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01 Engine System LG956L
01 Engine System LG956L
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Section 1 Overview
1
Introduction of the meaning
LG956L is equiped with Weichai
engine which is in-line, four-
WD10G220E23
Water Diesel
10
Displacement Code
(Displacement is 10L.)
Construction machinery
220
Power(220ps)
E2
Variant code
WD
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Section 1 Overview
2Characteristics of the Weichai
engineWD10G220E23
1High reliability, long life
Using the tunnel structure, the
crankcase and the seven main bearing
cap are forged as one piece by
high-quality alloy steel, nitrided
crankshaft and connecting rod, and
strength bolts with flexible design, to
ensure the high reliability of the engine
moving parts. Reasonable design of the
high power function of the camshaft
profile can make the engine distribution
system has higher reliability and lower
mechanical vibration noise.
Characteristics of the use of construction
machinery are fully considered,
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Section 1 Overview
2
Powerful engine
large torque reserve
Using the imported Ps3000, Ps7100 fuel
injection pump with low inertia porous injector,
through fuel supply characteristics correcting
and efficiency turbocharger proper matching can
achieve a good dynamic and make the torque
reserves reach more than 20%, to provide strong
horsepower for all kinds of engineering
machinery.
3
Good economy
Three new structures of piston rings, best
matching cylinder clearance, equiped with new
type of combustion chamber and the best swirl
ratio, overlapping curve is honed on the cylinder
plate form to aviod leakage, ensure a more
perfect geometry of cylinder bore, and reduce
the consumption of fuel and oil, the lowest fuel
consumption of the turbocharged engine reaches
194g/kW.h, , oil consumption less than
0.5g/kW.h.
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Section 1 Overview
4
Powerful engine
High
torque reserve
The exhaust can meet the Euro II
emission standard, which are well suited
for working in limited space such as
tunnels, warehouse, cabins, etc.
5
Good ability to adopt the
plateau
The new type of turbocharger has a
function of air intake reflow, which can
broaden the scope of the diesel engine
high effiency workspace, compensate for
the power loss in plateau, and can
provide good adaptability in plateau.
6
Good low temperature start
The cold starting device is added to
ensure the engine can start smoothly at 40 .
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mechanism
1
Basic components
assembly.
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General form
General type
characteristic
Application
General
Gantry
Tunnel
large mechanical
loadload of diesel engine
Tunnel form
FORM
Gantry form
crankcase.
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2
Cylinder liner
Function
The main function of the cylinder liner
is to guide the piston direction and seal
the gas inside the cylinder.
Classification of cylinder
sleeve
There are two types of cylinder liners:
Dry cylinder liner and wet cylinder liner,
Wet cylinder liner
Form
Characteristic
Advantage
Aisadvantage
Demand
Wet
cylinder
sleeve
Cooling effect,
casting
convenient,
easy
disassembly
Poor rigidity,
easy
leakage(water
and gas)
Dry
cylinder
sleeve
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Integral-type
Double-cylinder
split type
form
characteristic
application
integral
old-fashioned
engine
Single-cylinder
split type
wide application
three cylinder
per block
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1
top
2
head
3
skirt
4
land
5
ring groove
6
pin boss
7
reinforcing rib 8
Snap ring groove 9
Oil discharge hole and Oil discharge groove
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1
top
2
head
3
skirt
4
land
5
ring groove
6
pin boss
7
reinforcing rib 8
Snap ring groove 9
Oil discharge hole and Oil discharge groove
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G2
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Compression ring
Oil ring
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Rectangular ring
Twist ring
increase seal.
Taper face ring
and
Twist ring
Keystone ring
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Function
Good for cylinder
piston
lubrication.
Harm
Large lubricating oil
Cylinder
Cylinder
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Oil ring
FunctionThe main function of the engine oil
ring is is to distribute oil, scrape oil, and play an
assistant role to sealing the gas, which can be
divided into two types, common oil ring and
combination oil ring.
A: General oil ring
The general oil ring is also called integral oil
ring, with a groove machined in the middle of the
outer cylindrical surface of the ring, and a hold
Function of oil
scraper ring
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Function
Structure
Hollow cylinder.
Material
Assembly
Connecting rod head
Snap
ring
clip rings.
Half floatingThe the floats in the pin seat,
transition fit .
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Connecting rod
small end
Function
Connect the piston with the crankshaft,
transfer the force from piston to crankshaft, and
Connecting rod
shank
Classification
Generally, the engine connecting rod can be
divided into two types, the equal type and the
oblique fractional type.
Connecting rod
large end
Inclined cut
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1-steel backing
2-oil groove
3-locating tang
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crankshaft
Connecting rod
journal
collar
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1
flywheel 3
bush
4
bolt
5 support7 gear ring
8 flange
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1
Absorber
Absorber
2
Pulley
3
Bolt
Function
resonance
Principle
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1-6
5-2
3-4
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Crank
corner
0~60
60~120
2-4.
T h e c y l i n d e r o f t h e We i c h a i
WD10G220E23 engine, near the fan, is
the first cylinder.
Cylinder
1
Cylinder
2
Cylinder
3
Cylinder
4
Cylinder
5
Cylinder
6
exhaust
intake
power
compre
ssion
intake
power
compre
ssion
120~180
intake
180~240
240~300
power
exhaust
power
300~360
360~420
420~480
intake
exhaust
power
exhaust
660~72
0
compre
ssion
power
540~600
compre
ssion
compres
sion
intake
compre
ssion
480~540
600~660
exhaust
intake
exhaust
exhaus
t
intake
power
compr
ession
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7
the air inlet and outlet, which regularly controls
the opening and closing of the intake and exhaust
valve, supply mixture fresh air to the cylinder
the cams push the tappet and rod and pass the
action to the rocker arm which rotate around an
3
maximum pushing process, the valves will return
to the original position and be closed.
1-pushrod
2-tappet
3-camshaft
4-valve
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Valve group
Locking plate
(1) Valve
The function of the valve is to control the
opening and closing of the inlet and outlet valve,
Snap ring
resist high temperature, high pressure and
impact, require the valve to have the following
characteristic: sufficient stiffness, strength, wear
resistance, high temperature resistance, corrosion
resistance, impact resistance.
(2) Valve guide
It's function is to guide the valve, ensure the
valves do straight reciprocating motion. In
adition, it has the function of heat transfer, pass
heat from the valve head to the rod shaft, and
spread out through the cylinder head.
Valve spring
Valve cone angle
valve
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4
valve spring
Locking plate
Snap ring
Valve spring
Valve cone angle
valve
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1
Camshaft
The camshaft controls the opening and
Cam shape
Push rod
SixSix-stroke
engine camshaft
Rocker arm
tappet
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Cam shape
SixSix-stroke
engine camshaft
Rocker arm
tappet
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Intake valve
Exhaust valve
0.3mm
0.4mm
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clearance
with
feeler
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Valve phase
2
valve overlap
As the inlet valve opens early, the exhaust
Compression
process
Working process
3 Ai r
Exhaust process
Intake process
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Valve phase
Compression
process
Intake process
80
Weichai WD10G220E23 engine:
Exhaust advance angle =34 39
Exhaust lag angle =61 67
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valve phase
3Intake and exhaust valve opening
4
Valve phase
Compression
process
Working process
+ +
80
generally =40-
Exhaust process
Intake process
generally: =10-30
81
Intake lag angle =26 34
exhaust advance angle =76
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Oil injector
1.overview
(1) composition of fuel supply system
The fuel supply system consists of injection
pump, fuel supply pump, fuel filter, injector,
high pressure oil pipe, low pressure oil pipe
and other accessories.
quality according to
High pressure
pump
Low
pressure
pipe
Fuel filter
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the
connector
Injector assembly
must act quickly, the oil cut off must act swiftly
to avoide oil drip.
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1structure
2function
The function of the delivery pump is to
send the fuel from the fuel tank to the low
pressure oil chamber of the oil injection
pump by passing through the oil filter.
The fuel delievery pump is equipped with a
manual pump, which is used to exclude the
air in the low pressure oil channel, and
ensure the channel full of diesel oil, so that
the engine can easily be started.
The screw in the air filter inlet channel is
equipped with a strainer to filter the
impurities in the fuel.
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3working principle
The eccentric gear pushes the piston move
downward through the push rod, volume of the
working chamber under the pistion decreased,
the inlet valve closed, the outlet valve opened,
and the volumn of the pressure chamber above
the piston increases, which causes the generation
of a vacuum, and the diesel can flow into the
pressure chamber along the direction of the
arrow by passing through the outlet valve.
Eccentric gear turns away, the piston moves
upward under the force of the spring, negative
pressure created in the working chamber beneath
the piston, the outlet valve closed, and the inlet
valve openned, oil flows into the working
chamber, the volume of pressure chamber B
decreased by the upward movement of the
piston, the pressure of the diesel in the chamber
increased, oil flowed to the outside, which
pressure controlled by the spring pretightening
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Outlet
valve
Injector unit
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Overflow pipe
unit
Return oil tank
Pressure adjusting
valve
Injector unit
spring
Requirement:
Uniform atomization
Rapid injection
No post-drop phenomenon
The shape and direction of the oil
beam suit the form of the combustion
chamber.
Push rod
Connect oiloilinjector pump
Injector unit
body(nozzle)
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Electric
pump
Oil inlet
M16X1.5
Electronic
controller
Oil outlet
M16X1.5
Water filter
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Turn
input
Negative
earth
Union DJ431DJ431-4C
24VDC power
30A fuse
T15
switch
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3injector style
Currently the fuel injectors adopted by the
Filter
needle
Inlet port
Outlet port
adjusting
washer
Pressure
adjusting
spring
block
Injector
body
Spring seat
Needlevalve part
Tensioning
cap
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Function
Lubrication
Wash
antirust
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2 Splash lubrication T he wa y of
using oil droplets or oil mist flied up by
engine parts to lubricate friction surface is
called the splash lubrication, such as cylinder
wall, piston pin, valve cam tappet surface,
etc.
3
Composition lubrication
4
Grease lubrication
Such as
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Engine oil
pump
Oil
pan
Engine oil
cooler
Engine oil
filter
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1-oil strainer
2-gasket
3-washer
4-bolt
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Drive gear
Pump body
Pump cover
Driving
gear shaft
Drive
n gear
Driving spring
gear
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spring
By-pass
valve
of
the
moving
part,
mechanical
lever
Filter
insert
pressing
spring
Paper filter
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Water
inlet port
insert
Water
inlet port
cover
insert
Water outlet
port
by-pass valve
Oil outlet port
Engine cooler
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Air filter
Air inlet
pipe
Natural
ventilation
etc.
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Radiator
cap
Radiator
Water temperature
indication
conditions.
Shutter
Water
pump
Divide water
pipe
Fan
Drain
plug
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Water pump
Pump shaft
Pump impeller
Water outlet
pipe
thermostat.
Water inlet
pipe
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3.Thermostat
The engine thermostat contains a thermal
element( wax which could expand when
heated and contract when cooled ) which can
be moved up and down according to the
different remperature.
When the coolant temperature is low, the
wax will contract, which will close the
mouth of the channel leading to the radiator,
and open the channel leading to the water
to radiator
to radiator
Thermostat
Spring
Thermostat
Spring
valve
valve
Plunger
Plunger
pump(small circulation).
When the coolant temperature rises to a
certain extent, the was will expand, which
will open the mouth of the channel leading to
the radiator, and close the channel leading to
the water pump(large circulation).
From
engine
Hot
sensing
body
From
engine
Hot
sensing
body
Cooling water in
high temperature
To pump
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Valve seat
Small
spring
Valve
Vice
valve
Support
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Large
spring
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Shell
, the
, the
, the
Large
spring
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Function
Valve seat
and the
1-air filter
2-intercooler
3-piston
4-turbocharger
6-silencer
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Spare part
1.Air filter
Function
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Engine
Air outlet line
Turbocharger
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Air outlet
2.Turbocharger
outlet connection
Rear cover
Inlet connection
plate.
Air compressor casing could be
installed in different directions around
the axle.
Air inlet
Air compressor
impeller
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Heat
shield
Air
outlet
Thrust bearing
and seat
Floating bearing
Exhaust
flange
Air inlet
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reduce vibration
reduce noise
Rotor
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Oil inlet
Oil outlet
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Serial
number
1
Cause of malfunction
Repairing method
Check the starting system, cranking speed shall not be less than 110 r/min.
1. Check fuel pipe connector for loose. Release bleed screw on the fuel
filter, and use hand pump to pump fuel, until the overflow of fuel without
air bubbles.
2.Release high pressure fuel pipe connection on injector, and use hand
pump to pump fuel, until the overflow of fuel without air bubbles.
The delivery pump can not feed Check the fuel inlet lines for leaks and fuel delivery pump for
fuel or feed intermittently
malfunction.
10
Check valve clearance, valve spring, valve guides and sealing of valve
seat, it is necessary to grinding valve seats if the sealing is poor.
11
12
Serial
number
Repairing method
10
92
Cause of malfunction
Serial
number
93
Cause of malfunction
Repairing method
Check the air filter and air intake pipes and clean-up.
Serial
number
1
2
3
4
94
Cause of malfunction
Poor fuel quality, with excessive
water in fuel
Compression pressure is low,
incomplete combustion
Air supply or fuel feed timing is
not correct
Compression pressure is low,
incomplete combustion
Repairing method
Replace fuel up to specification.
Check piston ring and cylinder head gasket and
replace it.
The specialized staff to check and adjust.
Check piston ring and cylinder head gasket and
replace it.
Serial
number
1
2
3
4
5
6
95
Cause of malfunction
Oil thin, or use improper oil
The oil pump rotor is worn or assembly
clearance is too large
Oil filter pressure regulator valve failure
The pump inlet pipe cracks
The pump inlet pipe mounting bolts loose
Shaft bearing clearance is too large
Repairing method
Select appropriate oil according to
specification
Replace the pump
Repair
Repair, replace
tighten to specified torque
Check and replace
Serial
number
96
Cause of malfunction
Repairing method
Check, clean
Serial
number
1
2
3
4
97
Cause of malfunction
External oil line leaks
Diesel engine is overload
The type of oil is improperly
The piston is stuck or excessively worn
Repairing method
Check and repair
Reduce the load
Use as required
Check, repair, and replace if necessary
Cylinder boring for increased piston or
installing the repair-using cylinder liner
Check and replace
Serial
number
1
2
3
4
5
6
98
Cause of malfunction
Insufficient cooling water, the
water flow is too small
Whether the belt is too loose
Water pump leakage
Thermostat is failure or
damaged
Water temperature sensor is
damaged, the water temperature
sensor failure
The cylinder head gasket is
blow-out
Repairing method
Check whether the cooling water is sufficient and
add if necessary
Adjust
Repair in time
Check and replace
Check whether the actual temperature is identical
to the gauge indicating value; if not, replace the
temperature sensor or the temperature gauge
Check and replace
THE END
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