffing of cylinder bore replace.
8. Fail to replace engine oil filter element in
Replace it according to related requirements.
time
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Service Manual for WD10 Diesel Engine
2. Too low cooling water temperature Check the thermostat and replace it if necessary.
11. Breakage or wear of piston ring Check or replace the damaged parts.
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Service Manual for WD10 Diesel Engine
7. Worn clutch slipping Adjust working torque of the clutch or replace it.
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Service Manual for WD10 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.
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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.
Signs Information
Wear protective gloves
No open flames
No smoking
Inflammable material
Extinguisher nearby
Some unpredictable potential danger may occur during the use of engine, safety information
described in this manual cannot include all of the 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
and no property loss would bring.
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Service Manual for WD10 Diesel Engine
Signs Information
8mm socket
Dedicated tool
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 wouldnt bring damage to the engine or potential safety hazard.
414 Notes for Health Protection
The notes listed below aim at reducing contamination risk to engine maintenance personnel, related
personnel should strictly observe these notes in the process of disassembling and assembling.
(1) Avoid exposing to used engine oil long-time repeatedly.
(2) Please wear protective suit and gloves if possible.
(3) Do not put oil stained rag in your pocket.
(4) Avoid dirtying your clothes with oil, especially underwear.
(5) Wash your work clothes as often as possible; get rid of oiled clothes and shoes that cannot be
cleaned.
(6) Once get cut or be injured, seek for medical help as soon as possible.
(7) Be sure to use protective cream before work, so that stained oil on the skin can be easily
cleaned.
(8) Use soap and hot water or use hand sanitizer nail brush to clear away all oil dirt on your hands.
In case naturally secreted oils will be cleared in the same time, products that containing lanolin
can replace the naturally secreted oils to help moisturize the skin.
(9) Never clean your skin with gasoline, kerosene, fuel oil, thinner or solvent.
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Service Manual for WD10 Diesel Engine
(10) Be sure to seek for medical help immediately if any adverse reaction happened to your skin.
(11) If possible, clear away oil dirt on parts before transporting the engine.
(12) Please wear google or protective mask if there is risk of damaging your eyes. Eye washing fluid
must be prepared within reach.
(13) When maintaining the engine, prevent oil or other liquid spilling on the ground. If hydrocarbon
or other liquid is accidently leaked, be sure to take all requisite measures to quarantine this area,
to keep the environment clean and avoid personal injury.
(14) Local safety and environmental standards must be strictly observed when transporting, storing
and recycling chemicals, such as hydrocarbon, ethylene, ethylene glycol and petroleum.
Please comply with the relevant laws and regulations on environmental protection when handling
waste oil and hydrocarbon. For further instructions please contact local officials.
Most engine-related (use, maintenance and repair) accidents are caused by failing to comply with
safety regulations and basic notes. So you should be able to realize the danger ahead and take
relevant preventive measures to avoid the accident. Relevant training is required for engine operator
and maintenance personnel, good skills and appropriate tools pave the safety road.
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.
Before proceeding the maintenance or repair operation, place a sign or label with Do Not Use on
starting switch.
Before using barring rod to rotate the engine, necessary precautions should be taken:
Ensure the maintenance site and its surroundings are suitable for safety operation.
Ensure the maintenance shop or engine surrounding area is clean.
Before operation, please remove your finger ring, necklace and wrist watch. And wear
appropriate close-fit work clothes.
Before operation, please check whether relevant protective devices (google, gloves, shoes,
mask, work clothes and helmet etc.) are within validity period.
Please dont use failure or inappropriate tools.
ATTENTION: The engine must be shut down during the maintenance.
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Service Manual for WD10 Diesel Engine
Cylinder
cover
Cylinder cover shield
Valve
Engine oil Tappet
cooler cap
Camshaft
Engine oil filter
Oil
Flywheel Piston dipstick
housing Generator A/C
Engine compressor
oil
cooler Air compressor
Injector Belt
Flywheel Crankshaft
Connecting rod
Electromagnetic fan
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Service Manual for WD10 Diesel Engine
Cylinder cover is located on top of cylinder block, combustion chamber is jointly formed by
cylinder cover and piston head. Parts that connected with cylinder cover are intake pipe, exhaust
pipe, water outlet pipe, EVB oil pipe, injector, cylinder cover shield, oil-gas separator, cylinder
cover gaskets and parts of valve mechanism. As shown in Fig. 4-2
Cylinder
Cylinder cover shield gasket cover shield Rocker seat, rocker and valve springs
Nut
Clamping Rear hanger plate
block
EVB oil pipe Injector
Cylinder cover main bolt
Front hanger plate
Water outlet pipe
Intake pipe
Exhaust pipe
Valve rod sealing cartridge
Cylinder Cylinder cover
cover gasket
Cylinder cover auxiliary bolt
Oil-gas separator
Cylinder block
Valve
(1) Remove exhaust pipe, refer to disassembly of air intake and exhaust system for details;
(2) Remove intake pipe, refer to disassembly of air intake and exhaust system for details;
(3) Remove oil-gas separator;
(4) Remove water outlet pipe;
(5) Remove front and rear hanger plates;
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Service Manual for WD10 Diesel Engine
(12) Remove inner and outer springs of intake and exhaust valves, and then take out the spring seats,
valve collets and valves, refer to disassembly of valve mechanism for details;
(13) Remove valve rod seal cartridges.
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Service Manual for WD10 Diesel Engine
Cylinder cover
shield
(1) Cylinder cover shield gaskets are disposable, and should be replaced during maintenance.
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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.
(3) Clean up cylinder cover shields and install them on cylinder cover orderly.
(4) Install cylinder cover shield bolts and tighten them.
Water outlet
pipe bolt
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Service Manual for WD10 Diesel Engine
(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.
(2) If there is water leakage in pipe joint, try to replace the joint with new one and tighten it, and
check whether the problem is still exist; if connecting thread is damaged, then the pipe should
be replaced.
(1) It is recommended to take intake pipe gasket as disposable part and replace it during
maintenance;
(2) Clean up water outlet pipe joint surface and install it on cylinder cover, fasten the pipe with
bolts;
(3) Tighten the fastening bolts;
(4) Tighten the fixing bolt of high pressure fuel pipe clamp;
(5) Install intake pipe, refer to 46 Intake and Exhaust System for details;
(6) Connect sensor wiring harness to water outlet pipe;
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Service Manual for WD10 Diesel Engine
Oil-gas separator
oil return pipe Bolt
(1) Remove the two fixing bolts of oil-gas separator intake pipe joint on cylinder block;
(2) Remove the bolt that used to fix oil-gas separator on front hanger plate;
(3) Remove the outlet pipe clamp and oil return pipe clamp of oil-gas separator, remove the clamp
of oil sump return pipe;
(4) If the connecting pipe that connected to oil-gas separator oil return pipe end needs to be
disassembled, loose the pipe sleeve first.
For further disassembly, refer to Fig. 4-5.
(1) Check appearance of each part, check them for failure as damage, crack and rubber pipe
hardening, and replace relevant parts.
(2) Check whether oil-gas separator is unblocked by inflating the intake pipe, if the airflow is not
smooth, blow away the impurities and oil dirt with compressed air. Replace the oil-gas
separator if necessary.
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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.
Hexagon bolt
Hexagon bolt
Hanger plates are fixed on cylinder cover with bolts, used to hang the engine. Firstly remove the
parts fixed on the plate, such as oil-gas separator, and then remove the hexagon bolts orderly, take
down the plate.
Check whether there is crack or big distortion on hanger plates, check whether the hexagon bolts
are in good condition. Replace the damaged parts to avoid accidents.
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Service Manual for WD10 Diesel Engine
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. 4-6), required tightening
torque is 100~125Nm.
Nut
Clamp block
Clamp block
Cylinder cover
Before removing the cylinder cover, it is required to remove the parts that are installed on cylinder
cover first, including: intake pipe and exhaust pipe (refer to 46 Intake and Exhaust System for
details), fuel pipes and wiring harnesses (refer to 47 Fuel system for details), cylinder cover shield,
oil-gas separator, water outlet pipe and hanger plates (refer to 42 Cylinder Cover Assembly for
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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;
(2) Remove cylinder cover main bolts;
(3) Remove injector, due to injector nozzle is above cylinder cover base plane, he injectors must be
removed in advance to prevent the cover crashing the injectors during removal;
(4) Remove cylinder cover, put the removed cylinder cover on paper board to prevent wearing
upper surface of combustion chamber and other sealing surfaces. If more than one cylinder
cover needs to be disassembled, then it is required to mark the cylinder number on the cover for
fault analysis;
(5) Remove cylinder cover gasket, if more than one cylinder cover gasket needs to be disassembled,
then it is required to mark the cylinder number on the gaskets for fault analysis;
(6) If cylinder cover auxiliary bolts need to be replaced or checked, then remove the bolts;
(7) Remove rocker seat, intake valve and exhaust valve (refer to 45 Valve Mechanism)
(8) If the valve rod seal cartridge needs to be checked or replaced, then disassemble the seal
cartridge with dedicated tool, or clamp the seal cartridge lateral wall with a plier, and rotate to
take it out upward, removed seal cartridge cannot be reused.
(1) Check the cylinder cover for water leakage, oil leakage, air leakage and other abnormal
phenomenon before disassembling, if there is such problem, replace cylinder cover gasket to
see whether the problem is solved, refer to this section for cylinder cover gasket disassembling
method.
(2) Check the cylinder cover appearance for discoloration and crack, if crack is discovered, liquid
penetrant test should be done.
(3) Check valve recession before disassembling valve mechanism. Valve recession is the vertical
distance between valve undersurface and cylinder cover undersurface, the difference between
measured value and required value of valve recession can reflect wear degree of valve and
valve seat. A depth micrometer can be used to measure valve recession, as shown in Fig. 4-8.
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Service Manual for WD10 Diesel Engine
(4) After disassembling valve mechanism, check cylinder cover intake and exhaust passage for
water leakage and other problem, if leakage is discovered, liquid penetrant test should be done
after cleaning to locate the problem, replace the cylinder cover.
(5) Clean cylinder cover, focus on combustion chamber surface, valve seat, intake and exhaust valve,
intake and exhaust passage, remove the carbon deposit and mucilage glue, and check the surface
condition.
(6) Check valve guide pipe inner diameter. Due to 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. The inner diameter of guide pipe can be measured
with an inside micrometer, as shown in Fig. 4-9. Allowed range for inner diameter of guide
pipe is 11~11.018mm. If it exceeds allowed range, the cylinder cover must be replaced to
ensure reliability of diesel engine.
Fig. 4-9
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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.
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.
(3) Install valve rod seal cartridges
Spring
Cylinder cover
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;
3) Apply pin-plane mode to locate the cylinder cover before fastening cylinder cover bolts;
4) Assemble cylinder cover.
(5) Install clamp blocks
1) Clean up the clamp blocks;
2) Apply clean lubricating oil on clamp block bearing surfaces, and then install them on
cylinder cover orderly, avoid applying too much lubricating oil to prevent oil leaking into
cylinder cover gap.
3) Clamp block groove direction should be the same as cylinder cover gap direction;
4) Screw on cylinder cover auxiliary nuts with hand.
(6) Install cylinder cover main bolts
Fig. 4-14 Cylinder cover main bolt (Left) Cylinder cover main bolt for hanger plate (Right)
1) Cylinder cover main bolts are allowed to use three times, replace them after 2 times reuse;
2) Centre the cylinder covers orderly, apply proper amount of clean engine oil on thread and
bearing surface of cylinder cover main bolts and nuts, and then install the bolts and nuts on
cylinder cover and clamp blocks respectively. Notice that there are two kinds of clamp
blocks: one is installed between two adjacent cylinder covers, the other is installed on two
sides, as shown in Fig. 4-15.
3) Pre-tighten cylinder cover main bolts and auxiliary nuts with torque wrench to 30~50Nm;
4) Knock each clamp block so that they can be in position;
5) Pre-tighten cylinder cover auxiliary nuts to 100Nm with torque wrench orderly and mark
the nuts;
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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 90with torque wrench orderly and
mark the new position of the nuts;
8) Tighten each cylinder cover main bolt for further 90with torque wrench orderly and mark
the new position of the bolts;
9) Tighten each cylinder cover auxiliary nut for another 90with torque wrench orderly and
the tightening torque should reach 120~160Nm;
10) Tighten each cylinder cover main bolt for another 90with torque wrench orderly and the
tightening torque should reach 240~340Nm;
Fig. 4-15 Assembly of cylinder cover auxiliary nuts and clamp blocks
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Cylindrical pin
Rivet
Self-locking gasket
Hexagon socket head cap
screw
Hexagon bolt
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Compound gasket
Main oil gallery
rear plug
Rivet
Seal ring
Key point 1:
Assembling:
Tightening torque 22~29Nm Grade 8.8
Tightening torque 29~35Nm Grade 10.9
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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:
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.
Key point 4:
Assembling:
Cylinder sleeve should be checked for crack carefully before assembling, and clean up the cylinder
sleeve, press it into cylinder hole with dedicated tool, apply molybdenum powder on cylinder sleeve
external surface before the press-in process.
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Cylinder
Bowl shape plug Bowl shape plug block
Camshaft
sleeve
Oil
Oil dipstick pipe head dipstick
Bowl shape plug
Oil dipstick pipe
Bowl
shape plug
Crankshaft
sleeve
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Key point 1:
Disassembling:
Remove camshaft sleeve with dedicated tools and protect other sleeves in this process.
Assembling:
Check camshaft sleeve for scratch before assembling and replace it if necessary. Oil hole on
camshaft sleeve should be aligned to oil hole on camshaft fitting hole.
Key point 2:
Assembling:
Clean up crankcase upper surface and apply sealant on it before assembling
Key point 3:
Assembling:
Connect dipstick pipe sleeve to oil dipstick pipe properly, apply dipstick pipe sleeve bottom with
sealant, and knock dipstick pipe sleeve into the fitting hole on crankcase with copper hammer.
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Seal ring
(1) Remove engine front cover fastening bolts (key point 1);
(2) Remove engine front cover (key point 2);
(3) Remove engine front cover seal ring (key point 3);
Key point 1: The removed engine front cover should be placed in clean environment, check and
ensure inner side of engine front cover is clean before assembling.
Key point 2: Apply sealant on the fitting surface of engine front cover, make sure the sealant is
evenly distributed and no discontinuity.
Key point 3: Check whether seal ring is damaged, replace it if so. When assembling, seal ring
should be fully pressed into engine front cover seal groove.
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Seal ring
Hexagon plug
Compound gasket
Cylindrical pin
Key point 1:
Assembling:
Tighten gear housing fastening bolts according to the following order crosswise.
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.
Key point 3:
Disassembling:
When disassembling gear housing, firstly take down gear housing fastening bolts, and then remove
intermediate gear shaft and engine oil pump intermediate gear shaft. The removed gear housing
should be placed in clean environment.
Assembling:
Insert intermediate gear shaft into the gear and then place the assembly into gear housing; Apply
sealant on cylinder block water inlet and outlet ports and press-in the seal rings.
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Stud
Spring washer
1-type
hexagon bolt Flywheel housing
Flywheel
housing bolt
Monitoring
window cap
Hexagon bolt
Cylindrical pin
Key point 1:
Assembling:
Tighten flywheel housing bolts according to the following order crosswise. Apply oil on bolt flange
before assembling, flywheel housing bolts are allowed to use twice at most.
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.
Seal ring
Flat washer
Hexagon flange
toothed bolt
Oil sump
Seal gasket
Magnetic screw plug assembly
(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;
(4) Take down oil sump and the seal ring;
(5) Remove the compound gasket and magnetic screw plug assembly.
Key point 1:
Disassembling:
Before the disassembling, all engine oil should be drained out. Put an engine oil container under
drain screw plug of oil sump, screw off the plug with a plug wrench to drain oil out.
Key point 2:
Assembling:
Tighten oil sump fastening bolts according to the order illustrated in the chart below.
Fig. 4-28
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Hollow bolt
Seal gasket
Nozzle assembly
Elastic
cylindrical pin
Key point 1:
Assembling:
Tightening torque for hollow bolts
Key point 2:
Assembling:
Check the locating pin for damage and replace it if necessary. Align the pin to pin hole on engine
block and knock nozzle body gently with copper hammer to fully fit the pin.
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Key point 1:
Assembling:
Thrust plate should be used in pairs. When assembling, firstly put crankshaft into engine block, and
then install upper thrust plates (without lug). Apply lubricating grease on lower thrust plates and
adhere them on crankcase, and should be assembled together with crankcase. For thrust plates, the
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Service Manual for WD10 Diesel Engine
Key point 1:
Assembling:
Clean up the oil seals and fitting holes before assembling, no dirt is allowed. Apply lubricating oil
on the oil seal and the dedicated press-fitting tool first, and then press-in the seal slowly with the
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Service Manual for WD10 Diesel Engine
tool.
Disassembling:
Removed oil seals should not be reused.
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44 Crank-Rod Mechanism
Flywheel bolt
Bearing
Flange
Engine block
Piston-rod assembly
(1) Check before disassembling. Check connecting rod axial backlash, check tightening torque of
connecting rod bolts; Tilt and lay the engine on its side, rotate the flywheel until the to-be
removed piston is in BDC, remove connecting rod bolts and cap; Rotate the flywheel until the
to-be removed piston is in TDC, knock the piston out with wooden hammer, proceed with
caution to avoid jamming cylinder block with connecting rod big end. Remover other pistons in
the same way, number and place them orderly.
(2) Screw off front end pulley bolts, take down the pulley and damper.
(3) Screw off flywheel bolts, take down flywheel assembly, bearing, etc.
Crankshaft
Piston-rod assembly
Piston
Connecting rod
body
Connecting rod
cap
Connecting rod
Connecting bearing shell
rod bolt
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Service Manual for WD10 Diesel Engine
(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.
(2) Remove first compression ring, second compression ring and oil ring with piston ring plier and
mark them.
(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.
(2) Check wear condition of piston ring outer edge; Check wear condition of piston ring upper and
lower end face.
(3) Check wear condition of piston pin external surface.
(4) Check whether there is crack on connecting rod big end bottom hole, connecting rod body and
connecting rod small end oil hole; Check alloy layer of connecting rod shell for abnormal wear
and peeling phenomenon; Check wear condition of connecting rod side faces, check crooking
condition of connecting rod body.
(5) Check wear condition of connecting rod bearing shell, check its alloy layer for discoloration,
peeling and slippage phenomenon.
(1) Install one circlip into piston circlip groove with internal circlip plier, and rotate the circlip to
ensure it is properly fitted. The end with corner angle should face inward, and its opening
should be upward.
(2) Insert small end of connecting rod into piston inner cavity and align it to piston pin holes, and
then install piston pin, finally install the other circlip to the other side of the piston. Note that
connecting rod oblique incision and piston cooling oil gallery inlet should be in the same
direction, apply proper clean lubricating oil on connecting rod small end hole and piston pin.
(3) Arrange the assembled piston-rod assembly in cylinder number order, and then install oil ring,
second compression ring and first compression ring into piston ring grooves orderly with piston
ring plier. The face with mark TOP should be upward, and the ring should be flexible in ring
groove.
(4) Clean up cylinder inner wall, crankshaft connecting lever and piston-rod assembly, and apply
clean lubricating oil on each motion pair.
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(5) Adjust opening direction of each ring: The opening direction of first compression ring should
be 30to 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 120to both
that of first compression ring and second compression ring, also should be perpendicular to
piston pin center line. As shown in Fig. 4-35.
Oil ring
Fig. 4-35 Schematic diagram for installation of piston rings
(6) Rotate the flywheel with external force until cylinder 1, 6 get to BDC, fit cylinder 1, 6
piston-rod assembly and loose-fit connecting rod bolts. Connecting rod parting surface should
face left side of cylinder block (i.e. engine oil cooler side). The numbered pistons should not be
mixed, install each piston to the corresponding cylinder; connecting rod cap and connecting rod
should be used in pairs, apply clean lubricating oil on connecting rod bolts before assembling.
(7) Tighten connecting rod bolts: Firstly pre-tighten the bolts to 120Nm in symmetry, and then
tighten each bolts for further 905, in the meantime tighten torque should be up to
170~250Nm. Assemble other piston-rods in the same way.
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Crankcase
Flywheel bolt
Flange
Engine block
Pulley bolt
(1) Put the engine crankcase upward, and then remove main bearing bolts and place them orderly;
(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);
(3) Classify the removed parts according to the requirements.
(1) Check whether there is crack on fillet area of crankshaft main journal and neck of crankshaft;
Check the joint part of crankshaft and main bearing for crack, check and dredge the oil gallery.
(2) Check the wear condition of crankshaft main journal and neck of crankshaft, and check whether
there is line-like puckering, metal peeling and crack.
(3) Check the wear condition of front and rear oil seals.
(4) Check whether there is failure like thread damage on main bearing bolts
(5) Check crankshaft flange bolt holes for crack.
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(6) Check wear condition of crankshaft journal, check bend and distortion condition of crankshaft.
(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.
Flywheel
Flywheel ring gear
Hexagon bolt
Bearing
Crankshaft
Flywheel bolt
Baffle ring
Stud
Locating pin
(1) Check whether there is failure like thread damage on flywheel bolts.
(2) Check flywheel surface for conquassation.
(3) Check whether flywheel ring gear is damaged.
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Service Manual for WD10 Diesel Engine
Flange Crankshaft
Damper
Crankshaft pulley
Pulley bolt
Screw off pulley bolts and then take down pulley and damper orderly.
After assembling the timing gear housing, install the damper and crankshaft pulley orderly.
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Service Manual for WD10 Diesel Engine
Crankshaft
Push the shells out with hand, and mark the removed shells (should be corresponded with fitting
holes on engine block and crankcase).
(1) Clean the bearing shells and check their wear condition.
(2) Check and ensure there is no peeling, locating lip damage and transverse crack on the shell.
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45 Valve Mechanism
Adjusting nut
Hexagon screw
Intake rocker
Supporting arm Adjusting screw
Adjusting bolt assembly
Adjusting nut Valve lock clamp
Rocker shaft Upper valve spring seat
Valve inner spring
Exhaust rocker
Adjusting screw Valve outer spring
Lower valve spring seat
Valve cap
Valve
Pushrod
Camshaft
(1) Remove rocker and rocker shaft, refer to disassembly of rocker and rocker shaft for details;
(2) Remove intake and exhaust valves, refer to disassembly of valves for details;
(3) Remove valve tappet and pushrod, refer to disassembly of valve tappet and pushrod for details;
(4) Remove camshaft and camshaft timing gear, refer to disassembly of camshaft and camshaft
timing gear for details;
(5) Remove intermediate gear, refer to disassembly of intermediate gear for details.
(1) Install intermediate gear, refer to assembly of intermediate gear for details.
(2) Assemble camshaft and camshaft timing gear, refer to assembly of camshaft and camshaft
timing gear for details;
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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;
Camshaft
Thrust plate
Camshaft bearingshell
Camshaft timing gear
Locating pin
Hexagon screw
Hexagon bolt
(1) Rotate camshaft to check whether camshaft and timing gear are flexible and smooth;
(2) Measure camshaft axial movement with a dial gauge, compare it with required range
0.1~0.4mm;
(3) Check timing gear backlash;
(4) Rotate crankshaft until camshaft timing gear is in cylinder 1 TDC. Remove the hexagon bolts
of camshaft timing gear and take down the gear and locating pins;
(5) Remove the hexagon bolts of camshaft thrust plate, take down the plate;
(6) Take down camshaft.
(1) Check whether there is wear trace on cam working surface, check main journal for seizure and
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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
cylinder 3)
The fourth main journal (Between cylinder 3 and
cylinder 4) 0.06
(3) Measure tappet maximum lift (distance between cam tip and base circle)
(4) Check timing gear for interference and severe tooth face wear.
After disassembling, examine camshaft and timing gear, and parts with wear or large parameter
deviation should be repaired or replaced.
(1) Rub-up camshaft fitting hole with towel and check the hole for bump damage, apply proper
amount of lubricating oil on camshaft sleeve inner surface. For camshaft fitting hole that
involving bump damaged should not be reused even after repair.
(2) Place camshaft guide tool and lubricating sleeve into the fitting hole, rub-up camshaft and
check for bump damage, and then insert camshaft into camshaft fitting hole, remove camshaft
guide tool and lubricating sleeve after the camshaft is properly fitted. Be careful not to crash
camshaft sleeve during the inserting process.
(3) Install camshaft thrust plates, loose-fit the pre-glued hexagon bolts and tighten them.
Tightening torque of the bolts should be 29~35Nm.
(4) Apply KB277 sealant on camshaft fitting hole bowl shape plug fore-end, the sealant trace
should be continuous and enclosed. And then press the plug into camshaft fitting hole and clean
up the remnant sealant around the plug, make sure the plug is free of turnup.
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(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
position is aligned to the half line on flywheel housing, install timing gear.
(7) The mark on timing gear should be aligned to OT mark on timing gear housing.
(8) Screw on the pre-coated hexagon bolts and tighten them diagonally, required tightening torque
is 32~36Nm. Leave a white mark on one of the bolts after tightening, measure and record the
side clearance between timing gear and intermediate gear according to requirements.
(9) Required side clearance between timing gear and intermediate gear is 0.015~0.33mm. Install
the cylindrical pins.
Hexagon bolt
Adjusting nut
Supporting arm
Adjusting bolt assembly
Intake rocker
assembly Exhaust rocker assembly
Rocker shaft
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Service Manual for WD10 Diesel Engine
(1) Clean up the rocker and check its appearance for crack.
(2) Check rocker inner hole for abrasion and scratch, and measure its diameter.
(3) Check the ball pin and rocker other end arc surface for abrasion.
(4) Check whether all oil galleries are smooth.
(5) Measure diameter of rocker inner hole and rocker shaft, and ensure the fit clearance meets the
requirements:
Model Check items Standard value Measured value
Diameter of rocker
23.972~23.993
inner hole
WP10
Diameter of rocker
23.927~23.960
shaft
(1) Apply a small amount of lubricating oil on valve rocker seat and then fit intake and exhaust
valve assembly on rocker seat. Loose-fit the hexagon bolts, ensure proper clearance between
rocker and rocker seat so that the rocker can rotate flexible;
(2) For the last assembling step of EVB rocker, firstly place supporting arm on rocker seat and then
loose-fit hexagon bolts and EVB adjusting bolt assembly, tighten the supporting arm;
(3) After the assembling, rotate crankshaft to check whether rocker is flexible.
(4) Check and adjust intake and exhaust valve clearance
1) Rotate the engine until cylinder 1 reach its TDC, at this point flywheel mark should be
aligned to flywheel housing mark, make sure cylinder 1 is in compression stroke.
2) Adjust intake valve clearance of No. 1, 2, 4 cylinder and exhaust valve clearance of No. 1,
3, 5 cylinder, required intake valve clearance is 0.30.03mm, while that for exhaust valve
is 0.40.03mm, and EVB valve clearance should be 0.250.03mm. Tightening torque of
intake and exhaust valve adjusting nut is 30~40Nm. Methods to adjust intake and exhaust
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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:
In the adjusting process, you should rotate the valve clearance adjusting screw 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).
11 Hexagon bolt 12 Supporting arm
1 Adjusting nut
2 Bolt
3 Valve-rocker assembly
4 Steel ball
10 Pushrod end
5 Valve-rocker piston
6 Piston spring
7 Roller pin
9 Rocker seat
8 Ball valve spring
Fig. 4-44
As shown in Fig. 4-45, place a 0.25mm feeler gauge between rocker piston and exhaust
valve, and adjust valve clearance to 0.25mm by adjusting bolt assembly 2, tighten the
locknut. ATTENTION: In the adjusting process, you should rotate 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
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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.
4) Check valve timing of cylinder 1 in cold state, intake valve TDC 18~23, exhaust valve
TDC 20~25.
Pushrod
Cylinder cover
Engine block
Tappet
(1) After removing rockers and rocker shafts, directly take out pushrods, place them orderly;
(2) After removing cylinder covers (refer to disassembly of cylinder cover for details), directly take
out valve tappets, place them orderly;
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(1) Check valve tappets and pushrods, replace them if necessary. Before installing the tappets, it
must be cleaned with compressed air, and check whether the oil channels are unblocked;
(2) Apply clean lubricating oil evenly on valve tappet fitting surfaces;
(3) Install valve tappets into engine block tappet-fitting holes
(4) After assembling cylinder covers (refer to assembly of cylinder cover for details), clean the
pushrods with compressed air and check whether the oil channels are unblocked;
(5) Apply clean lubricating oil on pushrod and ensure the round head is applied with sufficient oil.
(6) Install pushrod, put the pushrod into valve tappet through cylinder cover.
Valve cap
Valve lock clamp
Upper valve spring seat
Valve inner spring Valve outer spring
Valve
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Service Manual for WD10 Diesel Engine
(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;
(2) Take valve out of valve seat.
(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 for carbon deposit;
(4) Check valve retainer end faces for carbon deposit and sintering.
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Sleeve
Intermediate gear shaft
Gasket Bolt
Intermediate gear
(1) Remove air compressor, refer to disassembly of engine accessory system for details;
(2) Remove fuel injection pump, refer to disassembly of fuel system for details;
(3) Remove camshaft timing gear, refer to disassembly of valve mechanism for details;
(4) Remove the four M10 fastening hexagon bolts of intermediate gear, take down the gaskets.
Screw a M8 bolt into the gear shaft end hole to pull the shaft out, pay attention to avoid
intermediate gear falling off;
(5) Take down intermediate gear assembly and intermediate gear shaft along with the gear housing,
and then take them out from the opening of gear housing.
(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 mark should face outward. And then upside-down the engine (to prevent intermediate gear
assembly falling off) and install intermediate gear assembly.
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Intake pipe
Turbocharger
Exhaust pipe
(1) Loosen air filter fixing bolts and hose clamps, take down air filter and hoses.
(2) Loosen clamps of intercooler rubber hoses, take down turbocharger compressor outlet hose and
intercooler intake pipe adapter.
(3) Remove fixing bolts of turbocharger oil inlet and outlet pipes, take down the pipes and gaskets.
(4) Remove tail pipe fixing bolts and turbocharger fixing bolts, take down turbocharger.
(5) Remove intake heater wiring and screw off intake pipe fastening bolts; take down the pipe,
refer to 462 Disassembly, Inspection, Maintenance and Assembly of Intake Pipe for details.
(6) Remove heat shield bolts and take down heat shield, screw off fastening bolts of exhaust pipe,
take down the pipe, refer to 463 Disassembly, Inspection, Maintenance and Assembly of
Exhaust Pipe for details.
Nut
Stud
Intake pipe end
Intake pipe gasket cover gasket
Intake pipe
Intake pipe end
cover
Intake heater
Intake heater
gasket
(1) Screw off intake pipe bolts orderly, take down the pipe and gaskets;
(2) Screw off intake pipe adapter fastening nuts, take down the adapter, intake heater and heater
gaskets;
(3) Screw off intake pipe end cover fastening nuts, take down intake pipe end cover and gaskets
orderly.
(1) Check intake pipe for crack and distortion, replace the pipe if necessary.
(2) Check intake pipe gaskets and end cover gaskets for deformation and dilaceration, replace it if
necessary.
(3) Check intake heater for burnout and short circuit, replace it if necessary.
Assembling steps are contrary to disassembling ones. Recommended tightening torque for intake
pipe bolts is 23Nm.
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Exhaust pipe
heat shield bolt
(1) Screw off exhaust pipe heat shield bolts orderly and take down the shield;
(2) Remove exhaust pipe fastening bolts, take down front and rear exhaust pipes and gaskets.
(3) Separate front and rear exhaust pipes, remove front exhaust pipe adapter and seal rings.
(1) Check whether there is crack on exhaust pipe, whether the flange is deformed, replace the pipe
if necessary.
(2) Check whether there is air leakage on exhaust pipe flange, replace the gasket if necessary.
(3) Check exhaust pipe gasket for deformation and dilaceration, replace it if necessary.
(4) Check exhaust pipe seal rings for sintering, rust and carbon deposit, replace it if necessary.
Assembling steps are contrary to disassembling ones. Note the following points during assembly:
(1) Pay attention not to scratch exhaust pipe adapter when assembling the seal rings, the openings
of four seal rings should staggered for 90.
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(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.
Stud
Lock nut
Stud
Turbocharger gasket
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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.
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(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.
(4) Check air filter, clean it timely if there is too much dust accumulated in the filter.
(1) Loose-fit one end of the preassembled turbocharger oil inlet pipe to engine block main oil port.
Pay attention to adjust the position of the pipe, so that it can be easily connected to
turbocharger.
(2) Install turbocharger gasket on exhaust pipe flange.
(3) Install turbocharger oil return pipe and studs on turbocharger assembly, apply 0# molybdenum
disulfide and clean lubricating oil on the studs. Tighten oil return pipe fixing bolts to 22~29Nm.
(4) Place a gasket on exhaust pipe flange and fix them on turbocharger assembly, loose-fit 2-type
all-metal hexagon lock nuts and tighten them.
(5) Pour proper amount of clean lubricating oil into turbocharger oil inlet port, and clean up the
overflowed oil.
(6) Connect oil inlet pipe to turbocharger with a gasket, fix them with hexagon bolts and
self-locking gaskets, tighten the bolts to 22~29Nm. Rotate supercharger impeller and it should
be flexible and free of resistance.
(7) Knock-in turbocharger oil return elbow. Fitting surface of the elbow should be applied with 271
thread sealant.
(8) Install turbocharger oil return hose and hose clamps, tighten the clamps. Note that the direction
of two clamps should be uniform, straighten out the house.
(9) All gaskets are disposable and should be replaced once removed.
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47 Fuel System
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(1) Screw off the hexagon nuts that connecting fuel injection pump flange and gear housing;
(2) Disconnect fuel injection pump module and gear module from the engine;
(3) Remove fuel injection pump gear lock nut;
(4) Screw off the hexagon bolts that connecting fuel injection pump and the flange;
(5) Remove fuel injection pump flange.
The structure of fuel injection pump is illustrated in Fig. 4-57. Rotate the flywheel until cylinder 1
reaches compression TDC, at this point the mark on injection pump gear should be aligned to mark
on injection pump flange.
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(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;
(3) Install injection pump gears, specification of fuel injection pump gear lock nut is M241.5,
tighten the nut to 250~300Nm directly;
(4) Install the threes pump fixing studs on engine block;
(5) Rotate the flywheel until cylinder 1 reaches compression TDC, at this point rotate injection
pump gears until the mark on injection pump gear module is aligned to mark on injection pump
flange, install injection pump module. Insert a 4 pin into the corresponding hole on middle
flange and pump gear, pull out the pin after fastening common rail module, and seal the hole up
with M5 screw (applied with sealant). After the assembly, the mark on driving gear of injection
pump should be aligned to mark on driven gear. As shown in Fig. 4-58. Tighten the hexagon
nuts to fasten the injection pump on gear housing.
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Assembling steps are contrary to disassembling ones. ATTENTION: Tightening torque of high
pressure fuel pipe fastening nuts is 30~40Nm.
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(1) Remove the hexagon bolts that used to fix injector pressing block;
(2) Remove injector pressing block and fixed block;
(3) Take injector assembly out of cylinder cover.
(1) O-shape seal rings of injector and high pressure joints, high pressure joint thread, and fitting
surfaces of high pressure joint and nuts must be applied with lubricating oil;
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(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;
(5) Pre-tighten high pressure joint to 15~20Nm (nuts);
(6) Tighten injector clamping bolt for 10Nm+120;
(7) Tighten high pressure joint to 50~55Nm (nuts);
(8) High pressure joint, O-shape seal rings and sealing gaskets are disposal and cannot be reused,
check the O-shape seal rings and sealing gaskets for sealing performance after assembling.
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48 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.
F
a
n Oil dipstick module
Tensioning wheel
and belt module
Pulley
Fan clutch
Fan
Check fan, fan clutch, fan connecting plate and water pump pulley for crack and damage.
(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.
(2) Assembling steps are contrary to disassembling ones.
Water pump
gasket Water pump
Stud
Pipe joint
gasket
Pipe joint
Supporting block Wave spring washer Hexagon flange nut
Pipe joint module Hexagon bolt
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(1) Check pipe joint and pipe joint module for blockage and crack damage, replace if necessary.
(2) Check pipe joint gasket and water pump gasket for crack damage, replace if necessary.
(3) Check the bolts, nuts and studs for thread damage, replace if necessary.
(4) Check water pump for crack damage, replace it if necessary.
(1) Before the assembly, check pipe joint, pipe joint module, hexagon bolts, wave spring washers,
supporting block, nuts, studs, pipe joint gaskets, water pump gaskets and water pump, make
sure there is no manufacturing and use defect.
(2) Clean up gear housing inner cavity that connected to water pump.
(3) Assembling steps are contrary to disassembling ones.
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Clamp
Block cap
(1) Check whether the clamps are in good condition, replace if necessary.
(2) Check the two cooling water adapters for crack damage, replace them if necessary.
(3) Check thermostat for fracture damage, replace it if necessary.
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(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.
(3) Assembling steps are contrary to disassembling ones.
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49 Lubricating System
Hexagon plug
Hollow bolt
(1) Remove oil sump, refer to disassembly of oil sump for details.
(2) Remove oil strainer.
(3) Remove crankshaft pulley, damper and the hexagonal head plug from gear housing, refer to
disassembly of crank-rod mechanism for details.
(4) Remove engine oil pump intermediate gear module.
(5) Remove engine oil pump.
(6) Remove main oil gallery pressure limiting valve.
(7) Remove engine oil filter.
(8) Remove the hollow bolt (for compressor water supply) on engine oil cooler cap and the
hexagon bolts that used to fix the oil dipstick module.
(9) Remove engine oil cooler.
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Remove the two hexagon flange bearing surface toothed bolts, take down engine oil pump and
gasket, as shown in Fig. 4-66.
(1) Check the engine oil pump for crack damage, check whether its inner cavity is smooth, replace
it if necessary.
(2) Check engine oil pump gasket for oil leakage, replace the gasket if necessary.
(1) Check the pump and pump gasket before assembling, make sure there is no manufacturing
defect and damage.
(2) Clean up the fitting surface between oil pump and crankcase.
(3) Install engine oil pump gasket.
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(1) Check whether there is crack on intermediate gear and intermediate gear shaft. Replace if
necessary.
(2) Check the seal ring for breakage and replace it if so.
(1) Before the assembly, check engine oil pump intermediate gear module, intermediate gear shaft,
hexagon bolt and seal ring, make sure there is no manufacturing and use defect and damage.
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(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).
(5) Install intermediate gear shaft.
(6) Install and tighten the hexagon bolt.
Remove the four bolts on engine oil filter and take down engine oil filter assembly and filter seat
gasket. As shown in Fig. 4-68.
(1) Check the engine oil filter assembly for damage, replace it if necessary.
(2) Check the engine oil filter seat gasket for damage, replace it if necessary.
(1) Before the assembly, check engine oil filter assembly and filter seat gasket, make sure there is
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Supporting block
Seal gasket
Drain all coolant out before the disassembly. Screw off engine oil cooler cap fixing bolts orderly
and take down the cap and cap gasket.
(1) Check the engine oil cooler cap for crack damage, replace it if necessary.
(2) Check engine oil cooler cap gasket for water leakage and replace the gasket if it is damaged.
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(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.
(3) Install and tighten engine oil cooler cap fixing bolts.
Seal ring
Engine oil cooler
Wave spring washer
Hexagon socket
cap bolt
Screw off the four bolts on engine oil cooler and take down engine oil cooler and the seal rings, as
shown in Fig. 4-70
Check the engine oil cooler for crack damage, replace it if necessary.
(1) Check the cooler before assembling, make sure there is no manufacturing defect and damage.
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(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.
Fig. 4-71 Exploded view of main oil gallery pressure limiting valve
Screw off main oil gallery pressure limiting valve, as shown in Fig. 4-71.
4973 Inspection and Maintenance of Main Oil Gallery Pressure Limiting Valve
(1) Check service condition of the valve spring, replace the spring if necessary.
(2) Check the valve for crack damage, replace it if necessary.
(1) Check the valve before assembling, make sure there is no manufacturing defect and damage.
(2) Clean up the valve and valve fitting hole on engine block.
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Hexagon plug
Compound gasket
Safety valve spring
Safety valve
Screw off the hexagon plug, and then take down compound gasket, safety valve spring and safety
valve orderly, as shown in Fig. 4-72.
(1) Check service condition of safety valve spring, replace the spring if necessary.
(2) Check safety valve, hexagon plug and compound gasket for crack damage, replace if necessary.
(1) Check safety valve, safety valve spring, hexagon plug and compound gasket before assembling,
make sure there is no manufacturing defect and damage.
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(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.
Gasket
Hexagon bolt Flat washer
Engine oil stainer
Screw off the two hexagon bolts, take down the oil strainer and gasket, as shown in Fig. 4-73.
Check the strainer and gasket for crack damage, replace if necessary.
(1) Check the strainer and gasket before assembling, make sure there is no manufacturing defect
and damage.
(2) Clean up fitting surface between oil strainer and engine oil pump, clean up the strainer inner
cavity.
(3) Install the strainer and gasket.
(4) Install and tighten the hexagon bolts.
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4 Ring gear
2 Stud
1 Starter motor 3 Hexagon nut
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1 Air compressor water inlet pipe module 2 Air compressor oil inlet pipe module
3 Hydraulic pump module 4 Air compressor water outlet pipe module
5 A/C compressor draw-in module 6 (Generator) poly V-belt
7 (A/C compressor) V-belt 8 A/C compressor module 9 Generator module
10 Generator draw-in module 11 Air compressor intake pipe module
Fig. 4-75 Exploded view of engine accessory system
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Air compressor
intake pipe Air compressor
Air compressor exhaust pipe Hexagon flange
bearing surface
water outlet pipe toothed bolt
Air O-shape
Air compressor compressor seal ring
oil inlet pipe
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(1) Remove A/C compressor draw-in bolt and disassemble A/C compressor V-belt (refer to
disassembly of A/C compressor for details).
(2) Screw off generator draw-in nut (M10).
Generator Draw-in nut (M10)
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(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
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It means there is no
NO voltage in B+ terminal,
Is the test lamp on?
the wire to battery
positive is in failure.
YES
Connect one end of test lamp to
generator D+ terminal instead of E
terminal.
NO Circuit in generator D+
Is the test lamp on?
terminal is in failure
YES
YES
Is the test lamp on? Generator failure
NO
Generator is fine
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(2) Charging
indicator
doesnt go
a. Rated power of
out when
indicator lamp is small a. 2~6w lamp is recommended, or repair the
engine
or parallel exciting circuit.
idling, it only
resistance gets loose. b. Adjust engine idling speed.
goes out
b. Too low idling speed.
when engine
is in high
speed.
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markedly once f. Check whether wires in If the wire or connector gets too hot in
loaded. charging system are heavy load condition, then the wire or
loose, oxidized and connector should be replaced.
producing too much f. Oxidized lead foot and the housing that
heat, check whether used to install grounding bolts should be
bolt connections are polished before reassembling.
loose. Retighten the loose nuts and lug plates,
g. Measure output voltage re-plug the loose connectors firmly.
of generator W/R/AC ATTENTION: Reassembled or
terminal (should be retightened parts should be run in heavy
about half of B+ load and will be overheat, check whether
terminal voltage). the overheat is still there 3~5min later.
h. Check whether battery g. If there is big difference between terminal
charging is normal. W/R/AC output voltage and normal range
and big voltage drop happened after the
engine loaded, then it means failure in
generator rectifier bridge or stator, repair
or replace.
h. If charging current drops to about 10A
10min later, or charging current reaches to
30-90A for a long time, then the battery is
damaged, repair or replace the battery.
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(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.
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The belt is too tight, which leads to Adjust the belt tension, it is suitable if the belt is
4
vibration of A/C compressor depressed 10~14mm after loading 10kg force.
Misalignment of pulley shafts, or the
Reassemble the compressor to keep the shafts
5 belt is not on the same plane, which
aligned and belt on the same plane.
leads to vibration of A/C compressor
Loose compressor fastening bolts;
6 Tighten the bolts; replace compressor support.
loose or damaged support
2 Clutch coil failure or loose connector Tighten the connector, replace the clutch.
Low voltage or clutch coil burnout Find out the cause for low voltage, increase the
3 due to short circuit, which leads to voltage or check the circuit, replace the
clutch fail to pull-in or slipping compressor if there is short circuit.
High-low pressure switch failure or Check the switch, find out what caused the open
5
open circuit circuit, and replace if necessary.
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.
3) If necessary, clean the system when replacing the compressor, replace the reservoir, expansion
valve or gas-liquid separator and throttle pipe at the same time.
4) The compressor is sealed with 0.06~0.10MPa dry nitrogen, so be careful when removing
compressor intake and exhaust sealing plugs. After removing compressor intake and exhaust
sealing plugs, connect the compressor to refrigerating system immediately, and also vacuum
the system to prevent moisture in the air absorbed by lubricating oil.
5) Apply a small amount of lubricating oil on the seal rings of compressor intake and exhaust
pipelines before assembling.
6) Fixing bolts of compressor intake and exhaust pipes must be of high strength, refer to Table 4-4
for tightening torques.
Table 4-4 Bolt tightening torque
Thread specification Tightening torque (Nm)
M161 10~12
M81 20~25
M81.25 25~30
M101.25 40~50
7) When assembling the compressor, the bolts should be evenly tightened, keep pulley shaft and
engine shaft in parallel, and the belt should be in the same plane. Adjust the belt tension, it is
suitable if the belt is depressed 10~14mm after loading 10kg force.
8) Freezing lubricating oil of different brands cannot be mixed, otherwise normal operation of
A/C compressor cannot be guaranteed.
9) Slow down the refrigerant draining process, to prevent freezing lubricating oil spraying along
with the refrigerant.
10) Fill lubricating oil through the intake port or oil drain bolt.
11) Avoid direct solar exposure when parking in summer, in order to prevent burdening the A/C.
For start the machine after solar exposure, firstly you should open the window to dissipate the
heat, close the window and turn on the A/C 1 minute later.
12) To avoid the accumulated sundries and dirt on condenser affecting the cooling performance,
clean the condenser with water if it is dirty.
13) ATTENTION: When cleaning the condenser, do not crash and deform the fins, straighten the
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1 Hollow bolt 2 Combined sealing washer 3 Air compressor water inlet pipe
4 Combined sealing washer 5 O-shape seal ring 6 Air compressor lubricating oil pipe
7 Hollow bolt 8 Combined sealing washer 9 Air compressor gear
10 Air compressor 11 Hexagon flange bearing surface toothed bolt
12 Water outlet pipe joint body 13 Air compressor water outlet pipe
14 Combined sealing washer 15 Hollow bolt 16 Hexagon bolt
17 Water outlet pipe fixing support 18 Water inlet pipe locknut
19 Air compressor intake adapter 20 Air compressor exhaust adapter
21 Water inlet pipe joint body 22 Water inlet pipe joint body 23 Hollow bolt
24 Clamp 25 Air compressor intake pipe 26 Clamp
Fig. 4-87 Exploded view of air compressor
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(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. As shown in Fig. 4-88.
Air compressor
intake pipe Hexagon flange
Air compressor bearing surface
exhaust pipe toothed bolt
Air compressor
water outlet pipe
Air compressor
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Theoretical air
Joint inner Pipe joint inner Pipe inner Pipe length
displacement
diameter (mm) diameter (mm) diameter (mm) (mm)
(m3/h)
17 14 14 18
>17~ 16 16 20
>20~ 18 18 22
500
>30~ 20 20 24
>40~ 22 22 26
>50~ 24 24 28
Single cylinder air compressor (Standard load cycle) 25% 3.6m 13m
Single cylinder air compressor (Heavy load cycle) 25~35% 3.6~4.6m 16m
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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. Check the cooling fin and should replace the damaged parts. For
compressor water cooling parts, please: Check the cooling pipe size (recommended minimum
pipe diameter is 9.5mm), Check the flow rate of air refrigerant, minimum allowed flow rate is
5L/min when the engine is running. If refrigerant flow rate is small, check whether cooling pipe
and accessories are rusted or twisted.
5) Check and ensure water temperature is under 93oC; check the air valve on gasholder and ensure
it can work normally. It is suggested to equip the machine with automatic exhaust valve and air
drier.
6) When the brake is not used, air leakage (pressure drop) should not exceed 6.9kPa/min, and
when depressing the brake, that value is 20.7kPa/min. If there is severe leakage, check the
system and remove the fault. Check whether unloading system is working and repair it.
7) Check whether oil pressure in crankcase is too high, replace or repair ventilating device of
crankcase if so. If the oil dipstick is loose or partially raised, then oil pressure in crankcase is in
problem.
8) Check engine oil pressure (air compressor oil inlet port), compare it with rated pressure.
9) Replace with qualified lubricating oil (engine oil).
Only after ruling all the causes above out should the air compressor be repaired or replaced.
(4) Air compressor produces abnormal sound.
Fault phenomenon: Metal crash, rhythmic knock or grinding squeal
Possible causes:
1) Connecting rod sleeve or bearing shells are severely worn, connecting rod bolts are loose, main
bearing shell is worn or damaged that result in crash noise.
2) The belt is too loose, driving and driven pulley groove type is not uniform, which lead to
slipping squeal.
3) No engine oil is supplied to air compressor, dry friction of metal leading to squeal.
4) Loose fixing bolts.
5) Loose gear fastening nuts results in oversized tooth space, which will bring rhythmic knock.
6) Foreign matter in piston head.
Troubleshooting:
1) Check whether connecting rod bearing shells, connecting rod sleeve and main bearing shell is
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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.
2) Check whether the driving and driven pulley groove type is uniform, replace if not. Adjust the
belt tightness degree (press the belt with your thumb, it is suitable if the belt is depressed about
10mm).
3) Check engine oil pressure (air compressor oil inlet port), check whether engine oil pipe is
damaged or blocked, adjust, clean or replace the invalid pipe if the oil pressure is insufficient;
Check engine oil quality and impurity content, compare it with application standard, replace the
oil immediately if out of limits; check whether there is engine oil supplied to air compressor,
conduct a comprehensive inspection if not.
4) Check whether compressor fixing bolts are loose and tighten them.
5) For gear-driven compressor, check the fitting condition of the gears, tighten loose nuts, and
replace the gear if there is fitting problem.
6) Clean up foreign matter.
(5) Air compressor burning
Fault phenomenon: For belt-driven compressor, its main shaft is locked; for gear-driven
compressor, the bearing shell or connecting rod bearing shell is abnormally loose.
Possible causes:
1) The lubricating oil is deteriorated or too many impurities in the oil.
2) Insufficient oil supply or no oil supply.
3) Compressor inner oil channel is blocked by misplaced bearing shell.
4) Damaged bearing shell or connecting rod bearing shell, or too small fit clearance.
Troubleshooting:
1) Check engine oil quality and impurity content, compare it with application standard, replace the
oil immediately if out of limits;
2) Check engine oil pressure (air compressor oil inlet port), check whether engine oil pipe is
damaged or blocked, adjust, clean or replace the invalid pipe if the oil pressure is insufficient;
3) Check installation position of bearing shell, oil hole on bearing shell should be aligned to
housing oil hole.
4) Check whether bearing shell and connecting rod bearing shell are damaged, check whether
crankshaft is damaged or worn when replacing or repairing the shell.
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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.
3) Poor lubrication between piston and cylinder sleeve, undersized clearance or scuffing will
result in overheat, check and repair or replace unserviceable parts.
(1) Place the O-shape seal ring in compressor ring groove. Make sure compressor main axis is
perpendicular to engine timing gear housing fitting surface, and push the compressor into the
mounting hole gently, ensure the helical gears are normally engaged and air compressor flange
face should be parallel with engine fitting surface, loose-fit the compressor with three M10
hexagon toothed bolts, and tighten the bolts with 13mm open end wrench (or double offset ring
spanner) to 44~58Nm.
Hexagon flange
bearing surface
toothed bolt
Air
compressor
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1 Hexagon bolt (2, not the same) 2 Spring washer 3 Steering pump
4 Sealing gasket 5 Steering pump fitting hole
Fig. 4-91 Exploded view of steering pump
Screw off steering pump fastening bolts with 16mm wrench, take down the bolts and spring
washers. Knock the pump housing gently with rubber hammer to take down the pump and sealing
gasket.
(2) Remove steering pump fastening bolts and spring washers, take down the pump and sealing
gasket.
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.
(1) Leaking oil
Fault phenomenon: Oil level in steering system is dropping, oil leakage is involved.
Possible causes:
1) Check all connecting parts of oil pipes, oil cups, steering gear and booster pump for oil leakage.
If steering pump oil inlet pipe is loose, generally there is oil leakage phenomenon in the inlet
port.
2) So never strike the pump oil inlet pipe (interference fit is adopted between the pipe and pump).
3) Check steering pump pipe joints, replace the seal ring if the joint is leaking, tighten the pipe
fixing bolts.
4) Check engine cylinder block, engine oil sump, steering pump oil cup, transmission box and
transmission box oil cooling pipe for oil leakage. (ATTENTION: Undamaged booster pump
wouldnt leak oil).
5) Leaking of booster pump oil cup may be caused by poor cleanliness of steering system (result
in blockage of booster pump flow-pressure control valve element), under the circumstance of
rapid steering, high pressure oil leaks out through air hole of oil cup cap due to blockage of
pump oil outlet port. Thereby, this is what results in booster pump fake leaking.
6) Leakage of steering pump, damaged steering pump seals.
Troubleshooting:
1) Replace the failure seals and pipes, tighten each pipe joint fixing bolt.
2) Refill oil if insufficient.
3) Overhaul the engine, engine oil sump, transmission box and cooling oil pipes if there is oil
leakage problem.
4) Check the leaking position carefully, disassemble and clean booster pump flow-pressure
control valve (do not disassemble booster pump), check the cleanliness of steering system and
clean up the leaked oil.
5) Replace steering pump.
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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. But oil
viscosity tends to be much smaller under high temperature and high system pressure
(mainly caused by overloading and rapid steering), and the oil can cap will be burst out
under high oil pressure and temperature, the driving safety is at risk. The only to solve this
problem is to cool the steering system, such as improve heat dissipation by adding extra
radiating device, and refresh the steering system oil (Old oil mustnt be reused). Do not
overload the system for too long and avoid long time extreme steering.
According to our experience, replace the pump or steering gear wouldnt solve the problem,
the only suggestion is to improve heat dissipation and avoid long-time overloading and
extreme steering. Do not replace the pump or steering gear.
b) Hard steering no matter it is cold start or hot start:
The problem indicates that there is damaged part or oil shortage in steering system, refer to
other normal diagnoses to solve this problem.
Generally, a pressure gauge is needed to measure steering system pressure to determine
part damage condition.
5) Poor sealing performance of steering gear oil seals, leads to internal leakage or blockage and
damage of steering gear control valve. Replace the steering gear.
6) Due to pressure control valve of steering system is designed in steering gear, we can detect
steering system pressure with pressure tester, to check whether the reading changes as the
steering wheel rotates; or adjust pressure tester regulating valve to check whether reading
changes along with the adjustment of regulating valve.
7) For high oil pressure problem, which is generally caused by overloading and long-time extreme
steering, result in the system fails to dissipate the heat effectively and timely. Currently, more
than 80% heavy truck fault is caused by this.
(3) Steering pump and steering system produces abnormal noise
Fault phenomenon: Abnormal noise occurs when steering.
Possible causes:
1) Air in steering system, low oil level in oil cup, oil leakage and blockage of oil cup filter
element, which lead to steering pump oil absorption problem.
2) Overloaded system results in high oil temperature, and produces noise.
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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.
Troubleshooting:
1) Check steering system (oil cup, pump, steering gear and pipelines) for oil leakage.
2) Check steering system oil cup (including filter screen and oil level) for air, bubble and blockage
problem.
3) Use echoscope to detect the noise source (oil cup, pump, steering gear and pipelines).
4) Check steering system oil temperature at normal idle engine speed. Cool the system if the
temperature is high, and replace the damaged parts.
(4) Troubleshooting of other steering pump faults
Steering pump gear teeth collision
Driving gear collision is mainly caused by dynamic balance failure. Main cause for dynamic
balance failure is improperly installed steering pump (steering pump driving gear and engine
driving gear are not concentric).
Elimination method: Detect the dimension and material of driving gear, steering oil pump
manufacturer is responsible for the disqualification. If the gear is qualified, refit the pump.
Steering pump shaft breakage
Shaft breakage is mainly caused by dynamic balance failure. Main cause for dynamic balance
failure is improperly installed steering pump (steering pump driving gear and engine driving gear
are not concentric).
Elimination method: Detect the dimension and material of driving gear, steering oil pump
manufacturer is responsible for the disqualification. If the gear is qualified, refit the pump.
Steering pump housing cracking
Cracking of steering housing back cavity, main cause for this failure is improper sealing of steering
pump oil inlet and outlet joints, directly lead to infiltration of impurities and blockage of filter
screen and damping hole, then result in steering pump safety valve failure and high system pressure.
1) Applied thread seal tape when installing oil inlet and outlet joints, the thread seal tape blocked
filter screen and damping hole.
2) Flat gasket + thread sealant seal style is applied, too much thread sealant went into damping
hole and blocked it, and result in steering pump housing crackingWe suggest no thread
sealant.
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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. As shown in Fig. 4-93.
(2) Two applicable connecting types of oil inlet and outlet joints: copper washer (or combination
flat gasket) and O-shape ring. Thread seal tape or thread sealant is strictly prohibited.
(3) Steering pump oil inlet and outlet joint screwing-in length should be suitable, neither too short
nor too long. Refer to Fig. 4-94 and Fig. 4-95.
Screwing-in
length is too Screwing-in
long, oil inlet length is
channel is suitable
blocked
Screwing-in
length is too Screwing-in
long, damping length is
hole is blocked suitable
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