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WD10 stage II Engine Manual of Weichai(EN)-V1-20190625
WD10 stage II Engine Manual of Weichai(EN)-V1-20190625
WD10 stage II Engine Manual of Weichai(EN)-V1-20190625
Special Tips
● Before operating the diesel engine, you must carefully read the service instructions for
the diesel engine and strictly follow the operating and maintenance procedures
specified in the maintenance instructions.
● The injection pump and fuel injector are precision components and must not be
disassembled by the user, otherwise all three guarantees of the company service will be
invalid.
● The turbocharger rotor shaft is a precision high-speed rotating component. Do not
disassemble and collide. Otherwise, all three guarantees of the company service will be
invalid.
● Diesel engine main bearing bolts and connecting rod bolts have strict torque and corner
requirements, and users must not loosen and remove. Connecting rod bolts are
single-use bolts and must not be reused. Otherwise, all "three guarantees" implemented
by the company will be invalid.
● Lubricating oil or fuel added to the diesel engine must be in accordance with the
maintenance instructions and filtered by a dedicated cleaning filter. The fuel must be
precipitated for more than 72 hours. Before operating the engine, please ensure that the
amount of the coolant and lubricating oil meets the requirement.
● Never operate the diesel engine without air filter to prevent air from entering the cylinder
without being filtered.
● Before using the new engine, the run-in should be done for 50 hours first.
● After starting the diesel engine, raise the engine rpm gradually, and do not make it run at
high speed suddenly, it should not stay in idling for a long period of time either; after
running with high load, it should not be stopped instantly (except special circumstances),
and should run at low speed for 5 to 10 minutes after stopping.
● If the operating environment can be lower than 0°C, and the coolant with antifreeze
additive is not used when stopping, drain coolant from the reservoir and engine.
● The inspection and repair of electrical system shall be carried out by professional
technicians.
● In order to prevent corrosion, the diesel engine is sealed by oil before being delivered
from the factory. Generally, the diesel engine has an oil seal period of one year. After
that, inspection should be carried out and necessary supplementary measures should
be taken.
● Please go to the regular gas station to add the fuel of the specified grade. Failures
resulting from improper fuel are not covered.
● For the China Stage II diesel engine, the China Stage II special diesel fuel should be
used. Otherwise, Weichai will not be responsible for diesel engine exceeding the
emissions standard due to failure of adding fuel as specified.
● Please go to Weichai Power designated service station for repair and maintenance, use
the spare parts specified by Weichai Power for maintenance. Failures resulting from not
using the specified spare part are not covered.
WD10 two-valve China Stage II series diesel engine service manual
FORWARD
The WD10 series China Stage II diesel engine is a high-speed diesel engine developed by
Weichai Power Co., Ltd. with a new design concept. This series of diesel engine has the
advantages of having compact structure, reliability, excellent technical specifications in power,
economy and emission, etc, quick start, simple operation and convenient maintenance. It is the
ideal power for heavy-duty vehicles.
This manual briefly introduces the technical parameters, performance indicators, structural
characteristics and precautions for use and maintenance of WD10 series China Stage II diesel
engine. If the user can use the diesel engine in accordance with the requirements specified in
this manual, it will greatly extend the service life of the diesel engine.
This manual describes the basic models of the WD10 series China Stage II diesel engine. As
the product continues to develop, its structure will be improved, and the contents of the
instruction manual can be delayed. Users (or sellers) can visit http://www.weichai.com website
for the latest product information.
Users are welcome to provide us suggestions and comments on further improvements of the
product.
July 2014
WD10 two-valve China Stage II series diesel engine service manual
Table of Contents
Section 1. Diesel Engine Operating Instructions ......................................................................................1
1.1 Exterior of Diesel Engine ................................................................................................................1
1.2 Definition of Diesel Engine Model ...................................................................................................3
1.3 Diesel Engine Technical Data.........................................................................................................3
1.4 Unpacking of Diesel Engine............................................................................................................6
1.5 Lifting of Diesel Engine ...................................................................................................................6
1.6 Installation of diesel engine ............................................................................................................7
1.7 Preparation Before Start-up............................................................................................................7
1.8 Starting of Diesel Engine ................................................................................................................7
1.9 Operation of Diesel Engine.............................................................................................................8
Section 2. Diesel engine maintenance guide..........................................................................................10
2.1 Fuel, Lubricant, Coolant and Auxiliary Materials...........................................................................10
2.1.1 Fuel oils ...........................................................................................................................10
2.1.2 Diesel Engine Oil .............................................................................................................10
2.1.3 Lubrication of the tensioner..............................................................................................12
2.1.4 Antifreeze additive for engine Cooling System ................................................................12
2.1.5 Auxiliary Material .............................................................................................................12
2.2 Daily Maintenance ........................................................................................................................14
2.3 Maintenance Content of All Levels of Maintenance ......................................................................17
2.4 Long Term Storage and Maintenance ..........................................................................................22
2.4.1 Clean ...............................................................................................................................22
2.4.2 Protection.........................................................................................................................22
2.4.3 SEAL,OIL.........................................................................................................................22
Section 3. Diesel engine typical failure and treatment............................................................................24
3.1 Diagnostic Method ........................................................................................................................24
3.2 Causes and troubleshooting .........................................................................................................25
3.2.1 Diesel Engine Cannot Start..............................................................................................25
3.2.2 Stop Soon After Starting ..................................................................................................25
3.2.3 Loss of power ..................................................................................................................25
3.2.4 Fuel Consumption Excessive...........................................................................................26
3.2.5 Black Exhaust Smoke......................................................................................................27
3.2.6 White Exhaust Smoke, Blue Exhaust Smoke ..................................................................27
3.2.7 Turbocharger Intake Port, Intake Pipe Stacking Oil .........................................................28
3.2.8 No Stability of RPM..........................................................................................................28
3.2.9 Very Low Oil Pressure .....................................................................................................28
3.2.10 Coolant Temperature High...............................................................................................29
3.2.11 Parts Wear Too Fast........................................................................................................29
3.2.12 Louder Noise ...................................................................................................................29
3.2.13 Starter Motor Does Not Work...........................................................................................30
3.2.14 Starter Motor Is Running Poorly.......................................................................................30
3.2.15 The Generator Does Not Generate Electricity At All ........................................................31
3.2.16 Alternator Insufficient Charging........................................................................................31
3.2.17 Charging Current Is Unstable ..........................................................................................31
WD10 two-valve China Stage II series diesel engine service manual
Figure 1-1 WD10 two-valve China Stage II series diesel engine outline drawing (side)
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WD10 two-valve China Stage II series diesel engine service manual
Figure 1-2 WD10 two-valve China Stage II series diesel engine outline drawing (free end)
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WD10 two-valve China Stage II series diesel engine service manual
Variant Number
Emission Stage
kW Rating
Displacement
DESIEL
WATER
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WD10 two-valve China Stage II series diesel engine service manual
Table 1- 2 WD10 two-valve China Stage II series diesel engine performance parameters
Unit WD10G
Engine Model 240 E 211 220E211 220 E 221 220 E 231 210E211 210E221 210 E 241
Engine Type — Liquid Cooling, 4-Stroke, Direct Injection, Supercharged Intercooler
Displacement L 9.726
Bore × Stroke m×m 126 × 130
No. of
— 6
cylinders
Valves per
2
cylinder
Fuel Injection Mechanical
kW Rating kW 175 162 162 162 154 154 154
Rated r/min 2200 2200 2100 2000 2200 2100 1900
Peak Torque N.m 920 860 920 1050 860 920 920
Peak torque r/min 1400-1600 1300-1600 1200-1400 1300-1600 1200-1400
Emission
— China Stage II
Level
Cold Start -
without °C -5
starting aid
White smoke
Opacity After idle for 20 seconds≤15%
emission
Cold Start -
with starting °C -25
aid
Noise Level
dB(A) <104
from 1 m
Fuel supply
advance °C 8~9
angle
Bi. Life km 800,000
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WD10 two-valve China Stage II series diesel engine service manual
Table 1- 3 WD10 two-valve China Stage II series diesel engine performance parameters (continued)
Unit WD10G
220E231 200E251 175E251 156E261
Engine Model 175E231 220E261 (p8500 (p8500 (p8500 (p8500
pump) pump) pump) pump)
Engine Type — Liquid Cooling, 4-Stroke, Direct Injection, Supercharged Intercooler
Displacement L 9.726
Bore×Stroke mxm 126X130
No. of
— 6
cylinders
Valves per
2
cylinder
Fuel Injection Mechanical
kW Rating kW 128 154 162 148 128 115
Rated r/min 2000 1800 2000 1850 1850 1800
Peak Torque N.m 750 1050 1050 930 810 750
Peak torque r/min 1300-1500 1100-1300 1200-1400 1000-1200 1000-1200 1000-1200
Emission
— China Stage II
Level
Cold Start -
without °C -5
starting aid
White smoke
Opacity After idle for 20 seconds≤15%
emission
Cold Start -
with starting °C -25
aid
Noise Level
dB(A) <104
from 1 m
Fuel supply
advance °C 8~9 5~6 7~8
angle
B10 life km 800,000
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
TRUE Wrong
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WD10 two-valve China Stage II series diesel engine service manual
2) Press the clutch pedal and the accelerator pedal and turn the electric key to start the
diesel engine. If the engine cannot be started within (5~10)s, wait for 1 minute and
repeat the above starting process. However, if it cannot be started three times in a row,
stop starting, and only start after troubleshooting and repairing the failure. After the
engine is started, pay attention to the meter readings. The oil pressure meter should
display the pressure immediately. Note that the cold engine cannot be operated at high
speed. It must be run for a while at idle speed, but the idle speed should not be too long.
3) Use starting aid during startup at low temperature. The electrical heating flange begin to
operate via relay, so as to realize smooth starting at -30°C.
1.9 Operation of Diesel Engine
1) After the diesel engine starts, run the engine at idle speed for a few minutes, then raise
the speed to (1000-1200) r/min, and add partial load, only when the water temperature
is higher than 60 ° C, oil temperature is higher than 50 ° C, the engine can be allowed to
enter full load operation. The load and speed shall be gradually increased, to avoid
sudden loading or unloading.
2) The diesel engine is suitable for working under medium load within 50 hours running-in
period, and the vehicle should not have a trailer.
3) It is necessary to decelerate in time on the slope, and it is not suitable for long-term
operation under high torque conditions. It is also not advisable to make the load too
small and the speed is too low, because it is prone to failures such as excessive oil
consumption.
4) When the diesel engine is in normal operation, it is allowed to run continuously at rated
power and speed. But if it is operated at 105% of rated speed and 110% of rated power,
it can only be allowed for up to 20 minutes. After the engine is unloaded, the diesel
engine shall idle for 1 min~2 min before stopping.
5) The following parameter values and check points to be noted during use:
Lubricating oil main oil rifle pressure (350~550) kPa.
Oil pan oil temperature less than 110°C.
Coolant outlet temperature (72~93)°C.
Exhaust gas temp. after turbo≤550°C
Intake Air Temperature (from intercooler) (55±5)°C.
Check the color of the exhaust to identify the working quality and load of the injector. If the
smoke is very bad, stop the engine and make inspection.
Check for the diesel engine has no water leakage, air leakage or oil leakage. If it is found,
stop the engine and perform the troubleshooting.
6) The operator shall be aware of the following characteristics of the diesel engine:
① The fuel consumption is low at peak torque, and the fuel consumption increases at
higher speed;
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WD10 two-valve China Stage II series diesel engine service manual
② The torque reaches the optimum value in the engine medium speed range of 1200 r/min
~ 1600 r/min;
③ Engine power increases as speed increases and reaches rated power at nominal
speed.
7) Precautions for operation in cold environments;
① Fuel: Different grades of diesel fuel are used depending on the outdoor temperature in
winter.
② Lubricating oil: select lubricants of different viscosities as per season.
③ Coolant: Cooling System Add antifreeze additive. Different grades and different
amounts of coolant are used depending on the outdoor temperature.
④ Starting: starting aid can be used when necessary in winter. After the diesel engine is
started, only operate the engine at high speed and under load after the oil pressure and
water temperature are normal.
⑤ Always check the electrolyte level, viscosity and unit voltage before the cold season
begins. If the diesel engine is not used for a long time and at a very low temperature, the
battery shall be removed and stored in a warmer room.
⑥ Parking: When parking in cold weather, first remove load, then run at idle speed for 1
min~2 min. Stop engine after coolant temperature and oil temperature drops. Note that
never drain the coolant with antifreeze after parking. If coolant is not added with
antifreeze, you must open the drain valve or water plug in the block, oil cooler cover,
radiator, inlet pipe, etc., then drain the coolant to prevent the engine from freezing.
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
For Weichai Power special oil, select viscosity based on temperature, refer to Table 2-2.
Table 2-2 Cross Reference for Viscosity and Ambient Temperature
SAE Viscosity Grade Applicable Ambient Temperature (°C)
0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40
20W-50 -15-45
CAUTION:
1) Before starting the diesel engine, first check the height of the oil level in the oil
pan.
2) Do not check the oil level when the diesel engine is running.
3) It is strictly forbidden to mix the oil of Weichai Power with other manufacturers'
oils at the same time
Refer to Table 2-3 for the amount of oil refills and the number of filter elements for each
Weichai Power model.
Table 2-3 Engine Oil Refill Amount and Number of Filter Elements for Weichai Power Models
Number of Filters
Lubricating Diesel Engine Gas Engine
Model Oil Fill
Fuel Filter
Quantities (L) oil Fuel Gas
Oil Filter
Seconda filter Filter
Primary
ry
WP4 9〜12 1 1 1 1 1
WP5 13〜16 1 1 1 1 1
WP6 16〜24 1 1 1 1 1
WP7 20〜24 1 1 1 1 1
WP10 22〜26 2 1 1 2 1
WP12 25〜28 2 1 1 2 1
WP13 25〜28 2 1 1 2 1
Note:
1) The oil refill is for reference only, and the actual filling amount shall be subject
to the oil dipstick.
2) If the vehicle is equipped with Weichai Shuihanbao or water-separater filter, it
is necessary to replace Shuihanbao or water-separater filter elements when
replacing fuel filter.
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WD10 two-valve China Stage II series diesel engine service manual
Please note: CE, CD, CC, CB, and CA grade lubricants are not allowed in the WD10
Series II diesel engine. Change the oil filter element at the same time when you
change the oil!
CAUTION:
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WD10 two-valve China Stage II series diesel engine service manual
Supplementary
Brand and Number Primary Usage Location of Application
Explanation
Flywheel Housing Capscrews
Camshaft thrust plate bolt
Camshaft timing gear bolt
Intermediate idler gear bolt
Front End Cover Bolt
Lubricating Oil Filter Head Capscrews
Application on the surface of the
Weichai Specific Lubricating Oil Cooler Capscrews
thread to prevent shock, medium As an option, DriLoc204
242 Threaded plug of the oil cooler regulator
force thread pre-coated
valve
Bolts for fuel pump drain line fixing adhesive can be used for
device precoating.
Air compressor shaft end thread
Strainer bolt
Bolts for sensors and harness fixture
Application on the outer surface
Weichai Specific
of the thread, to lock, seal and Cylinder head slave bolts
262
prevent shock
Weichai Specific
Anti-loose, fastening Cup plug for oil hole
271
Weichai Specific For sealing between core and
Other cup plugs
277 hole
Weichai Specific For sealing the top surface of
one Cylinder head push tube
270 cylinder head
Joint surface between cylinder block
and crankcase
Front and front end cover, rear end face
and flywheel housing connecting plate
Joint surface between oil filter head and
Weichai Specific crankcase
518 Application on a shiny metal Water pump back cover - front end face
(Updated product surface to seal of block
of 510) Flywheel Housing connecting
plate_flywheel housing
Joint surface between cylinder block
and oil cooler cover
Joint surface between cylinder block
and oil filler cap
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
Tank,
Expansion
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WD10 two-valve China Stage II series diesel engine service manual
Oil dipstick
• Check belts
The belt tensioning wheel is used to tension the belt, and the user checks the belt tension
by pressing the belt with hand, as shown in Figure 2-5.
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WD10 two-valve China Stage II series diesel engine service manual
• Check Voice if OK
• Check for speed, vibration is normal
2.3 Maintenance Content of All Levels of Maintenance
• Change engine oil
Unscrew the drain plug on the oil pan bottom side, drain the lubricating oil, and then screw
the drain plug; see Figure 2-7.
Open the filler cap (see Figure 2.3-1). Add lubricating oil from the lubricating oil filler port
and observe the dipstick scale until the requirements are met. Then install the filler cap.
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WD10 two-valve China Stage II series diesel engine service manual
Drain plug
Note: Waste oil should be placed in the designated location and container for
recycling.
• Replace the Oil Filter or Element.
① Remove the old lubricating oil filter;
② Fill the oil filter with clean engine oil;
③ Apply a lubricating oil on the pad before installing the new lubricating oil filter;
④ After the rubber pad touches the base, retighten it 3/4~1 turn for good sealing;
⑤ Start the diesel engine to check for oil leaks.
• Check/adjust intake/exhaust valve lash.
① In the cold state of the diesel engine, bar the engine forward (in the direction of the
diesel engine running) to the TDC of cylinders 1 and 6. At this time, the groove on the
flywheel is aligned with the pointer on the observation hole cover plate;
② Remove the valve rocker cover on the cylinder head and determine if the cylinder 1 or 6
is in the compression stroke (there are gaps between both intake and exhaust valves of
the cylinder in the compression stroke and the rocker arm).
③ Use the feeler gauge inspect the clearance between the upper surface of the valve
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WD10 two-valve China Stage II series diesel engine service manual
bridge and the valve rocker. WD10 diesel engine requires 0.3mm for intake Clearance;
and 0.4mm for exhaust clearance. If the clearance is too large or too small, adjust the
adjustment bolts on the rocker lever to achieve the clearance;
④ After checking cylinder 1 or 6, bar the engine 360 ° forward, to let cylinder 6 or 1 is in the
power stroke, check and adjust the remaining valves.
Table 2-7 Working status of each cylinder during the compression stroke of diesel engine
CAUTION:
When replacing the spin-on type pre-filter or reinstalling the fuel transfer tube, the
pre-filter needs to be air discharged.
Steps (as shown in Figure 2-9)
① Stop Engine.
② Remove the bleeder screw.
③ Use a hand pump to pump air until only oil spills from the bleed screw.
④ Retighten the bleeder screw.
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WD10 two-valve China Stage II series diesel engine service manual
open close
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
2.4.1 Clean
① After warming up, discharge the lubricating oil, clean the lubricating oil filter, and add
anti-rust oil;
② Drain fuel and add rust preventive oil;
③ Discharge water and add coolant with rust inhibitor;
④ Start the engine and idle 15 min~25 min;
⑤ Discharge lubricating oil, fuel, coolant and urea solution;
⑥ Protect other parts;
2.4.2 Protection
Use a lid or plastic cloth to block the inlet and outlet of the oil, gas, and water; seal the
entire diesel engine with a weatherproof anti-rust film.
Note: If you need to transport, you should add packaging.
2.4.3 SEAL,OIL
The oil sealing period of the diesel engine is one year. If exceeding 1 year, the engine
needs to be re-sealed with oil. The specific requirements and measures are as follows:
1) The oil seal operation should be carried out in a clean environment, before handling the
oil seal of the machine and parts, it should be cleaned first, no rust, oil and dust.
2) According to the specific requirements, the oil sealing can be carried out by dipping,
spraying, coating, filling and so on.
3) Oil seal portion and related process requirements:
① Intake/Exhaust Systems Seal: When the starter or the cranking device cranks the diesel
engine, spray JB-1 calibration fluid into the air inlet pipe port with a pneumatic spray gun
at least 15 seconds;
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WD10 two-valve China Stage II series diesel engine service manual
② Turbocharger oil seal: when stationary or the cranking device cranks the diesel engine,
spray JB-1 calibration fluid into the inlet/outlet ports of turbocharger with a pneumatic
spray gun at least 5 seconds;
③ Air Compressor seal: When idling or the cranking device cranks the diesel engine,
spray JB-1 calibration fluid into the inlet port of air compressor with a pneumatic spray
gun at least 5 seconds;
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WD10 two-valve China Stage II series diesel engine service manual
◆ Cylinder cutout method: cutout some cylinder, judge whether the source is in this
cylinder. The cylinder cutout method generally cutout the fuel supply to the cylinder
suspected of failure, compares the state change of the diesel engine before and after
cutting off cylinder, and narrows the scope for further finding the fault location or cause
◆ Comparison method: For some assembly or component, replace it to determine if there
is a fault.
CAUTION:
1. It is a very careful job to judge the cause of diesel engine failure. The diesel
engine must not be disassembled until the cause is basically clarified, otherwise
not only can not correct the problem , but it will cause more serious faults due to
improper assembly after disassembly.
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
Wear overalls
Do not smoke
During usage of engine, there can be many potential hazards arising suddenly. Therefore,
this manual can not provide warning to every potential hazard. If the procedure used is not
specifically recommended, please ensure that such procedure can operate safely and will
not cause any material damage.
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WD10 two-valve China Stage II series diesel engine service manual
5 mm hexagonal wrench
8mm Socket
Flat Screwdriver
Special Tool
If the method or tools used are not recommended in this manual, the users must first
ensure the safety of themselves and avoid to the lives of users themselves or others,
while ensuring that the ways of usage, maintenance or repair will not pose a damage or
safety hazard.
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WD10 two-valve China Stage II series diesel engine service manual
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1- Cylinder Block Pre-Assembly; 2-Cylinder Liner; 3- Cylinder Head Slave Bolt; 4-Elastic Cylindrical Pin;
5-Pre-Adhesive Set Screw; 6-Cylinder Pin; 7- Bowl Plug; 8-Pull Rivet; 9-Hex Head Bolt; 10-Hexagon
Head Head Bolt; 11-Self-Locking Ring; 12- Bowl Plug
13- seal ring; 14-main bearing bolt; 15-rivet; 16-bowl plug; 17-main oil passage rear plug; 18-composite
washer
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
d. Install
e. SERVICE POINTS
Point 1: Assembly
Tightening
22 N.m to 29 N.m Grade 8.8
Torque
Tightening Grade
29 N.m to 35 N.m
Torque 10.9
Point 2: Assembly
The main bearing bolts are symmetrically tightened in the order shown in Figure 4-3. Apply
cleaning lubricant to the support surface of the crankcase and the threaded portion of the
main bearing bolt before assembly.
Point 3: Assembly
The cylinder head slave bolts are tightened in the order shown in Figure 4-4 and reused up
to 2 times.
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WD10 two-valve China Stage II series diesel engine service manual
Cylinder liner should be carefully inspected before assembly to see if there are crack
defects, and clean the cylinder liner, use special tooling to press into the cylinder bore,
apply molybdenum powder on the surface of the cylinder liner before pressing.
a. Disassembly diagram
1- Bowl Plug; 2- Camshaft Bushing; 3-Dipstick Tube; 4-Dipstick Tube Sleeve; 5-Threaded Tube; 6-Bowl
Plug; 7-Dipstick; 8-Dipstick Pipe Head; 9-Dipstick Tube
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WD10 two-valve China Stage II series diesel engine service manual
10-Cylinder Block; 11-Bowl Plug; 12- Camshaft Bushing; 13-Crankcase; 14-Internal Threaded Pin;
15-Bowl Plug
Point 3: Assembly
Connect the dipstick tube to the dipstick tube casing, apply the sealant to the lower portion
of the dipstick tube casing, and lightly tap the dipstick tube casing into the crankshaft tank
dipstick tube hole with a copper hammer.
a. Disassembly diagram
c. Disassemble
d. Install
e. SERVICE POINTS
Point 1: Assembly
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WD10 two-valve China Stage II series diesel engine service manual
Point 2: Assembly
Check for dowel ring is missing, replace if necessary. Align the dowel ring with the pin hole
of the cylinder block and tap the nozzle body with a copper hammer lightly to fully insert the
dowel ring into the block pin hole.
a. Disassembly diagram
c. Disassemble
d. Install
1) Install crankshaft;
2) Install upper thrust plate (2);
3) Install lower thrust plate (1).
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WD10 two-valve China Stage II series diesel engine service manual
e. SERVICE POINTS
Point 1: Assembly
Use the thrust plates that are paired during assembly. First install the crankshaft into the
block, install the upper thrust plate (without lug), apply the grease to the lower thrust plate,
attach it to the crankcase, and assemble it with the crankcase. The thrust plate oil groove
side is outward.
a. Disassembly diagram
c. Disassemble
d. Install
e. SERVICE POINTS
Point 1: Assembly
The install hole and oil seal should be cleaned before the oil seal is fitted, and no dirt is
allowed. Install the oil seal with a special tool to smoothly press the oil seal. Before
assembly, apply the lubricant to the oil seals and press tools.
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WD10 two-valve China Stage II series diesel engine service manual
Remove
The oil seal is no longer used after removing it.
a. Disassembly diagram
c. Disassemble
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WD10 two-valve China Stage II series diesel engine service manual
d. Install
e. SERVICE POINTS
Point 1: Assembly
Tighten the gear housing fastening bolts symmetrically in the order shown in Figure 4-11.
Tightening
44N.m to 58N.m
Torque
Point 2: Assembly
Before assembling the seal ring, observe the seal ring for scratches and other defects. If
there is a defect, replace the new seal ring in time. When assembling, the seal ring is
applied with oil and completely pressed into the groove to prevent the groove from
scratching the seal ring.
Point 3: remove
When removing the gear housing, first remove the gear housing fastening bolt, and then
remove the intermediate gear shaft and the lubricating oil pump intermediate gear shaft.
Remove the gear housing and place it on a clean place.
Point 4: Assembly
First insert the intermediate gear shaft into the intermediate gear and put it into the gear
housing; apply the sealant on the back of the gear housing and press it into the seal ring.
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
d. Install
e. SERVICE POINTS
Point 1: After removing the front cover, it should be placed in a clean environment. Before
assembly, check the inside of the front cover for large dirt to ensure that the front cover is
clean.
Point 2: Apply sealant to the joint surface of the block before assembly of the front end
cover. The apply line must be continuous.
Point 3: check the seal ring for damage. replace the seal ring if necessary. When
assembling, the seal ring needs to be fully pressed into the front cover groove.
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1- flywheel housing ;2- flywheel housing bolts; 3-flywheel; 4-starter; 5-studs; 6-nuts
b. Preparation before disassembly
c. Disassemble
1) Unscrew the starter nut (6) and remove the starter (4).
2) Unscrew the fixed flywheel housing bolt (2).
3) Remove the flywheel housing (1).
d. Install
e. SERVICE POINTS
Point 1: Assembly
Torque the flywheel housing bolts in a crisscross pattern as the order shown below. Apply
the oil to the bolt flange face before assembly, the flywheel housing bolt can be reused
twice.
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WD10 two-valve China Stage II series diesel engine service manual
Point 2: Assembly
Apply a uniform sealant onto the joint surface of the cylinder block and the flywheel housing,
and lift and install the flywheel housing, be careful not to touch any other component.
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
d. Install
e. SERVICE POINTS
Point 1: remove
Drain oil before removing the oil pan. Place the oil container under oil pan drain plug and
loosen the drain plug with a plug wrench to release the oil.
Point 2: Assembly
The oil pan tightening bolts are tightened in the order shown;
Tightening 22N.m to
Torque 29N.m
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1. Cylinder Block; 2. Cylinder Head Slave Bolt; 3. Cylinder Head Gasket; 4. Cylinder Head; 5. Valve
Stem Sealing Sleeve; 6. Eye Bolt Clamping Block; 7. clamping block; 8. Eye bolt block; 9 nut; 10. Eye
bolt screw; 11. cylinder head main bolt; 12. clamping block; 13. clamping block;
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WD10 two-valve China Stage II series diesel engine service manual
3) Loosen the cylinder head main bolt and take the main bolt out and place it in suitable
place;
4) Remove fuel injector, because the fuel injector nozzle protrudes from the bottom of the
cylinder head, so be sure to remove the fuel injector before removing the cylinder head,
otherwise the fuel injector head will be easily damaged when the cylinder head is placed;
5) After removing the cylinder head, place it on the cardboard to avoid wearing the upper
surface of the combustion chamber and other sealing surfaces. If you need to remove
multiple cylinder heads, you need to mark the cylinder number on the cylinder head for
subsequent problem analysis.
6) Remove the cylinder head gasket. If multiple cylinder head gaskets are removed, the
cylinder number shall be indicated on the cylinder head gasket for following problem
analysis.
7) If the cylinder head slave bolts need to be replaced, or if they need to be inspected,
remove the cylinder head slave bolts;
8) Remove rocker lever seat, the intake and exhaust valves and other valve trains (see the
valve train information);
9) For inspect or replace valve stem seal sleeve, remove valve stem seal sleeve. Use
special tooling to remove valve stem seal sleeve, or use plier to clamp the outer side
wall of the valve stem seal sleeve, and remove the valve stem seal sleeve while rotating.
The valve stem seal sleeve is not recyclable.
d. Install
1) Assemble Cylinder head slave bolts
① Cylinder head slave bolt is allowed to use 2 times, please replace new parts after 2
times;
② The cylinder head slave bolt mounted on the first row of the oil cooler cover assembly
side (the shorter end of the thread) is coated with an anaerobic thread locker 262, and
the remaining slave bolts are pre-coated;
③ Clean the threaded holes in the cylinder block;
④ Tighten the bolts, tightening torque: (76~102) N.m.
2) Assemble the cylinder head gasket
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WD10 two-valve China Stage II series diesel engine service manual
① The cylinder head gasket can only be used once. If it is repaired, it must be replaced
with a new one;
② Wipe the inner wall of the cylinder liner, apply the cleaning lubricant, wipe the upper
surface of the block, and then place the cylinder head gasket according to the
corresponding pin hole;
④ Check that the holes on the cylinder head gasket are aligned with the holes on the
cylinder block, and check for the cylinder head gasket is assembled correctly.
3) Assemble the stem seals
Spring
① The valve stem sealing sleeve is only allowed to be used once, and new parts must be
replaced in case of repair;
② Check for the valve stem seal sleeve has no defects, and the valve stem seal spring is
good;
③ Install the valve stem seal sleeve on the valve guide;
④ Apply lubricant onto the lip of the valve stem seal sleeve;
⑤ Use the valve stem seal kit assembly tool and the rubber hammer to install the valve
stem seal.
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WD10 two-valve China Stage II series diesel engine service manual
Valve Guides
Cylinder Head
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
e. SERVICE POINTS
1) Before remove cylinder head, check the cylinder head and the block joint surface for
water leakage, oil leakage, gas leakage and other unnormal signs. If there is such a
problem, replace the new cylinder head gasket to see if the problem is solved. See the
section for disassembly and assembly of the cylinder head gasket.
2) Check the appearance of cylinder head, carefully check the cylinder head for
discoloration and cracks. If cracks are found, perform a dye penetration inspection.
3) Check the valve recession before remove the valve mechanism, the valve recession is
the vertical distance from the bottom surface of the valve to the bottom plane of the
cylinder head. The difference between the measured value of the valve recession and
the required value of the valve recession can reflect the degree of wear of the valve and
the valve seat. The valve recession can be measured using a depth micrometer, as
shown in Figure 4-24:
Refer to Table 4-1 for the valve recession required value. If the valve recession amount
exceeds the allowable range, you need to confirm the wear of the valve and the valve seat.
The valve seat wear can be measured by measuring the amount of valve recession after
installing an unused valve. If the valve recession still exceeds the required value, the
cylinder head needs to be replaced to ensure diesel engine reliability. If the valve recession
does not exceed the allowable value, remove the valve, inspect the valve and valve seat
sealing surface, to check the valve and valve seat sealing surface for obvious wear and
abnormal damage.
Table 4-1 Valve Recession Required Value
Valve Recession Required Value (mm)
Intake 0.85〜1.05
Exhaust 1.08〜1.48
4) After removing the valve mechanism, check the internal condition of the cylinder head
intake and exhaust line for any water leakage. If there is such a problem, you need to
clean the line and perform a dye penetration inspection to confirm the problem position.
Replace the new cylinder head if necessary.
5) Clean the cylinder head, especially the combustion chamber surface, valve seat, intake
and exhaust valves, intake and exhaust piping. Remove carbon and adhesive in the
surface area, and check the surface condition.
6) Check the inner diameter of the valve guide, the inner diameter of the valve guide is the
contact surface between the valve guide and the valve movement. If the clearance
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WD10 two-valve China Stage II series diesel engine service manual
between the valve guide and the valve stem exceeds the allowable value, the guiding
effect of the valve will be affected, reducing the reliability of the operation of the diesel
engine. Use a dial bore indicator to measure the inner diameter of the valve guide, as
shown in Figure 4-25. The allowable range of the valve guide I.D. is: (11~11.018) mm. If
the allowable range is exceeded, the cylinder head needs to be replaced to ensure the
reliability of the diesel engine.
7) Check the cylinder head gasket for visible damage and analyze the cause. No matter
whether there is any problem with the cylinder head gasket, replace it with a new one
after removal.
8) Before removing, check the rubber lip of valve stem seal sleeve for any abnormalities,
such as breakage and spring failure. However, always replace the valve stem seal
sleeve whenever it is removed.
a. Disassembly diagram
1. Cylinder Head Cover Gasket; 2. Cylinder Head Cover Lower; 3. Cylinder Head Cover Gasket; 4.
Cylinder Head Cover Upper; 5. Hexagon Flange Bolt 6. Hex flange face bolt; 7. cylinder head cover
Figure 4-26 Disassembly diagram of cylinder head cover
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
d. Install
1) The cylinder head cover pad is only allowed to be used once, and must be replaced with
a new one during repair. Before installing the cylinder head cover gasket, first check the
new cylinder head cover gasket for defects in manufacturing and use and damage.
2) Clean the upper surface of the cylinder head and assemble the cylinder head gasket in
sequence.
3) Clean the cylinder head cover, and correctly install on the cylinder head.
4) Install the cylinder head cover bolt and tighten. Install the mounting block and support
bracket in the corresponding positions as shown in Figure 4-26 and tighten the bolts.
e. SERVICE POINTS
1) Check the cylinder head cover itself for cracks, greater wear and other damage, if there
is a crack, replace it with a new cylinder head cover;
2) If there is oil leakage at the cylinder head cover gasket, it is necessary to check the
failure of the cylinder head gasket and the surface wear degree of the cylinder head
upper surface and cylinder head cover lower bottom sealing surface. If there is leakage,
you need to replace the new cylinder head cover gasket, and then check if it still leaks
oil.
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1. Eye bolt clamping block; 2. gas oil separator air intake connection; 3. bolt; 4. gas oil separator; 5. gas
oil separator air outlet tube; 6. Clamp; 7. Oil Separator Return Line; 8. Pipe Clamp; 9 Clamp; 10.
Connecting Pipe;
Figure 4-27 Disassembly diagram of gas oil separator
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WD10 two-valve China Stage II series diesel engine service manual
4) Install the pipe clip and clamp of the oil separator outlet pipe, return line and oil pan
return line;
e. SERVICE POINTS
1) Inspect the appearance of each component, check for parts damage, cracks, hardening
and cracking of the hose, etc. Replace the corresponding parts if necessary;
2) Check if the oil separator is unobstructed by inflating the oil separator into the intake
pipe. If the airflow is not smooth, the impurities and oil in the oil separator can be
removed by connecting the pressurized air to the oil separator. If the oil separator is
still not smooth after the above operation, replace the new oil separator;
3) If there is oil leakage at the joint between the air inlet and the cylinder block, check the
O-ring for damage and replace it.
4) According to Figure 4-28, ensure that the position of each hose and each interface is
correct, and pay attention to ensure that the rotation angle of the hose installation and
the fixture location match the diesel engine.
4.3 Crank and connecting rod mechanism
Shock Absorber
Flywheel
Pulley
Flywheel capscrew
Flanges Bearings
Block
Piston & connecting rod Assy
1. Checks before disassembly. Detect the connecting rod axial side clearance, inspect
connecting rod bolt tightening torque; Place the engine inclined, bar the engine letting
the piston to be removed to the bottom dead center, and remove the connecting rod bolt
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WD10 two-valve China Stage II series diesel engine service manual
and the connecting rod cap; Bar the engine to the top dead center and knock the piston
out with a wooden hammer. Be careful to avoid the big end of the connecting rod from
getting stuck in the cylinder. Use the same method to remove the remaining pistons and
arrange them in sequence;
2. Unscrew the front pulley bolts, remove the pulley and the vibration damper.
3. Unscrew the flywheel bolts and remove the flywheel Assy, bearings and other parts.
Crankshaft
Connecting
rod body
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WD10 two-valve China Stage II series diesel engine service manual
1. Use the hole retaining ring pliers to carefully remove the circlip on both sides of the
piston and push the piston pin out to remove the connecting rod body. Number the
piston pin and the connecting rod body separately and place them in order;
2. Use a piston ring mounting pliers to remove first ring, second ring, and an oil ring
respectively, and mark them separately.
1. Check the corner radius of piston and combustion chamber throat, piston pin retainer
for crack; check piston skirt, piston head for cylinder score; check that the piston pin
hole wear is normal.
2. Check if the outer ring of the piston ring is worn abnormally; check if the upper and
lower end faces of the piston ring are worn abnormally.
3. Check if the wear of outer circumference of the piston pin is abnormal;
4. Check the bottom hole of the connecting rod big end, connecting rod and small end oil
hole for cracks; check for the alloy layer of the connecting rod bushing is worn, or it is
peeling; check for the wear on the side of the connecting rod is abnormal, and check the
bending of the connecting rod.
5. Check the connecting rod bearing shell for wear, and if there is signs of discoloration,
peeling, slipping etc. on the alloy layer.
1. Use a hole retaining ring pliers to fit a hole circlip into the retaining ring groove of piston
and turn the retaining ring to ensure complete loading. The angular face of the retaining
ring shall be inward. The piston pin retaining ring opening position is upward.
2. Insert the small end of the connecting rod into the inner cavity of the piston, and align
the small end of the connecting rod with the pin hole of the piston, then insert the piston
pin, and finally install the retaining ring of the other side of the piston pin. Also note that
the direction of the oblique cut of the connecting rod is the opposite to the direction of
the oil inlet hole of the piston cooling oil passage, and apply appropriate amount of
cleaning lubricating oil onto the small end hole of the connecting rod and the piston pin
before assembly;
3. The assembled piston rod components are arranged in the order of the cylinder
numbers, and then use piston ring installation pliers to install the oil ring, the second gas
ring and the first gas ring into the piston ring groove in sequence. The "TOP" face of the
piston ring shall face upwards, and the ring shall be rotating freely turning in the ring
groove;
4. Wipe up the inner wall of the cylinder, the crank arm and the piston & connecting rod
components, and apply cleaning oil to every moving parts;
5. Adjust the opening direction of each ring: the first ring opening is installed at a position
30 offset to the center line of the piston pin, the opening of the second ring is offset from
the opening position of the first ring by 120, and the opening of the oil ring is
respectively offset from the openings of first and second gas rings by 120, and at the
vertical bisector of the centerline of the piston pin. As shown in Figure 4-43 below.
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WD10 two-valve China Stage II series diesel engine service manual
Oil ring
Figure 4-31 Opening Angle Schematic of Piston Rings Assembly
6. Crank the engine so that the cylinder 1 and 6 is at the bottom dead center position,
install the connecting rod component of cylinder 1 and 6 and loosely install the
connecting rod bolts. The separating surface of the connecting rod shall face the left
side of the cylinder block (Assy the oil cooler side). The piston shall have same cylinder
number as the cylinder, the connecting rod cap shall match with the connecting rod
body. Apply cleaning lubricating oil onto the connecting rod bolt before installation;
7. Tighten connecting rod bolt: first screw in, then use the torque of 120N·m to tighten
symmetrically, and finally angle tighten 90°±5° and meanwhile reach 170N·m ~250N·m.
Use the same method to install the remaining cylinders.
Crankcase
Flywheel capscrew
Flanges
Block
Pulley bolt
Figure 4-32 Assembly Exploded View of Crankshaft System
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WD10 two-valve China Stage II series diesel engine service manual
10. Apply cleaning lubricating oil onto the bolt bearing surface of the crankcase and the
threaded portion of the main bearing bolt. Loosely install the main bearing bolts, and
then pre-tighten all the main bearing bolts in the order shown in Figure 4.
11. At the first time, use a low torque pneumatic wrench. The torque reaches 80 N.m at the
second time and the torque reached 250 to 280 N.m at the third time. Complete the
crankshaft assembly.
Flywheel
Bearings
Crankshaft
Flywheel capscrew
retainer
Studs
Locating Pin
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WD10 two-valve China Stage II series diesel engine service manual
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WD10 two-valve China Stage II series diesel engine service manual
Timing Gear
Flanges Crankshaft
Shock Absorber
Pulley
Pulley bolt
Unscrew the pulley bolt and remove the pulley and damper in sequence.
After installing the timing gear housing, install the vibration damper and the pulley in
sequence, and fasten them on the crankshaft flange with the pulley bolts.
1. Clean the bearing shell and check the bearing shells for wear.
2. Check the bearing shell for metal peeling, locating lip damage and lateral cracks.
1. First clean the main bearing shell and the bottom hole of the assembly, and wipe it
clean;
2. If reusing bearing shells, when assembling, install them into the block (upper shell) and
the crankcase (lower shell) respectively in the order of removal of bearing shell. Pay
attention to distinguish the upper and lower shells, and the upper shells have oil groove;
if replace the new bearing shells, install it directly. Pay attention to the alignment of the
lips when installing, and apply a small amount of oil.
4.4 Valve Mechanism
Adjustment nuts
Flex Head Capscrews
Intake Rocker Lvr
Support arm
Adjusting Screw
Adjustment bolt assembly
Adjustment nuts Valve lock collet
Thrust plate
1) Assemble the intermediate gear, see the intermediate gear assembly steps;
2) Assemble the camshaft and camshaft timing gears. See the assembly procedures of
camshaft and camshaft timing gear for details;
3) Assemble the tappet and the push rod. See the assembly procedures of tappet and
push rod for details;
4) Assemble the intake and exhaust valves, see the assembly step of the intake and
exhaust valves;
5) Assemble the rocker arm and rocker arm shaft. See the assembly procedures of rocker
arm and rocker arm shaft for details.
Camshaft
Thrust plate
Camshaft bearing shell
① Rotating camshaft, check for the camshaft and timing gears are flexible and unblocked;
② Check the camshaft axial clearance with a dial gauge to determine if there is axial
turbulence. Compare it with the axial clearance of 0.1mm~0.4mm after assembly and
calculate the difference;
③ Check timing gear teeth side clearance;
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WD10 two-valve China Stage II series diesel engine service manual
④ On the engine install and remove workbench, turn the crankshaft so that the camshaft
timing gear is at the top dead center of cylinder one. Remove camshaft timing gear hex
head bolt, remove timing gear, dowel pin;
⑤ Remove camshaft thrust plate hex head bolt, remove thrust plate;
⑥ Remove camshaft.
① Check the cam surface in contact with the tappet for wear and check if the main journal
is stuck or worn;
② Measuring the camshaft spindle radial runout;
Table 4-2 Camshaft main journal runout measurement table
Cam Lobes Runout allowable max. value Measured
No. 2 main journal (between cylinder one and cylinder two) 0.04
No. 3 main journal (between cylinder two and cylinder three) 0.05
No. 4 main journal (between cylinder three and cylinder four) 0.06
No. 5 main journal (between cylinder four and cylinder five) 0.05
No. 6 main journal (between cylinder five and cylinder six) 0.04
③ Measure the actual maximum lift of the tappet (the distance between the inlet & exhaust
camshaft tip and the base circle)
Table 4-3 Actual maximum lift measurement table of the tappet
Cam Lobes standard value Measured
Intake tappet MAX lift 8.481mm
Maximum exhaust tappet lift 9.492mm
④ Check for timing gear has tooth broken or the tooth surface has a heavy wear
phenomenon.
After removed, inspect camshaft and timing gears, if there is wear or other large deviations
in the parameters, repair or replace the new camshaft.
① Wipe the camshaft bore with a towel and check the camshaft bore for bump. Apply oil to
the camshaft bushing. If the camshaft bore is found to have a bruise, it is not allowed to
be repaired.
② Place the camshaft guide tool and camshaft sleeve into the camshaft hole, wipe the
camshaft and check for flaws. Then insert the camshaft into the camshaft hole. When
finished, remove the camshaft guide tool and camshaft sleeve. Be careful not to scratch
the camshaft bushing when you insert it into the camshaft.
③ Install the camshaft thrust plate, loosely install the pre-coated hex bolt and tighten.
Control torque is 29 N·m~35N·m.
④ The front end of the Camshaft bore cup plug is coated with 277 sealant. The sealant
line is closed continuously. Then, inserted into the Camshaft bore on cylinder free end.
Wipe off the residual sealant around the cup plug. There is no crimping after inserted.
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WD10 two-valve China Stage II series diesel engine service manual
⑤ Crank to No.1 cylinder TDC (counterclockwise, view from the end of the timing gear
housing). At this time, the upper end surface of the piston is flush with the upper surface
of the cylinder block.
⑥ Draw an aligned line on the flywheel housing and the flywheel, install the dial, and zero the
dial. The position is aligned with the line on the flywheel housing, install the timing gear.
⑦ The engraved line on the timing gear should be aligned with the "OT" engraved line on
the timing gear housing.
⑧ Screw the pre-coated hex bolts and tighten it symmetrically. The tightening torque is 40
N·m~45 N·m. After tightening, mark with white mark on any bolt, inspect and record the
gap between timing gear and intermediate wheel side.
⑨ The clearance between timing gear and intermediate gear side is 0.015~0.33, Insert the
cylindrical pin into the clearance between timing gear and intermediate gear side.
4.4.3 Removal and Installation of Rocker Arm and Rocker Shaft
4.4.3.1 Assembly Exploded View of Rocker Arm and Rocker Shaft
Capscrew,
Hex Head Adjustment nuts
Support arm
Adjustment bolt assembly
Intake lever
assembly Exhaust lever assembly
Figure 4-39 Assembly Exploded View of Rocker Arm and Rocker Shaft
4.4.3.2 Removal Procedure of Rocker Arm and Rocker Shaft
Figure 4-40 Adjust intake valve lash Figure 4-41 Adjust exhaust valve lash
③ Crank 360°, so that the cylinder six are at the compression top dead center, adjust the
intake valve clearance of cylinder 6, 5, 3, and the exhaust valve clearance of cylinder 6,
4, 2.
④ Inspect cylinder one valve timing in cold condition, intake valve open, TDC
34°~39°°Exhaust valve open, TDC 26~31°.
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WD10 two-valve China Stage II series diesel engine service manual
Drive Bar
Cylinder Head
Block
Tappet
① Disassemble the rocker arm and the rocker arm shaft, and then directly take out the
push rods and place them in order;
② After the cylinder head is removed (see the cylinder head remove step), remove the
tappets and place them in order.
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WD10 two-valve China Stage II series diesel engine service manual
① Check the tappets and the push rods for problems and replace if there is a problem.
Before assembling the tappets, blow them with compressed air and check the oil holes
for open;
② Applying a clean lubricant to the valve tappet;
③ Put the valve tappet in the tappet hole;
④ After the cylinder head assembled (see the cylinder head assembly procedure), blow
the pushrod with compressed air and check for the oil hole is blocked;
⑤ Apply clean lubricating oil onto the push rod, being sure that the ball joint and socket
head has sufficient lubricating oil;
⑥ Install the pushrod and place the pushrod in the appropriate position.
Valve cap
Valve lock collet
Valve spring retainer, upper
Inner valve spring Outer valve spring
Valve spring
retainer, lower
Valves
① Use a valve spring compressor or valve overhead plier or other tool to press the valve
spring. Remove the valve lock collet, and remove the valve spring upper seat and the
inner and outer valve springs;
② Remove the valve from the valve seat.
① Check the valve stem and valve stem end faces for wear;
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WD10 two-valve China Stage II series diesel engine service manual
If the valve is worn or the carbon is seriously sintered, the valve needs to be replaced.
① Apply molybdenum disulfide paste evenly on the intake and exhaust valve stems, and
then install the intake and exhaust valves into the cylinder head to ensure that the
intake and exhaust valves slide in the guides without any binding;
② Apply the thread locker evenly on the bottom surface of the exhaust valve spring, and
then attach it to the cylinder head. Check for the bottom surface of the exhaust valve
spring is seated, replace or repair if necessary.
③ Install the intake valve spring lower seat. Put the valve stem protection sleeve on the
intake and exhaust valve guide, and then assemble the valve stem sealing sleeve;
NOTE: Check the internal spring of the valve stem seal for intactness before assembly.
④ Install the valve inner spring and the valve outer spring, make ensure that the direction
of the valve inner spring is opposite to the outer spring;
⑤ Install the valve spring upper seat. Press down the valve spring, and install the valve
lock collet;
⑥ After the valve lock collet is installed, use a rubber hammer to tap the exhaust valve to
seat it. If collet or valve spring upper seat can not seat, check the cause and repair.
Intermediate gear
Shim(s)
Shaft Bolts
Intermediate gear
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WD10 two-valve China Stage II series diesel engine service manual
① Remove air compressor, see remove instructions of the vehicle attachment system;
② Remove the fuel injection pump, see the fuel system removal instructions for details;
③ Remove camshaft timing gear, see the valve train remove instructions;
④ Check the intermediate gear mounting bolt mark to confirm that the bolt is rotating.
Remove four M10 hex head bolts on the intermediate gear and take off the washer. Use
an M8 bolt to screw into the shaft in the middle of the gear and pull out the shaft, taking
care to prevent the intermediate gear from falling;
⑤ The intermediate gear assembly and the intermediate gear shaft are removed with the
gear housing and taken out of the opening in the gear housing.
① Install the lubricating oil pump, crankshaft and Lubricating oil pump intermediate gear
assemblies in sequence
② Install the gear housing. Before installing the gear housing, place the intermediate gear
shaft in the intermediate gear assembly (intermediate gear, bushing) with the "V" mark
facing outward on the intermediate gear (the "V" mark will not be blocked by the
intermediate gear shaft). Place the intermediate gear assembly and the intermediate
gear shaft in the gear housing intermediate gear position. At this time, the diesel engine
is installed upside down, otherwise the intermediate gear assembly and the
intermediate gear shaft will fall.
4.5 Air Intake and Exhaust Systems
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
d. Install
4) Use the air intake piping bolts (3)(4)(5) to install air intake piping assembly (2) on the
diesel engine cylinder head with air filter bracket, adjustment washer (6) and air intake
piping gasket (1). (After screwing the guide bar into the air intake piping screw hole,
install the air intake piping component onto the cylinder head.)
5) Tighten the air intake piping bolts (3), (4), (5).
6) Loosely install the remaining bolt washers correspondingly.
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1. Shims
2. Rear Exhaust
manifold
3. Forward exhaust
manifold
4. Exhaust pipe seal
ring
5. Exhaust pipe bolt
c. Disassemble
The removal procedure is in reverse order to the installation procedure
d. INSTALLATION.
4) Adjust the seal ring (4) on the front and rear exhaust manifold (2) (3) to the adjacent
seal ring opening staggered 90°, make sure that the sealing ring is sealed reliably.
5) Use an exhaust pipe bolt (5) to install the assembled exhaust pipe on the cylinder head
with the exhaust pipe gasket (1) loosely. Apply molybdenum disulfide paste to the
threaded part of the exhaust pipe bolt.
6) Tighten the exhaust pipe bolt. Exhaust pipe bolt tightening torque (60-70)N·m, the bolts
are securely fastened.
4.5.2 Disassembly and assembly of pressurization system and lubricating oil pipe
system
a. Disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1, turbocharger gasket
2. Turbocharger
3. Stud
4. Type 2 full metal hex lock nut
5. Turbocharger exhaust outlet
plug
6. Stud
Figure 4-48 Turbocharger lubricating oil pipe system group disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
• Equipment conditions: pneumatic wrench, sleeve, copper hammer, lubricating oil, brush
• Preparation before disassembly: Remove the other peripheral parts that are installed on
the turbocharger.
c. Disassemble
d. Install
Loosely install the turbocharger exhaust outlet block 3.5-3 (5) onto the turbocharger 3.5-3
(2) with the studs 3.5-3 (6).
Use a copper hammer to drive the turbocharger return line assembly 3.5-4 (8) into the oil
return hole of the frame. The seal at the end is reliable.
Install the sleeve 3.5-4 (6) and the pipe joint with nut 3.5-4 (7) onto the turbocharger inlet
pipe assembly 3.5-4 (3), and assemble the assembled parts to the cylinder block. Apply
567 sealant to the sleeve end. Tighten the union nut.
The turbocharger 3.5-3(2) is assembled with the rear exhaust manifold of the exhaust
system assembly and the nut is tightened.
Use the turbocharger return line bolt 3.5-4 (9) to install the return line to the turbocharger
outlet with the self-locking washer 3.5-4 (4) and the flange washer 3.5-4 (2).
Remove the protective cover at the inlet of the turbocharger. Use the turbocharger inlet
pipe bolt 3.5-4 (5) to install the oil inlet pipe to the turbocharger inlet with the self-locking
washer 3.5-4 (4) and the flange washer 3.5-4 (1) and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
Pump, Injection
Fuel Filter(s)
Low Pressure Fuel
Lines
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WD10 two-valve China Stage II series diesel engine service manual
LUBE OIL
PIPE,
COMPL. Pump Support Bracket
Oil pump carrier
a) Remove the hex nut between the injection pump flange and the gear housing.
b) Remove the injection pump and gear assembly from the engine.
c) Remove injection pump locknut.
d) Remove the hex head bolt between the injection pump and the flange.
e) Remove injection pump flange.
4.6.2.3 Injection Pump check and repair check the fuel supply starting point
1. Turn the engine flywheel to 30°~40° before the Top Dead Center of Cylinder 1
compression stroke.
2. Remove the injection pump cylinder one high pressure fuel pipe and turn the flywheel
clockwise until the oil level of cylinder one high pressure oil pipe joint is agitated, and
read the fuel injection advance angle on the flywheel.
Adjust fuel supply starting point:
First, turn the flywheel to the specified fuel supply advance angle from BTDC (Before Top
Dead Center) of Cylinder 1 compression stroke (When turning the flywheel, follow the
direction of rotation of the diesel engine, do not reverse). Remove cylinder one high
pressure fuel line, place the throttle in the maximum fueling quantity position and discharge
the air in the fuel line, then slowly rotate the flywheel in the direction of rotation of the diesel
engine, Stop when cylinder one delivery valve is just out of the oil, record the fuel supply
position on the flywheel end, keep the oil pump in the above position and tighten the fixing
bolts. Observe the fuel supply advance angle. If it does not meet the requirements, loosen
the oil pump fixing bolt and turn the oil pump to adjust.
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WD10 two-valve China Stage II series diesel engine service manual
a) Adjust the number 1 cylinder into the compression top dead center (TDC) position,
loosely install the fuel injection pump flange and the fuel injection pump (the stud is
located in the middle of the waist hole of the fuel injection pump), and the fuel injection
pump gear is aligned with the injection pump flange line. Check the position of the fuel
pump gear scribe line during assembly (see the figure below, when the number 1
cylinder piston is 21° before the compression top dead center (TDC), the scribe line is
2.41° left from vertical line) or check the timing pin position.
b) Finally, adjust the fuel injection pump waist groove to achieve the specified fuel supply
timing.
c) Tighten the hex nut between the injection pump and the gear housing.
Gear scale
line
Figure 4-51 Fuel pump engraving position
1 (same as 2, 3, 4, 5, 6) - high pressure fuel pipe; 7 - banjo bolt; 8 - high pressure fuel fitting; 9 (14) - high
pressure fuel pipe support bracket; 10 (11, 12, 13) - high pressure fuel pipe clamp
Figure 4-52 High-pressure tubing assembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
1-fuel injector; 2-gasket; 3- seal ring; 4- clamping plate; 5-hex head bolt
a) Remove the hex head bolts that secure the fuel injector clamping block.
b) Remove fuel injector clamping block and fixing block.
c) Remove the fuel injector assembly from the cylinder head.
Fuel injector nozzle replacement must be carried out at Wuxi Weifu special repair location
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WD10 two-valve China Stage II series diesel engine service manual
a) Fuel injector fastening bolt M8 (quantity: 2): symmetrical tightening and note that side
clearance is consistent (20~25) N·m.
① Check the water pump gasket for break and other damage, if necessary, replace the
water pump gasket;
② Check the studs and nuts for thread scratches and other damage, and if necessary,
replace the studs and nuts;
③ Check the water pump for cracks and other damage, if necessary, replace the water
pump.
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WD10 two-valve China Stage II series diesel engine service manual
① Before assembly, inspect nuts, studs, water pump gaskets, and water pumps, make
ensure that there are no defects or damage in manufacturing and use.
② Clean the inner chamber of the gear housing connected to the water pump.
③ The specific installation procedure is in reverse order to the removal procedure.
Shown as follows:
① Remove the two clamps on the upper coolant hose that connect the outlet pipe and
thermostat.
② Remove the two clamps on the lower coolant hose that connect the outlet pipe and
thermostat.
③ Remove thermostat.
④ Remove the two coolant connection hoses.
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WD10 two-valve China Stage II series diesel engine service manual
① Check the four clamps for damage such as failure, and if necessary, replace the
clamps.
② Check the coolant connection hose for cracks and other damage. if necessary, replace
the good coolant hose.
③ Check the thermostat for damage such as breaks, and replace it if necessary.
① Before assembly, inspect clamps, hoses, thermostats, and thermostat covers, make
ensure that there are no defects or damage to manufacturing and use.
② Clean the outlet pipe and the water pump outlet pipe to ensure that no foreign matter
enters.
③ The specific installation procedure is in reverse order to the removal procedure.
The thermostat opening temperature parameter table is shown in Table 4-5:
Table 4-5 Thermostat Opening Temperature Parameter Table
Initial Opening Temperature Fully Opening Temperature
No.
(°C) (°C)
1 80 95
2 71 82
1-Electromagnetic Clutch Harness; 2-Hex Head Bolt (Full Thread) 3-Electromagnetic Fan Clutch; 4-Hex
Flange Face Bearing Toothed Bolt; 5-Bolt; 6-Hex Flange Face Bearing Toothed Bolt; 7- Hexagon Flange
Face Bearing Toothed Bolt; 8-Fan; 9-Hex Flange Face Bearing Toothed Bolt; 10-Hex Head Bolt
11-Wave Elastic Gasket; 12-Bracket Plate
See illustration:
① Loosen six fan fastening nuts and remove the fan;
② Loosen the hex head bolt that fix the gear housing to the clutch and support bracket
plate, remove the electromagnetic clutch;
③ Remove the harness and support plates.
Check the fan and clutch for cracks and other damage.
① Before assembly, inspect the fan, clutch, and fastening bolts, make ensure that there
are no defects or damages in manufacturing and use.
② The specific installation procedure is in reverse order to the removal procedure.
a. Disassembly diagram
1. Air Intake Piping Gasket; 2. Water Outlet Pipe; 3. Water Outlet Pipe Bolt;
4. Hose; 5. Thermostat; 6 Hose; 7. Clamp;
Figure 4-57 Outlet pipe disassembly diagram
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WD10 two-valve China Stage II series diesel engine service manual
c. Disassemble
1) First remove the sensor harness on the outlet pipe and remove the clamp that connects
to the water pump hose;
2) Loosen the outlet pipe fixing bolts in sequence;
3) Remove the outlet pipe;
4) The water outlet gasket on this model is shared with the air intake piping gasket and can
be removed after the remove water outlet, as shown in Figure 4-27.
5) If further removal is required, remove the clamp connected to the thermostat and the
hose as shown in Figure 4-27 to remove the hose and thermostat.
d. Install
1) Assemble the thermostat, O-ring, thermostat cover gasket and thermostat cover and
flange to the outlet pipe in sequence, and tighten the bolts;
2) The air intake piping gasket is recommended to be used once, and it should be
replaced when repaired;
3) Wipe the joint surface of the outlet pipe, install it on the cylinder head and install the
fastening bolts;
4) Tighten the fastening bolts;
5) Tighten the high pressure oil pipe clip fixing bolts;
6) Install the harness of the sensor on the outlet pipe, etc.
e. SERVICE POINTS
1) Check the water outlet tube for water leaks before removing. and check the water outlet
tube body for cracks, corrosion, etc. If there is a crack, replace the water outlet tube. For
corrosion that affects reliability, analyze the cause and replace it with a new outlet tube;
2) If water leakage occurs at each joint, replace the joint and tighten it to see if there is any
water leakage. If the connecting thread is damaged, replace it with the new water outlet
3) Check the thermostat for abnormal. If the engine water temperature is abnormally high,
you can replace the new thermostat for troubleshooting.
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GASKET-OIL PUMP
Lubricating Pump
Hexagon flange face
toothed bolt
Hexagon flange face
toothed bolt
Loosen the two hexagonal flanged toothed bolts on the lubricating oil pump and remove the
lubricating oil pump and the lubricating oil pump gasket as shown.
① Check the oil pump for cracks and other damage, whether the inner cavity is smooth, if
necessary, replace the oil pump;
② If there is a leaking lubricating oil phenomenon, check the lubricating oil pump gasket
for failure, and replace the lubricating oil pump gasket if necessary.
① Before installation, check the oil pump and shim to ensure that there are no defects or
damages in manufacturing and use;
② Clean the joint surface of the lubricating oil pump and the crankcase.
③ Install Lubricating oil pump gasket.
④ Install the lubrication oil pump.
⑤ Install two hex flanged toothed bolts, and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
4.8.2 Disassembly and Assembly of Lubricating Oil Pump Intermediate Gear Assembly
4.8.2.1 Lubricating oil pump intermediate gear assembly assembly exploded view
Figure 4-59 Lubricating oil pump intermediate gear group assembly exploded view
4.8.2.3 Lubricating oil pump intermediate gear assembly inspection and repair
① Check lubricating oil pump intermediate gears and intermediate gear shafts for cracks
and other damage. If necessary, replace the lubricating oil pump intermediate gear and
intermediate gear shaft
② Check the seal ring for breaks, if necessary, replace the seal ring
① Before assembly, inspect lubricating oil pump intermediate gear assembly, intermediate
gear shaft, hex bolt, seal ring, make ensure that there are no defects or damages in
manufacturing and use.
② Clean the joint surface of the crankcase and the lubricating oil pump intermediate gear
assembly and the lubricating oil pump intermediate gear assembly.
③ Install the seal ring on the intermediate gear.
④ Install lubricating oil pump intermediate gear (convex facing inward).
⑤ Install intermediate gear shaft.
⑥ Install the Allen head bolts and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
Lubricating oil
Lube oil cooler
filter head gasket
assembly
Wave elastic
washer
Hex Socket Head
Studded Screw
Loosen the 4 bolts on the lubricating oil filter and remove the lubricating oil filter assembly
and the lubricating oil filter gasket as shown above.
① Check the oil filter assembly for damage, if necessary, replace the oil filter assembly.
② Check the lubricating oil filter head gasket for damage, replace the filter head gasket if
necessary.
① Before assembly, inspect lubricating oil filter gasket and lubricating oil filter assembly,
make ensure that there are no defects and damages in manufacturing and use.
② Clean the joint surface of the lubricating oil filter assembly and the cylinder block.
③ Install the oil filter seat gasket and oil filter assembly.
④ Install wave elastic gaskets and bolts and tighten the bolts.
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WD10 two-valve China Stage II series diesel engine service manual
BLOCK
Hexagon flange
bolt
Sealing Shim
Before removing, first drain the coolant from the engine, loosen the bolts on the lubricating
oil cooler cover, and remove the lubricating oil cooler cover and gasket, as shown above.
① Check the lubricating oil cooler cover for cracks and other damage. If necessary,
replace the lubricating oil cooler cover
② Inspect lubricating oil cooler cover gasket. If there is water leakage, you need to check
the failure of the lubricating oil cooler gasket and replace the new lubricating oil cooler
gasket.
① Before installing the oil cooler cover gasket, check the oil cooler cover gasket and the oil
cooler cover to ensure that there are no manufacturing and use defects and damage.
② Clean the joint surface of the lubricating oil cooler cover and cylinder block, install
lubricating oil cooler cover shim.
③ Install lubricating oil cooler cover bolts and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
Ring seal
Lubricating Oil Cooler
Wave elastic washer
Loosen the 4 bolts on the lubricating oil cooler and remove the lubricating oil cooler and
seal ring as shown above.
Check the oil cooler for cracks and other damage, and if necessary, replace the oil cooler.
① Check the oil cooler before installation to ensure that there are no defects or damage in
manufacturing and use;
② Clean the oil coolers and the block joint surface.
③ Install seal ring and Lubricating oil cooler.
④ Install wave elastic washers and bolts and tighten.
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4.8.6 Disassembly and Assembly of Main Lubricating Oil Rifle Pressure Relief Valve
4.8.6.1 Assembly Exploded View of Main Lubricating Oil Rifle Pressure Relief Valve
Figure 4-63 Assembly Exploded View of Main Oil Rifle Pressure Relief Valve
4.8.6.2 Removal Procedure of main lubricating oil rifle Pressure Relief Valve
Loosen and remove the main oil rifle pressure relief valve, as shown in the illustration.
① Check if there is any problem with the elasticity of the main oil rifle pressure relief valve,
if necessary, replace the new oil rifle pressure relief valve.
② Check the oil rifle pressure relief valve for cracks and other damage, if necessary,
replace the new oil rifle pressure relief valve.
4.8.6.4 Installation Procedure of Main Lubricating Oil Rifle Pressure Relief Valve
① Before installation, check the oil rifle pressure relief valve to ensure that there are no
defects or damages in manufacturing and use;
② Clean the oil rifle pressure relief valve hole in the block and pressure relief valve;
③ Apply sealant onto the threads of the main oil rifle pressure limiting valve.
④ Install the oil rifle pressure relief valve and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
Safety nets
Loosen and remove the hex plug and remove the compound washer, relief valve spring
and relief valve in sequence as shown.
① Check the relief valve for spring tension and, if necessary, replace the new relief valve
spring.
② Check relief valve, hexagonal screw plug, composite gasket for cracks, if necessary,
replace new parts.
① Before assembly, inspect relief valves, relief valve springs, composite washers and hex
plugs, make ensure that there are no defects or damage in manufacturing and use.
② Clean the lubricating oil cooler bypass valve and the lubricating oil cooler bypass valve
hole on the cylinder block.
③ Install the relief valve, the relief valve spring and the compound washers in sequence.
④ Install hex plug and tighten.
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WD10 two-valve China Stage II series diesel engine service manual
Shim(s)
Capscrew, Hex
Washer, Flat
Head
Oil strainer
Loosen the two hex head bolts on the filter and remove the lubricating oil filter and gasket
as shown above.
Check the filter and gasket for cracks and other damage, and if necessary, replace the filter
and gasket.
① Before installation, check the strainer and shim to ensure that there are no defects or
damages in manufacturing and use;
② Clean joint surface between the oil strainer and the oil pump and the oil strainer inner
chamber;
③ Install gasket and strainer.
④ Install the Allen head bolts and tighten.
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4 Ring gear
2 Stud
4.9.1.3 The starting system installation step is in reverse order to remove step.
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WD10 two-valve China Stage II series diesel engine service manual
When the user require warranty repair, first test on the vehicle to determine if it is a
alternator failure. Tool: Test light, the flow is shown below.
No
It means that there is no voltage at
Is the test light on? the B+ end of the alternator, and the
i b t th iti t i l f
Yes
Connect the E terminal to the D+
end of the alternator
Yes
Start Engine
Yes
Yes
Is the test light Alternator is
on?
No
No Faults with
alternator
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WD10 two-valve China Stage II series diesel engine service manual
a) Not Charging
Fault 1: No Charge
Vehicle Symptom Fault Detection Malfunction disposal
(1) The charging a Check if the excitation ① If the voltage at the alternator indicator is very low, the excitation
indicator does not go voltage from the circuit indicator power is too small or the line is connected loosely.
out when the engine is alternator to ground is Adjust indicator power or detect line connectors and connection
running between 1V~3V; points.
② If the voltage at the alternator indicator terminal is zero, it means
that the alternator end of excitation circuit has a short circuit to
ground, check the line.
③ If the voltage at the alternator indicator end is the battery voltage, it
indicates that there is a problem with the excitation circuit of the
vehicle. At the same time, the alternator regulator and the excitation
tube can be damaged. Repair the alternator only after the excitation
line is repaired.
b Detect whether the ① If the B+ voltage to ground is zero, check continuity in the positive
voltage at the output of and negative leads between the alternator and the battery.
the alternator B+ is ② If the B+ ground voltage is significantly lower than the battery
about 24V of battery voltage, check the contacts of the positive and negative leads
voltage. between the alternator and the battery for looseness or battery
damage.
Recommended detection method: connect a 2W indicator light between
alternator output B+ and excitation terminal D+/L to observe the
working status of indicator light:
① The brightness of the indicator is normal. After the engine is started,
the indicator light is off, and the generator output voltage is 27
V~28.5 V; The excitation circuit of the vehicle have failed, it needs to
be repaired.
② The brightness of the indicator is normal. After the engine is started,
the indicator light does not go out, and the generator output voltage
is 27 V~28.5 V; Generator regulator have failed, it needs to be
replaced.
3. The brightness of the indicator is normal. After the engine is started,
the indicator light does not go out, and the generator output voltage
is the battery voltage; Generator regulator, rectifier bridge, stator or
internal wiring have failed, it needs to be repaired or replaced.
(2) The key is turned a Check the charging ① Check if the alternator indicator has voltage on the ground. If not,
on but the charging indicator replace the indicator or check the line.
indicator is off b Check if the excitation ② If there is a alternator regulator or rotor failure, repair or replace
circuit is open the alternator.
(3) The charging a Low indicator power or ① It is recommended to use 2w~6W bulb or repair line
indicator does not go loose parallel ② Adjust engine idle speed
out when the engine is excitation resistor
idling, and goes out at b Engine idle speed is
high speed. too low
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a) Remove the air compressor intake air piping, water inlet piping, water outlet piping and
oil inlet piping;
b) Remove three hex head bolts on the air compressor flange and remove the air
compressor.
Trouble phenomenon: There is no compress air going out from air compressor.
Cause:
a) The air compressor relief valve is stuck. The valve is deformed or broken.
b) Excessive carbon deposits in the intake and exhaust ports.
Troubleshooting and repair:
a) Check the relief valve assembly, and clean or replace the failed parts;
b) Remove and inspect the cylinder head. Inspect the valve disc, and replace the
deformed and broken valve disc;
c) Remove and inspect the cylinder head. Clean the valve seat plate and valve disc.
Trouble Phenomenon: When the engine is running and the air compressor is inflating the
air tank, the air pressure gauge indicates that the air pressure does not reach the starting
pressure value.
Cause:
a) Air pressure gauge failure.
b) The drive belt between the air compressor and the engine is too loose or slippery or the
pipeline between air compressor and air tank is broken or the joint leaks.
c) Excessive deposits of oil-water separator, piping or air filter and blocked;
d) The air compressor exhaust valve disc is not tightly sealed, the spring is too soft or
broken. The air compressor cylinder head bolt is loose, has sand hole and the cylinder
head gasket are damaged and leaking.
e) The air compressor cylinder liner and the piston and piston ring are worn out and even
leaking.
a) Observe the air pressure gauge. If the indicated pressure is insufficient, let the engine
run at medium speed for a few minutes. If the pressure still does not rise or rise slowly,
or when the brake pedal is depressed, the deflation sound is very strong, it means that
the air pressure gauge is failed, and needs to be repaired.
b) If the above test has no deflation sound or deflation sound is small, check whether the
air compressor belt is too loose, and whether the joint is loose, broken or leaking from
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WD10 two-valve China Stage II series diesel engine service manual
the air compressor to the air tank, and to the control valve intake pipe;
c) If the air compressor does not inflate the air tank, check if there is too much dirt in the
oil-water separator and the air filter and the pipeline and thereby blocked. If it is blocked,
remove the dirt;
d) After the above inspection, if the cause of the failure is still not found, further check
whether the air compressor exhaust valve is leaking, whether the spring is too soft or
broken, whether the cylinder head has sand hole or whether the gasket is damaged.
Based on the fault that is found, replace or repair damaged parts;
e) Check if the air compressor cylinder liner and piston ring are excessively worn;
f) Check and adjust the installation direction of the unloading valve to match the direction
of the mark (arrow).
4.10.2.3.3 Air compressor oil carryover
Trouble Phenomenon: The oil overflows from the air filter and the exhaust port, and
excessive oil overflows when the air storage tank (wet) discharges water.
Cause:
a) Inspiratory obstruction or poor air intake filtration;
b) Oil return is blocked;
c) The cylinder liner of the air compressor, the piston and the piston ring is worn out, or the
oil ring is reversed and stuck, resulting that the lubricating oil flows up.
d) Air compressor is not cooled completely.
e) Dirty material is not often discharged from the air tank;
f) The air compressor runs for too long.
g) The pressure in the engine crankcase is too high;
h) Engine oil pressure is too high.
i) Lubricating oil deterioration.
j) The air compressor is defective.
Troubleshooting and repair:
a) Check the air compressor filter. If there is any damage, defect or dirty air filter, replace
the damaged parts in time; check the air compressor intake pipe for kinks or
deformation to ensure the minimum required inner diameter of the intake pipe.
Table 4-6 Minimum inner diameter of intake pipe joint and intake pipe
Theoretical Air Joint Inner
Fitting Inner Pipe I.D. Line Length
Discharge Diameter
Diameter (mm) (mm) (mm)
(m3/h) (mm)
≤17 Φ14 Φ14 Φ18
>17~20 Φ16 Φ16 Φ20
>20~30 Φ18 Φ18 Φ22
≤500
>30~40 Φ20 Φ20 Φ24
>40~50 Φ22 Φ22 Φ26
>50~60 Φ24 Φ24 Φ28
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WD10 two-valve China Stage II series diesel engine service manual
c) Inspect and measure wear and damage of the air compressor cylinder liner and piston
ring, and check the assembly conditions. If the wear is serious, replace.
d) For the air cooling part of the air compressor, remove the oil, soot or dirty materials
accumulated on the fins. Replace any damage parts as necessary; inspect damaged
fins, replace any damage parts as necessary. For the water cooling part of the air
compressor: check the proper cooling pipe size (the recommended minimum diameter
of the pipe is 9.5 mm) and check the coolant flow of the air compressor. The minimum
allowable flow rate is 5 liters per minute when the engine is adjusting its speed. If the
coolant flow is small, check for rust, kinks and limiting factors accumulated in the
cooling pipes and fittings.
e) Check that the water temperature cannot exceed 93°C. Check the air valves on the air
tank to make sure they are working properly. It is recommended that the vehicle is
equipped with an automatic exhaust valve. Provide an air drying device for drying the air
appropriately in front of the air tank.
f) In the case that the vehicle brake is not used, the leakage rate shall not exceed 6.9 kPa per
minute, and 20.7 kPa per minute in the case of braking. If there is too much leak, check the
system for leaks, and repair. Check if the unloading system is working and repair.
g) Test to see if engine crankcase pressure is too high. Replace or repair the ventilation
equipment of the crankcase. The looseness or partial lifting of the dipstick indicates a
problem with the pressure in the crankcase.
h) Check engine lubrication pressure (at the air inlet of the air compressor) and compare it
to the rated pressure.
i) Change to qualified lubricating oil.
j) The air compressor can only be replaced or repaired if it is confirmed that none of the
above reasons exist.
4.10.2.3.4 Abnormal sound in air compressor
Trouble Phenomenon: Metal knock, even tapping, rubbing or whistling.
Cause:
a) The connecting rod bearing shell is severely worn, the connecting rod bolt is loose, the
connecting rod bushing is seriously worn, the main shaft wears seriously or damages,
resulting in knocking sound;
b) If the belt is too loose, the main and auxiliary belt grooves do not match, causing the slip
to produce whistling;
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WD10 two-valve China Stage II series diesel engine service manual
c) After the air compressor is running, there is no immediate oil supply, and the dry friction
of the metal produces whistling;
d) The fixing bolt is loose;
e) The gear fastening nut is loose, causing excessive knocking to produce a knocking
sound;
f) There is a foreign object on the top of the piston.
Troubleshooting and repair:
a) Check for the connecting rod bearings, connecting rod bushing and main bearing are
worn, strained or burnt, and the connecting rod bolt is loosen. Check for the main oil
passage of the air compressor is blocked; It is recommended to replace the bearing,
bushing and main bearing with severe wear or strain, tighten the connecting rod bolt
(torque standard value 35N·m-40N·m), and align the air compressor oil hole with the air
compressor oil inlet hole; Unblock the main oil passage. When reassembling, pay
attention to the main shaft bearings.
b) Check whether the groove type of main and auxiliary pulleys are the same. If they are
inconsistent, replace them and adjust the belt tightness (press the belt with your thumb,
the distance of sag shall be 10 mm);
c) Check the oil inlet pressure and oil pipeline for damage or blockage. If the pressure is
insufficient, adjust, clean and replace the failed pipeline immediately. Check the oil
quality and impurity content of the lubricant. If it exceeds the standard, it should be
replaced immediately. Check whether the air compressor is supplied with oil, if there is
no oil supply, it should be thoroughly inspected immediately.
d) Check if the air compressor fixing bolt is loose, and fasten;
e) For the geardriven air compressor, also check whether the gear is loose or the condition
that gear is installed and fitted. Retighten the loose nut, or replace if there is any
problem of engagement;
f) Remove foreign objects.
4.10.2.3.5 Air compressor bearing shell stuck
Trouble Phenomenon: The main shaft of belt driven air compressor is locked; the bearing
shell or connecting rod bearing of gear driven air compressor is abnormally loose.
Cause:
a) Lubricating oil deterioration or excessive impurities.
b) Insufficient oil supply or no oil supply.
c) The bearing shell shifts, causing the internal oil passage of the air compressor blocked;
d) The bearing shell and the connecting rod bearing shell are scored or the clearance is
too small.
Troubleshooting and repair:
a) Check the oil quality and impurity content of the lubricating oil. Compare with the
standard, if exceeding, change it immediately;
b) Check the oil inlet pressure of air compressor and oil pipeline for damage and blockage.
If the pressure is insufficient, adjust, clean or replace the failed pipeline immediately.
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WD10 two-valve China Stage II series diesel engine service manual
c) Check the installation position of the bearing shell, the oil hole of the bearing shell must
be aligned with the oil hole of the casing;
d) Check if the bearing shell or connecting rod shell is burnt or scored. Check the
crankshaft diameter for damage or wear when cleaning and replacing the bearing.
Replace it when it exceeds the standard.
e) Check and adjust bearing shell lash.
4.10.2.3.6 Air compressor leaking oil
Trouble Phenomenon: The air compressor has a lubricant overflow on the outside.
Cause:
a) Oil seal falls off or oil seal defects resulting in oil leakage;
b) Loose main shaft causes oil seal to leak oil.
c) The joint surface leaks, and the inlet and return oil pipe joints are loose.
d) Excessive tensioning of the belt causes the main bearing shell to wear.
e) Casting or processing defects.
Troubleshooting and repair:
a) In the oil seal area, check the oil seal for cracks and the inner lip for cracks or flanging.
In one of the above condition, it should be replaced: check the oil seal and the spindle
joint surface for scratches and defects. If scratches and defects are found, it should be
replaced. Check whether the oil return is unblocked. and the unsmooth oil return causes
the pressure of the crankcase too high, resulting in the oil seal to leak or fall off. The
minimum pipe diameter of the oil return pipe must be ensured, and the oil pipe is not
twisted, bent, and the oil returns smoothly. Check the oil seal and the size of the case,
and replace it if it does not meet the standard;
b) Forcefully move the main shaft to check if the journal clearance is too large. If the
clearance is too large, replace the bearing shell and oil seal at the same time.
c) Inspect seal sealing of each joint, repair or replace the gasket; inspect the inlet and
return connection bolts and the housing threads and tighten.
d) Check and re-adjust the belt tightness, a distance of 10 mm is acceptable if pressed by
thumb;
e) Check the defects in the casting or processing of the case (such as whether the oil
return hole in the location where the case installed is open), repair or replace the
defective parts.
4.10.2.3.7 Air compressor overheating
Trouble Phenomenon: The air compressor exhaust temperature is too high; the operating
part is hot.
Cause:
a) If the relief valve or the unloading valve does not work, the air compressor will no rest;
b) The severe leakage of the air brake system causes the air compressor to have no rest;
c) Insufficient oil supply at the operating part, scuffing of cylinder bore.
Troubleshooting and repair:
a) Check the relief valve Assy when the air intake is unloaded, and if stuck clean, repair or
replace the failed part. When unloading, check whether the unloading valve is blocked
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4.10.2.4 Air compressor install step is in reverse order to the remove step
Air Filters
Connection elbow
Support Bolt
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WD10 two-valve China Stage II series diesel engine service manual
4) Remove the support bolt between the air cleaner support bracket and the main cylinder
head bolt.
4.10.3.3 Air filter system assembly steps
The air filter system install step is in reverse order to the remove step.
Muffler
Connection elbow
Studs
Nuts
Washer
Bracket-Silencer
Block
Support Bolt
1) Remove the connecting elbow by loosening the stud and nut between the turbocharger
and the flange surface of the connecting elbow and the hexagonal bolt and nut between
the elbow flange and the muffler on the other side.
2) Loosen the 4 bolts and nuts between the silencer and the muffler bracket to remove the
silencer.
3) Loosen the nuts and bolts on the silencer bracket and remove the wave spring washer
and silencer bracket.
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WD10 two-valve China Stage II series diesel engine service manual
4) Remove the support bolts and support blocks between the silencer support bracket and
the cylinder head main bolt.
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