WD10 two-valve China Stage II diesel manual

WD10 two-valve China Stage II series diesel engine service manual
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M WP10 Two-valve China Stage II series M
2 diesel engine service manual
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Weichai Power Co., Ltd.

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WD10 two-valve China Stage II series diesel engine

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
J invalid. J
M ● The turbocharger rotor shaft is a precision high-speed rotating component. Do not M
2 disassemble and collide. Otherwise, all three guarantees of the company service will be
invalid.
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● 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
a single-use bolts and must not be reused. Otherwise, all "three guarantees" implemented
by the company will be invalid.
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● Lubricating oil or fuel added to the diesel engine must be in accordance with the
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maintenance instructions and filtered by a dedicated cleaning filter. The fuel must be
precipitated
t for more than 72 hours. Before operating the engine, please ensure that the
amount of the coolant and lubricating oil meets the requirement.
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● Never operate the diesel engine without air filter to prevent air from entering the cylinder
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being filtered.
_ the new engine, the run-in should be done for 50 hours first.
● Before using
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● After starting the diesel engine, raise the engine rpm gradually, and do not make it run at
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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),
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and should run at low speed for 5 to 10 minutes after stopping.
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● 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.
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.
J This manual briefly introduces the technical parameters, performance indicators, structural J
characteristics and precautions for use and maintenance of WD10 series China Stage II diesel
M engine. If the user can use the diesel engine in accordance with the requirements specified in
M
2 this manual, it will greatly extend the service life of the diesel engine.
8 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
forathe latest product information.
Userspare welcome to provide us suggestions and comments on further improvements of the
product._
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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
J 1.5 Lifting of Diesel Engine ...................................................................................................................6 J
1.6 Installation of diesel engine ............................................................................................................7
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1.7 Preparation Before Start-up............................................................................................................7
2 1.8 Starting of Diesel Engine ................................................................................................................7
8 1.9 Operation of Diesel Engine.............................................................................................................8
Section
_ 2. Diesel engine maintenance guide..........................................................................................10
2.1 Fuel, Lubricant, Coolant and Auxiliary Materials...........................................................................10
a 2.1.1 Fuel oils ...........................................................................................................................10
p2.1.2 Diesel Engine Oil .............................................................................................................10
_ Lubrication of the tensioner..............................................................................................12
2.1.3
2.1.4 Antifreeze additive for engine Cooling System ................................................................12
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2.1.5 Auxiliary Material .............................................................................................................12
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2.2 Daily Maintenance ........................................................................................................................14
2.3 Maintenance u Content of All Levels of Maintenance ......................................................................17
2.4 Long Term Storage
_ and Maintenance ..........................................................................................22
2.4.1 Clean ...............................................................................................................................22
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2.4.2 Protection.........................................................................................................................22
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2.4.3 SEAL,OIL.........................................................................................................................22
o failure and treatment............................................................................24
Section 3. Diesel engine typical
3.1 Diagnostic Method ........................................................................................................................24
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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
3.2.18 Alternator Excessive Charging.........................................................................................31

3.2.19 Generator Has Abnormal Noise.......................................................................................32
Section 4. Disassemble and assembly of the engine .............................................................................33
4.1 General Information ......................................................................................................................33
4.1.1 Hazard Sign .....................................................................................................................33
4.1.2 Safety signs .....................................................................................................................34
4.1.3 Required Tools ................................................................................................................35
J 4.1.4 Health Precautions ..........................................................................................................35 J
4.1.5 Environmental Protection Measures ................................................................................36
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4.1.6 Engine Remove and Install Precautions ..........................................................................36
2 4.2 Engine Block Group......................................................................................................................36
8 4.2.1 Engine block group disassembly and assembly ..............................................................36
_ 4.2.2 Cylinder block pre-assembly disassembly and assembly ................................................39
4.2.3 Removal and Installation of Piston Nozzle.......................................................................41
a 4.2.4 Removal and Installation of Thrust Plate .........................................................................42
p4.2.5 Removal and Installation of Front/Rear Oil Seals ............................................................43
_ Removal and Installation of Gear Housing ......................................................................44
4.2.6
4.2.7 Front end cover remove and install..................................................................................45
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4.2.8 Removal and Installation of Flywheel Housing ................................................................46
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4.2.9 Removal and Installation of Oil Pan.................................................................................48
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4.2.10 Removal and Installation of Cylinder Head Cover ...........................................................49
4.2.11 Removal
_ and Installation of Cylinder Head Cover ...........................................................56
4.2.12 Removal and Installation of Oil/Gas Separator ................................................................57
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4.3 Crank and connecting rod mechanism .........................................................................................59
4.3.1 Disassembly r and Assembly of Crank and Connecting Rod Mechanism..........................59
4.3.2 Disassemblyoand Assembly of Piston/Connecting Rod Assy...........................................60
4.3.3 Crankshaft disassembly and assembly............................................................................62
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4.3.4 Removal and Installation of Flywheel and Ring Gear ......................................................64
4.3.5 Disassembly and Assembly of Vibration damper, Crankshaft pulley ...............................66
4.3.6 Disassembly and Assembly of Crankshaft Bearing Shell ................................................66
4.4 Valve Mechanism .........................................................................................................................67
4.4.1 Disassembly and Assembly of Valve Mechanism............................................................67
4.4.2 Disassembly and Assembly of Camshaft.........................................................................68
4.4.3 Removal and Installation of Rocker Arm and Rocker Shaft .............................................70
4.4.4 Removal and Installation of Tappet and Push Rod..........................................................72
4.4.5 Disassembly and Assembly of Valve ...............................................................................73
4.4.6 Intermediate gear disassembly and assembly .................................................................74
4.5 Air Intake and Exhaust Systems...................................................................................................75
4.5.1 Disassembly and installation of Air Intake System...........................................................75
4.5.2 Exhaust system removal and installation .........................................................................76
4.5.2 Disassembly and assembly of pressurization system and lubricating oil pipe system .....77
4.5.4 Disassembly and assembly of turbocharger lubricating oil pipe system ..........................79
4.6 Fuel System..................................................................................................................................80
4.6.1 Disassembly and Assembly of Fuel System ....................................................................80
4.6.2 Removal and Installation of Fuel Injection Pump .............................................................81
4.6.3 Removal and Installation of High Pressure Fuel Lines ....................................................82

4.6.4 Removal and Installation of Injector.................................................................................83
4.7 Cooling System ............................................................................................................................84
4.7.1 Water pump disassembly and assembly..........................................................................84
4.7.2 Removal and Installation of Thermostat ..........................................................................85
4.7.3 Disassembly and Assembly of Fan..................................................................................86
4.7.4 Removal and Installation of Water Outlet Tube ...............................................................87
J 4.8 Lubricating Oil System..................................................................................................................89 J
4.8.1 Lubricating oil pump disassemble and assembly.............................................................89
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4.8.2 Disassembly and Assembly of Lubricating Oil Pump Intermediate Gear Assembly ................90
2 4.8.3 Remove and Installation of Oil Filter ................................................................................91
8 4.8.4 Lubricating oil cooler cover disassembly and assembly ..................................................92
_ 4.8.5 Disassembly and Assembly of Lubricating Oil Cooler......................................................93
4.8.6 Disassembly and Assembly of Main Lubricating Oil Rifle Pressure Relief Valve ..................94
a 4.8.7 Lubricating oil cooler bypass valve disassemble and assembly ......................................95
p4.8.8 Disassembly and Assembly of Filter ................................................................................96
_ System ............................................................................................................................97
4.9 Starting
4.9.1 Disassembly and Assembly of Starting System...............................................................97
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4.9.2 Disassembly and Assembly of Starter .............................................................................97
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4.10 Vehicle Accessory System ...........................................................................................................98
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4.10.1 Removal and Installation of Alternator .............................................................................98
4.10.2 Disassembly
_ and Assembly of Air Compressor .............................................................104
4.10.3 Air filter system disassembly and assembly...................................................................110
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4.10.4 Disassembly and Assembly of The Silencer System ..................................................... 111
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Appendix A Matching Clearance of Main Parts of Diesel Engine.......................................................113
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Appendix B Evaluation Reference of Wear Amount of Main Friction Pair in Diesel Engine ...............114
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Section 1. Diesel Engine Operating Instructions
1.1 Exterior of Diesel Engine
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Figure 1-1 WD10 two-valve China Stage II series diesel engine outline drawing (side)
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Figure 1-2 WD10 two-valve China Stage II series diesel engine outline drawing (free end)
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1.2 Definition of Diesel Engine Model
Variant Number
Emission Stage
kW Rating
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Displacement
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2 DESIEL
8 WATER
_ Diesel Engine Technical Data
1.3
a Table 1-1 WD10 two-valve China Stage II series diesel engine performance parameters
p Type
Water cooled,4-Stroke, direct injection, supercharged
intercooler
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Bore/Stroke (mm) 126/130
t Displacement (L) 9.726
s Compression 17:1
u Firing Order 1-5-3-6-2-4

Fuel System Mechanical
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Valve lash cold (mm) Intake valve 0.3, exhaust valve 0.4
e Intake valve open, before the top dead center 34°~39°
valve timing (intake lash:r0.3, exhaust lash: 0.4)
Intake valve close, after the bottom dead center 61°~67°
Exhaust valve open at 76°~81° before BDC
o Exhaust valve close at 26°~31° after TDC
Thermostat opening temperature (°C) 83 (Fully Opened)
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Startup Mode Electric Start
Modes of Lubrication Pressure Lubricated
Lube Oil Capacity (L) 24
Cooling options Water cooling forced circulation
Oil Pressure (kPa) 350~550
Idle speed oil pressure (kPa) 100~250
Allowed pitch angle(°) Front/rear long term10/10 short term30/30
Exhaust pipe side /
Allowed heel angle(°) long term45/15 short term45/30
injection pump side
Crankshaft rotation direction (view from the free
Clockwise
end)
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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
J cylinders
— 6 J
M Valves per
2
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cylinder
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Fuel Injection Mechanical
8 kW Rating kW 175 162 162 162 154 154 154
_ Rated r/min 2200 2200 2100 2000 2200 2100 1900
aPeak Torque N.m 920 860 920 1050 860 920 920
Peak torque r/min 1400-1600 1300-1600 1200-1400 1300-1600 1200-1400
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Emission
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Level
— China Stage II
Cold Startt -
without °C -5
starting aids
White smoke uOpacity After idle for 20 seconds≤15%
emission
Cold Start - _
with starting °C -25
aid e
Noise Level
dB(A)
r <104
from 1 m
Fuel supply
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advance
angle
°C n 8~9
Bi. Life km 800,000
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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
J No. of J
— 6
cylinders
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Valves per
2 2
cylinder
8 Fuel Injection Mechanical

kW Rating kW 128 154 162 148 128 115
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Rated r/min 2000 1800 2000 1850 1850 1800
aPeak Torque N.m 750 1050 1050 930 810 750
p torque
Peak r/min 1300-1500 1100-1300 1200-1400 1000-1200 1000-1200 1000-1200
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Emission
— China Stage II
Level
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Cold Start -
without s °C -5
starting aid
White smoke u
Opacity After idle for 20 seconds≤15%
emission
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Cold Start -
with starting °Ce -25
aid
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Noise Level
from 1 m
dB(A) o <104
Fuel supply n
advance °C 8~9 5~6 7~8
angle
B10 life km 800,000
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1.4 Unpacking of Diesel Engine

When unpackaging the diesel engine, user shall first check the diesel engine and
accessories against the factory packing list, and check for any appearance damage, loose
connectors, etc., and then performs the following work:
1) Wipe off the rust-proof layer as well as the corrosion inhibitor on the exposed parts.
2) Drain the sealing diesel fuel from fuel filter and inside of fuel system (the engine is also
J allowed to be started before sealing fuel drained off, but not allowed to be operated at J
load until the sealing fuel of fuel system has been used up and the normal fuel has
M been provided).
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NOTE: The fuel sealing period of the diesel engine is one year. Inspected shall be
8 made and necessary supplementary measures shall be taken for more than one year.
_ See 2.4.3 for methods and precautions for re-sealing.
a3) Rotate the flywheel and spray solvent into the intake manifold until the sealing fuel in
the cylinder is exhausted.
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4) Spray solvent into the inlet and outlet of the turbocharger until the sealing fuel is
_exhausted.
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5) According to the agreement between the factory and the user, if oil is not filled into the
oil pan,
s oil should be added according to the regulations; if the oil pan is filled with
engine oil containing running-in accelerator, it is recommended that the user drive the
vehicleu2000km (or 50 hours), then drain the old oil and fill with the new oil.
_agreement between Weichai and the user, and if the coolant is filled as user
6) As per the
required at the
e factory, coolant performance shall be checked during unpackaging. The
coolant can be used if its antifreezing performancecould meet -30°C or -35°C, pH is
r total rigidity value is 5°d~15°d[9°f~15°f(rigidity)], otherwise it shall be
7~8 (neutral), and
drained off and refilled
o with new coolant containing antifreeze.
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1.5 Lifting of Diesel Engine
When lifting, keep the center line of the crankshaft of the engine horizontal. Do not tilt or
unilaterally lift. Lifting and seating should be slow (see Figure 1-3).
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TRUE Wrong
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Figure 1-3 Diesel engine eyebolt diagram
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1.6 Installation of diesel engine
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8 When installing, ensure that the crankshaft centerline of the diesel engine is coaxial with
the input shaft axis of the transmission (gearbox, transmission or alternator, etc.), and that
_ the crankshaft is not subjected to additional axial forces due to installation.
1.7aPreparation Before Start-up
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1) Check coolant level
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If the engine is already installed on the vehicle or the stand, the coolant level can be seen
through t the glass sight hole on the expansion tank at any time. If the coolant is not enough,
open the filler cap and add the coolant. When opening the filler cap with the pressure relief
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valve and the air discharge button, if the engine is hot, you must first press the air
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discharge button to release the air before opening the cap. Do not add a large amount of
coolant to the engine when it is hot. Otherwise, the parts will be damaged due to huge
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temperature change. If in a unusual case that there is no coolant, it is allowed to slowly add
cold water of notetoo low temperature, and add the coolant from the filling port until it
overflows. Start the engine. While the engine is running (1000 r/min), keep filling the
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coolant until the liquid level is stable, then cover the filler cap.
2) Check fuel level
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If the engine is already installed on the vehicle, turn on the power switch, check the fuel
level from the fuel gauge or check the fuel tank.
3) Check engine oil level
The oil level shall be between the upper and lower lines of the dipstick. If necessary, add oil
from the oil filler port.
4) Check that the connections of the various accessories of the diesel engine are reliable
and eliminate abnormality. Check if the starting system circuit connection is normal and
the battery is fully charged. Then open the fuel tank valve, loosen the bleed screw on
the primary fuel filter, and use the hand pump on the primary fuel filter to bleed air from
the fuel system.
1.8 Starting of Diesel Engine
1) Put the power supply switch and key switch in the power-on position on the vehicle, put
the shift lever in the NEUTRAL position, and start the engine.
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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
J operate via relay, so as to realize smooth starting at -30°C. J
M 1.9 Operation of Diesel Engine M
2 1) After the diesel engine starts, run the engine at idle speed for a few minutes, then raise
8 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
a sudden loading or unloading.
2)p The diesel engine is suitable for working under medium load within 50 hours running-in
period, and the vehicle should not have a trailer.
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3) It ist 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
smallsand the speed is too low, because it is prone to failures such as excessive oil
consumption.
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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 beeallowed for up to 20 minutes. After the engine is unloaded, the diesel
engine shall idle
r for 1 min~2 min before stopping.
5) The following parameter
o values and check points to be noted during use:
Lubricating oil main oil rifle
n 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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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
J winter. J
M ② Lubricating oil: select lubricants of different viscosities as per season. M
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③ Coolant: Cooling System Add antifreeze additive. Different grades and different
8 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
a started, only operate the engine at high speed and under load after the oil pressure and
water temperature are normal.
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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
t shall be removed and stored in a warmer room.
battery
s When parking in cold weather, first remove load, then run at idle speed for 1
⑥ Parking:
min~2 min.
u 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, inletepipe, etc., then drain the coolant to prevent the engine from freezing.
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Section 2. Diesel engine maintenance guide
2.1 Fuel, Lubricant, Coolant and Auxiliary Materials
2.1.1 Fuel oils

Summer: No. 0 diesel fuel (GB252)
J Winter: Generally, No. -10 diesel, but when the ambient temperature is lower than -15°C, J
No. -20 diesel shall be used, and when the ambient temperature is lower than -30°C, No.
M -35 diesel shall be used.
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2 The fuel used must comply with the requirements of Table C.6 of Appendix C of the
8 national standard GB 17691.
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2.1.2 Diesel Engine Oil
aWeichai Power China Stage II series diesel engine uses CF-4 grade lubricating oil. See
p 2-1 for specific standards.
Table
_ Table 2-1 Weichai Power Special Engine Oil Selection Specification
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Category Product Type Package Size Applicable Models
s 10W-30 China Stage II Emission Diesel Engine:
CF-4 15W-40 4L, 18L, 170kg WD615, WD10, WD618, WD12, 226B
u 20W-50 series etc.
_ CH-4 10W-30 China Stage III Emission Diesel Engine:

15W-40 4L, 18L, 170kg WP4, WP5, WP6, WP7, WP10, WP12,
Diesel Engine e 20W-50 WP13 series etc.
Oil
10W-30 China Stage IV Emission Diesel Engine:
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CI-4 15W-40 4L, 18L, 170kg WP4, WP5, WP6, WP7, WP10, WP12,
20W-50 WP13 series etc.
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10W-30 China Stage V Emission Diesel Engine:
CJ-4 n 15W-40 4L, 18L, 170kg WP4, WP5, WP6, WP7, WP10, WP12,
20W-50 WP13 series etc.
Lubricating oil 10W-30
4L, 18L, 170kg | For Natural Gas Engines
for gas engine 15W-40
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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
J 20W-50 -15-45
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2 CAUTION:
8 1) Before starting the diesel engine, first check the height of the oil level in the oil
_ pan.
a2) Do not check the oil level when the diesel engine is running.
3)p It is strictly forbidden to mix the oil of Weichai Power with other manufacturers'
oils
_ at the same time
Refer tot Table 2-3 for the amount of oil refills and the number of filter elements for each
Weichai Power model.
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Table 2-3 Engine Oil Refill Amount and Number of Filter Elements for Weichai Power Models
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Number of Filters
_ Diesel Engine Gas Engine
Lubricating
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Model Oil Fill
Fuel Filter
Quantities (L) oil Fuel Gas
r Oil Filter
Seconda filter Filter
Primary
ry
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WP4 9〜12 1 1 1 1 1
WP5
n13〜16 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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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!
2.1.3 Lubrication of the tensioner

Use automotive lithium-based grease for lubrication of the tensioner (see the standard of
GB/T5671).
J 2.1.4 Antifreeze additive for engine Cooling System J

M The freezing point of Weichai Power special coolant is -25°C, -35°C,-40°C respectively. M
2 Select the Weichai special coolant according to the local ambient temperature. The
selection principle is that the freezing point is about 10 °C lower than the local temperature,
8 please refer to Table 2-4.
_ Table 2-4 Weichai Power Special Heavy Duty Engine Coolant
a Category Product Type Package Size

p Heavy Duty Engine
HEC-II-25
HEC-II-35 4kg, 10kg
_ Coolant
HEC-II-40
CAUTION:t
s coolant regularly to prevent corrosion damage and replace as necessary.
1) Inspect
u
2) Never use water and inferior coolant for cooling the engine.
_
2.1.5 Auxiliary Material
e
Table 2-5 Auxiliary materials for diesel fuel
No.
r
Name Color Usage and Application
o
Molykotte Pulver
Apply to a smooth metal surface to prevent seizure
1 (Fine molybdenum Black
powder)
n For example: outer surface of cylinder liner, etc.
Molykotte Gu.plus
Lubricate before the lubricant pressure is established.
2 (Molybdenum disulfide Dark Gray
For example: inlet valve stem etc.
oil agent)
12
Table 2-6 Reference for Diesel Engine Applying Sealant
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
J Weichai Specific
242
thread to prevent shock, medium
Lubricating Oil Cooler Capscrews
Threaded plug of the oil cooler regulator As an option, DriLoc204 J
force thread pre-coated
M valve
adhesive can be used for
M
Bolts for fuel pump drain line fixing
precoating.
2 device
Air compressor shaft end thread
8 Strainer bolt
Bolts for sensors and harness fixture
_ Application on the outer surface
Weichai Specific
a of the thread, to lock, seal and Cylinder head slave bolts
262
prevent shock
p
Weichai Specific
Anti-loose, fastening Cup plug for oil hole
271
_
Weichai Specific For sealing between core and
Other cup plugs
277 t hole
270
s
Weichai Specific For sealing the top surface of
cylinder head
one Cylinder head push tube
u Joint surface between cylinder block
and crankcase
_ Front and front end cover, rear end face
and flywheel housing connecting plate
e Joint surface between oil filter head and
Weichai Specific r crankcase
518 Application on a shiny metal Water pump back cover - front end face
(Updated product surface to seal o of block
of 510) Flywheel Housing connecting
n plate_flywheel housing
Joint surface between cylinder block
and oil cooler cover
Joint surface between cylinder block
and oil filler cap
13
2.2 Daily Maintenance

• Check coolant level and water temperature.
Observe the coolant level in the glass sight hole. If the coolant is not sufficient, open the
filler cap and add the coolant.
NOTE: When opening the filler cap, always press the vent button first, to prevent the
hot coolant from injuring when the engine is hot.
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2
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2
8
_
Figure 2-1 Water filler cap safety sign
a
p Tank,
_ Expansion
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Figure 2-2 Expansion Tank View
• Check oil level.

When the oil level is lower than the lower mark of the dipstick or higher than the upper mark,
never start the engine．
After the engine stopped, inspect the oil level at least 5 minutes later in order to ensure the
oil can flow back to the oil pan．
The oil capacity difference from low to high oil level is 3 L.
15
Oil dipstick
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2
Figure 2-3 Lubricating oil dipstick marking instructions
8
• Check fuel level
_
aCheck fuel level indicator in the dashboard and refill fuel in time.
• Check
p for leaks
Check
_ if there is any leaks of coolant, gas or oil on the exterior of the engine.
• Checktthe fan
Visually s
check the fan blade for damage and the connecting bolts for tight.
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Figure 2-4 inspect fan blade
• 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.
16
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2
8 Figure 2-5 inspect belt
_
• Check for exhaust color is normal
a
The normal exhaust color is light gray. If there is any change in color, determine the cause
p repair.
and
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Figure 2-6 Check color of exhaust gas
• 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.
17
J J
M Drain plug M
2 Figure 2-7 Oil drain plug
8
_
a Lubricating oil fill
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e Figure 2-8 lubricating oil filler
r
Note: Waste oil should be placed in the designated location and container for
recycling.
o
• Replace the Oil Filter ornElement.
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
18
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
1 cylinder 2 cylinders 3 cylinders 4 cylinders 5 cylinders 6 cylinder

J J
Cylinder# 1 Intake and Intake Exhaust Intake Exhaust
unadjustable
M Compression Stroke exhaust valves valves valves valves valves M
Cylinder# 6 Exhaust Intake Exhaust Intake Intake and
2 Compression Stroke
unadjustable
valves valves valves valves exhaust valves
8
• Change the fuel filter element.
_
Remove the old fuel filter core; if the water collection vessel installed on the strainer can
a① be reused, remove the water collection vessel.
p
② Lubricate the seal.
_
③ Screw the filter by hand until the seal engages with the port.
t
④ Continue
s to manually tighten the filter until the filter is securely installed (approximately
3/4 turn).
u
⑤ Bleed the air until no bubbles appear.
_
⑥ Perform a leak test.
e
CAUTION: r
When replacing theospin-on type pre-filter or reinstalling the fuel transfer tube, the
pre-filter needs to be air
n 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.
19
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2
8
Figure 2-9. Bleed the primary filter
_
aDrain the water from the sump:
Note:
p When the sump is full or the spin-on type filter has been replaced, the
collected water needs to be discharged.
_
Steps (as shown in Figure 2-10):
t
① Open the drain plug 2 on the bottom side of the sump 1 to drain the water.
s
② Retighten the drain plug.
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open close
Figure 2-10 Drain the water collector
Replace water collector:

Steps (as shown in Figure 2-11):
① Shut off the engine.
② Drain the water from the sump.
③ If possible, remove the screw 1 of the sump by hand. If it is too tight, use the installation
and removal tool in the new water collector.
④ Lubricate the seal ring 2 of the new water collector with a few drops of oil.
20
⑤ Install the screw by hand and tighten it with a tool.

⑥ If the water collection vessel is reused on a new spin filter, inspect it for damage.
⑦ Use a torque wrench to install and torque to 20 N.m.
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_ Figure 2-11 replace the water collector
• Checktthe air intake system

Check ifsthe air intake hose is aged and cracked, and the clamp is loose. Fasten or replace
parts as necessary
u to ensure the tightness of air intake system.
• Inspect the air_cleaner element. Figure 2-12 shows the air cleaner schematic diagram
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1. Paper filtering element

2. Blankelry safety filtering element
Figure 2-12 Air cleaner

The maximum allowable intake resistance of the diesel engine is 7 kPa. Check the
maximum intake resistance of diesel engine at the rated speed and full load. When the
intake resistance reaches the maximum allowable limit, clean or replace the filter according
to the manufacturer's specifications.
NOTE: Never operate the engine without an air filter, otherwise dust and impurities
entering the diesel engine will cause premature wear.
Remove the air filter element from the air filter, tap the end face to allow the dust to fall, or
use the compressed air to blow back (from inside to outside).
21
High pressure air pipe
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2
8 Figure 2-13 Clean the Filter Elements
_ Note: Do not blow the filter paper, do not wash the filter paper with water or oil, and
ado not force or beat the filter element.
p Term Storage and Maintenance
2.4 Long
2.4.1 _Clean
①
t
After warming up, discharge the lubricating oil, clean the lubricating oil filter, and add
s oil;
anti-rust
② u and add rust preventive oil;
Drain fuel
③ Discharge_water and add coolant with rust inhibitor;
④ e and idle 15 min~25 min;
Start the engine
⑤ r
Discharge lubricating oil, fuel, coolant and urea solution;
⑥
o
Protect other parts;
n
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;
22
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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_ Figure 2-14 Pneumatic Spray Gun Appearance Schematic
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Section 3. Diesel engine typical failure and treatment

The WD10 two-valve China Stage II construction machinery series diesel engine is
designed and manufactured under a strict quality assurance system. Each diesel engine
has been tested before being delivered from the factory. At the same time, the diesel
engine is a kind of precision machinery, and its efficacy must be guaranteed for a long time,
which is inseparable from normal maintenance. There are several reasons for the early
failure of the diesel engine, including:
J J
M ◆ Violation of operation, mismanagement and improper use; M
2 ◆ Failure to do periodic maintenance or even repair instead of maintenance;
8 ◆ Poorly manufactured parts, especially buy counterfeit and shoddy products that are
_ cheaper, will greatly shorten the life of the diesel engine;
a◆ Fuel and lubricant oil grades are used improperly or unqualified.

p
3.1 Diagnostic Method
_
Commonly used diagnostic methods for diesel engine faults are:
t
(1) Observation method: Judge the fault condition by observing the fault characteristics
suchsas smoke exhaust of the diesel engine, as shown in Figure 3-1.
(2) Auscultation
u method: According to the abnormal noise of the diesel engine, the nature
and extent of the fault location are judged by hearing, as shown in Figure 3-2.
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Figure 3-1 Observation method Figure 3-2 Auscultation
◆ 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.
24
2. For high-pressure oil pumps, turbochargers and other key components,

inspections and repairs do not only need dedicated equipment, but also need the
personnel with certain experience, so customers who have no experience and do
not meet the conditions should not disassemble them.
3.2 Causes and troubleshooting
3.2.1 Diesel Engine Cannot Start
J Cause of Failure Troubleshooting Method J

M (1) Does the starter work? If it does not work, first Correct the electrical line problem M
(2) The air temperature is too low Increase the starting aid measures
2
(3) Air in fuel system. Discharge air, inspect joint sealing, repair
8 (4) lift pump fuel filter or fuel pipe is blocked Check and remove dirt, inspect fuel cleanliness
_(5) Injection Pump is faulty Check plunger, oil outlet valve, repair or replace damaged parts
(6) a
Gas or fuel supply tube damage and oil
Inspect and adjust
leakage
p
(7) High pressure fuel pipe damage and
Repair and replace
leakage_
(8) fuel injector is faulty Inspect fuel injector atomize condition
t
Check the tightness of valve and cylinder gasket, the wear condition of
(9) Insufficient cylinder
s compression pressure
piston, repair or replace
u
3.2.2 Stop Soon After Starting
_
Cause of Failure
e Troubleshooting Method
Inspect tubing and joint tightness, bleed screw is tightened, discharge
r
(1) Air entering the fuel system
the struck air
(2) Fuel filter is plugged

o Remove filter body to remove internal contaminants and moisture,
replace element if necessary
n
(3) Poor fuel quality and high moisture content Clean the filter, change fuel
(4) Fuel delivery pump not operate Inspect lift pump piston, valve, cleaning and repair
(5) Idle speed is too low Rescale
3.2.3 Loss of power
Cause of Failure Troubleshooting Method

Inspect air filter, air intake piping, cleaning or replace filter
(1) Intake air blockage (air filter blockage)
element
Inspect valve timing, and check for exhaust pipe is blocked,
(2) Exhaust back pressure too high
adjust and repair if necessary
(3) Insufficient pressurizing system pressure Inspect to exclude leaks at pipe connections
(4) The turbocharger is not functioning properly Replace Group
4-1) Compressor, turbine runner dirty and blocked Clean or replace
4-2) Floating Bearing Failure Replace
4-3) There is carbon and sludge at the back of the
Wash
turbine and compressor
25

(5) The intercooler is damaged and leaks Replace or patch
Inspect tubing and joint tightness, check for filter and fuel line
(6) Fuel line leakage or blockage contamination, repair or remove blocked dirt, replace filter
element
(7) Fuel quality is poor Clean the fuel tank, filter parts and tubing, change fuel
(8) Injection Pump or governor is excessively worn Repair or replace
J (9) Injection pump smoke limiter diaphragm damage Replace Repair J

(10) smoke limiter air pipe damaged air leak Replace
M M
(11) Poor atomize of the injection nozzle Inspect injection pressure, nozzle deposit, adjust and repair
2 (12) Valve or fuel supply timing is incorrect Inspect and adjust
8 (13) Governor high speed adjustment is too low Inspect speed regulation characteristics, adjust
_ oil pan lubricating oil level is too high

(14) Inspect oil dipstick, discharge excess lubricating oil
Check the compression pressure when the engine is hot, replace
(15)aBlown head gaskets
damaged cylinder head gasket
p ring wear and broke, bearing gap too large
(16) Piston Replace worn parts, or overhaul engine
_ liner or piston wear or cylinder score

(17) Cylinder
t
3.2.4 Fuel Consumption Excessive
s
u
1- Air intake pipe blocked Inspect air filter, air intake piping, clean up
_
(2) Exhaust back pressure too high Inspect exhaust pipe and brake valve, clean up
(3) Fuel quality is poor e Change with fuel as specified
(4) Fuel line blockage r Check and repair
(5) Fuel line leakage Check and repair
o
(6) Poor fuel injector atomization Inspect and adjust or repair
n
Adjust the valve lash and fuel supply advance angle as
(7) Valve or fuel supply timing is incorrect
required
(8) Blown head gaskets Check the compression pressure
(9) Bearing shell clearance is too large, engine needs
Inspect and overhaul
overhaul
(10) Piston expansion cylinder Replace cylinder liner, piston and piston rings
(11) Insufficient pressurizing system pressure Inspect and excludes leaks in pipes and connections
(12) The turbocharger is not functioning properly Inspect and Replace.
(13) The intercooler is damaged or leaking Replace or patch
26
3.2.5 Black Exhaust Smoke

(1) Intake air piping blockage or exhaust back pressure too
Clean up
high
(2) Fuel quality is poor Cleaning and replace
(3) Valve or fuel supply timing is incorrect Adjust according to regulations
(4) Poor atomize of the injection nozzle Inspect, repair or replace
J J
(5) Injection Pump fuel flow excessive Check and Adjust
M (6) Insufficient pressurizing system pressure Inspect and excludes leaks in pipes and connections
M
2 (7) The turbocharger is not functioning properly Inspect and replace assembly
8 (8) The intercooler is damaged and leaks Replace or patch
_ The smoke limiter works incorrectly.

(9) Rescale
a White Exhaust Smoke, Blue Exhaust Smoke

3.2.6
p
_
(1) Poor fuel quality, high moisture content Changing the Fuel
t Inspect thermostat operating temperature, replace if
(2) Cooling water temperature is too low
necessary
s
(3) Turbocharger seal ring worn Check and replace
u
(4) Turbocharger thrust bearing worn Check and replace
_
(5) Turbocharger return line blocked Cleaning or repair
e nozzle
(6) Poor atomize of the injection Check and repair
(7) Valve or fuel supply timingr is incorrect Check and Adjust
(8) Low compression pressure, incomplete combustion and Check piston rings, cylinder liner, cylinder head gasket,
piston expansion o repair
(9) Piston rings, cylinder liner run-innis not good Continue to run-in
(10) Piston ring gap is not staggered Adjust and reassembly
(11) Piston oil ring failure Replace
(12) The matching clearance of piston and cylinder liner is
Repair, Replace
too large
27
3.2.7 Turbocharger Intake Port, Intake Pipe Stacking Oil

(1) Turbocharger seal failure Repair or replace turbocharger
(2) Gas oil separator failure Exchange
(3) oil pan lubricating oil level is too high, add too much Check and discharge the right amount of oil to meet the
lubricating oil requirements
J 3.2.8 No Stability of RPM J

M Cause of Failure Troubleshooting Method
M
2 (1) Poor fuel quality, containing water or waxy Changing the Fuel
8 (2) fuel suction line has air intrusion Inspect tubing and joint tightness, bleed air
_ The governor (mechanical pump) heavy hammer and

(3)
Check and Adjust
speed regulating spring work abnormally
a
(4) Fuel supply is uneven Check and Adjust
p nozzle atomize is unstable
(5) Injection Check and repair
_ surge
(6) Turbocharger
Inspect, clean the compressor passage, remove the clogged
dirt, and remove the carbon deposits in the exhaust passage
t
(7) Turbocharger bearing damage Replace
s
3.2.9 Very Low Oil Pressure
u
_ of Failure
Cause Troubleshooting Method
(1) Oil pan oil level is too e
low or lack of oil
Replace lubricating oil according to the regulations, choose
(2) Lubricating oil grade doesrnot meet the requirements
the appropriate lubricating oil brand and number
o is too high, oil
(3) Cooling System water temperature
Inspect cooling system
temperature is too high
n
(4) Excessive lubricating oil filter restriction Replace New Element
(5) Lubricating oil cooler is plugged Inspect and clean up
(6) Check the filter, lubricating oil pipe, joint gasket, etc. for Inspect, clean the compressor passage, remove the clogged
plugged or broken dirt, and remove the carbon deposits in the exhaust passage
(7) Oil pump inlet pipe leak Inspect tubing, fitting, repair or replace
(8) Main lubricating oil rifle pressure regulator has failed Check the valve, clean and repair
(9) Main lubricating oil rifle blocked Inspect and clean up
(10) Bearing shell clearance is too large, or bearing shell
Inspect and Replace.
damage
(11) Component is excessively worn and needs to be rebuilt Inspect engine work, overhaul
28
3.2.10 Coolant Temperature High

(1) The water level of the water tank is too low Check for water leaks, add water
(2) Plugged fins of the radiator Clean the water tank fins
(3) water pump belt loosen Adjust the tension according to the regulations
(4) Water pump gasket damage, water pump impeller wear Inspect and repair or replace.
J (5) The water pipe is damaged and has air entrained
Inspect water pipes, fittings, gaskets, etc., replace damaged J
parts
M (6) Thermostats malfunctioning Replace
M
2 (7) Water tank blockage Inspect water tank, clean or repair
8 (8) Oil pan oil level is too low or lack of oil Inspect oil level and oil leakage, repair and refuel
_
3.2.11 Parts Wear Too Fast
a
p
(1) The air filter element is unqualified or damaged Inspect, replace qualified filter element
_ Inspect air intake piping, gasket, connecting sleeve, repair
(2) Air Intake System Short Circuit
t or replace
(3) Lubricating oil filter element is not replaced in time Replace as required
s
(4) Oil pan oil level is too low or lack of oil Inspect oil level and oil leakage, repair and refuel
u
(5) lubricating oil grade does not meet the requirements Change with oil as specified
_
(6) Using the lubricating oil that the quality does not meet
Use the engine oil that meets the specified grade
the requirements
e
(7) Tubing plugged Clean the oil passage
r
(8) Piston rings are broken or worn Replacement damaged parts
o
(9) Cylinder liner or piston wear or cylinder score Remove the piston and cylinder liner, repair or replace
(10) Crankshaft and follower spindle n are out of concentricity Inspect mounting brackets, repair
(11) Component is excessively worn and needs to be rebuilt Check the mileage to determine overhaul
3.2.12 Louder Noise

(1) Fuel quality is poor Changing the Fuel
(2) Cooling water temperature is too low Inspect thermostat, replace if necessary
(3) Valve or fuel supply timing is incorrect Inspect and fix and adjust
(4) Poor atomize of the injection nozzle Inspect and fix and adjust
(5) Injection Pump fuel flow excessive Check and Adjust
Check for damage, the condition of bolt connection, replace
(6) Shock absorber worn
damaged parts
(7) Valve leakage or improper adjustment Remove the valve and adjust
(8) Gear Clearance Excessive or tooth fracture Check and replace the damaged part
(9) Cylinder liner or piston wear or cylinder score Inspect and repair or replace.
(10) Pushrod bending or breaking, rocker lever breaking Replace
(11) Piston rings are broken or worn Access or replace the damaged part
29
3.2.13 Starter Motor Does Not Work

(1) Fuse blown Replace fuse
(2) Poor contact of the cable Clean the line and tighten the post
(3) Low battery charge Inspect, charge or replace the battery
(4) Starter motor internal short circuit Repair motor or replace assembly
J (5) Bad brush contact Clean the brush surface or replace the brush J
M M
3.2.14 Starter Motor Is Running Poorly
2
8
(1) Low battery charge Charge or replace the battery
_(2) Bearing bush worn Replace Group
(3)aBad brush contact Clean the brush surface or replace the brush
p
(4) The commutator is dirty or singed
Remove oil and sand with sandpaper, or replace
assembly
_
(5) Wire end desoldering Re-Welding
t of the switch
(6) Poor contact Inspect switch and repair
(7) Worn clutchsslippage Adjust clutch working torque or replace assembly
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3.2.15 The Generator Does Not Generate Electricity At All

(1) Wiring open circuit, short circuit, connector loosen Inspect generator and ammeter wiring, repair
(2) Rotor, stator coil open circuit, short circuit or short to ground Repair or replace assembly
(3) Rectifier tube damage Replace Group
(4) The insulation of the post is damaged and the wire is broken. Repair
J (5) Regulator adjusted voltage is too low Repair J
M (6) Regulator contactor melting Repair or replace assembly M
2 3.2.16 Alternator Insufficient Charging
8
_(1) Wiring open circuit, short circuit, connector loosen Repair
(2)aRotor, stator coil open circuit, short circuit or short to ground Repair or replace assembly
p belt lossen
(3) Generator Inspect and adjust the belt tension
_
(4) The generator
connection
rectifier is damaged and the battery is in poor
Repair
(5) Regulatortadjusted voltage is too low Adjust

s coil or resistor wiring disconnected
(6) Regulator field Repair or replace
(7) The battery hasutoo little electrolyte or the battery is aging Fill the electrolyte or replace the battery
3.2.17 Charging _ Current Is Unstable

e
r
(1) The stator or rotor coil is about to open, short circuit Repair or replace
(2) Bad brush contact
o Repair
(3) The post is loose and the contact n is poor Repair
(4) Damaged voltage regulator Repair
(5) Improper voltage adjustment Check and Adjust
3.2.18 Alternator Excessive Charging

(1) Short circuit inside the battery Repair or replace
(2) Regulator adjusted voltage is too high Repair and adjust
(3) The regulator has poor ground connection Repair
(4) Regulator contactor failure, contamination, voltage coil or
Repair or replace
resistance wiring disconnected
31
3.2.19 Generator Has Abnormal Noise

(1) Improper mounting of the generator Repair
(2) The rotating part has touched the fixed part Repair or replace
(3) Bearing damage Replace the Bearings
(4) Rectifier short circuit Replace
J (5) The stator coil is shorted. Repair or replace J
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Section 4. Disassemble and assembly of the engine
4.1 General Information

When disassembling and assembling the engine, strictly follow the instructions in this
manual and pay attention to the operation identified with hazard and safety signs in this
manual, to ensure personal safety and avoid accidents.
J 4.1.1 Hazard Sign J

M This sign is a world-recognized warning sign. In this manual, this sign is used to emphasize M
2 the importance of the following information. Be sure you understand the consequence of
the hazardous situation and how to avoid it. Violation of warning messages may result in
8 property damage, personal injury, or even death.
_ Common hazard signs are usually used for general warnings. In this manual, warning
amessages are classified into different categories based on the levels of hazardous
consequences (slight injury, serious injury, and death).
p
_
t
s
u
_
e
r
This warning indicates a potentially hazardous situation.
o Failure to avoid the situation can result in serious personal
n injury or substantial property damage.
This warning indicates a potentially hazardous situation.
Failure to avoid the situation can result in slight personal
injury or property damage. This warning is also used for
hazardous operations.
The information provided in this precaution is used to
explain how to operate and install the engine company
products properly. However, simply reading the document will not eliminate the various
hazardous situations. Only correct understanding of the information contained in the
precautions will help you use it correctly.
The warnings in this guide cannot cover all possible situations! If the procedures and methods
that you decide to use are within the recommended range, please make sure that the operation
does not pose any danger to you and others and the equipment.
33
4.1.2 Safety signs

Picture DEFINITION
Wear hand protectors
Wear ear protectors
Wear eye protectors

J J
Wear head protectors
M M
2 Wear foot protectors
8 Wear a protective mask

_
Wear overalls
a
p Avoid naked flames
_
Do not smoke
t
Do not use a mobile phone
s
u Danger: battery acid
_ Danger:Live cable, risk of electric shock

e
Highly inflammable product
r
Away from the hanging weight object
o
n
Keep an extinguisher close by
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.
34
4.1.3 Required Tools

Picture DEFINITION
2.5 mm hexagonal wrench
5 mm hexagonal wrench
8mm Socket
J J
Flat Screwdriver
M M
2 Special Tool
8
10mm flat hexagonal angle wrench
_
a
If the method or tools used are not recommended in this manual, the users must first
p the safety of themselves and avoid to the lives of users themselves or others,
ensure
while_ ensuring that the ways of usage, maintenance or repair will not pose a damage or
safety hazard.
t
4.1.4 Health
s Precautions
The following
u "Protect Health Precautions" are designed to reduce the risk of
contamination.
_
a) Avoid repeated exposure to used oil for long periods of time.
e
b) Wear protective overalls and waterproof gloves, if possible.
r
c) Do not put the oil rag into your pocket.
o
d) Avoid oil stains on clothes,
n especially underwear.
e) Wash your protective clothing regularly. Throw away clothes and shoes with oil stains
which cannot be cleaned.
f) Take first aid measures immediately if being cut and injured.
g) Always apply a protective cream before work, which allow the mineral oil easier to be
removed when the skin is contaminated with oil.
h) Use soap and hot water, or wash your hands with hand sanitizer and nail brush to
remove any oil. If you wash away the natural oil from the skin, use products containing
lanolin to replace natural skin oil, helping to moisturize the skin.
i) Do not use gasoline, kerosene, fuel, scavenging water or solvents to clean the skin.
j) Receive medical attention immediately if you feel discomfortable on your skin.
35
k) Remove oil from the componentss before handling, if possible.

l) Use goggles or a face shield when there is a risk to your eyes. Eye wash liquid must be
available at your fingertips.
m) Do not allow oil or other liquid to splash onto the floor when servicing the engine. Take
all necessary measures to isolate the area in case of accidental leakage of
hydrocarbons or other liquids, to keep environment clean and protect personnel from
injury.
J n) The handling, storage and recycling of hydrocarbons, ethylene, glycol or petroleum J
M must comply with the safety and environmental standards in the country where the M
operation takes place.
2
8 4.1.5 Environmental Protection Measures
_ Please observe the relevant environmental protection laws and regulations regarding the
disposal of waste oil and hydrocarbons. Consult local officials for relevant details.
a
4.1.6p Engine Remove and Install Precautions
Most_accidents related to usage, maintenance and repair of engine are caused by failure to
follow safety instructions and basic precautions. Therefore, you shall be aware of the
possible t hazards and take appropriate preventive measures to avoid accidents. A person
shall to bes appropriately trained, have applicable skills, and use suitable tools to operate,
service, and repair the engine.
u
Failure to follow the instructions in this manual may result in serious accidents or hazards
_
to life. Weichai Power Co., Ltd. cannot foresee all potential hazards. The guidelines and
descriptions set eforth in this manual are not exhaustive as well.
Place a "Do Not Use"r sign or similar mark on the starter switch before proceeding with
maintenance or repair operations.
o
Before using the barringntool, take the necessary precautions to ensure that the service site
and the surrounding environment are safe for operation.
Ensure that the repair shop or the area around the engine is clean and tidy.
Remove the ring, necklace and watch before work. Wear a suitable overalls.
Before work, check if the corresponding protective equipment (glasses, gloves, shoes,
masks, overalls, helmets, etc.) is within the validity period.
Do not use tools that are faulty or inappropriate.
Please turn off the engine during maintenance or repair.
4.2 Engine Block Group
4.2.1 Engine block group disassembly and assembly
a. Disassembly diagram
36
J J
M M
2
8
_
a
p
_
t Figure 4-1 exploded view of the cylinder block
s Pre-Assembly; 2-Cylinder Liner; 3- Cylinder Head Slave Bolt; 4-Elastic Cylindrical Pin;
1- Cylinder Block
5-Pre-AdhesiveuSet 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
_
e
r
o
n
Figure 4-2 exploded view of the cylinder block
13- seal ring; 14-main bearing bolt; 15-rivet; 16-bowl plug; 17-main oil passage rear plug; 18-composite
washer
37
b. Preparation before disassembly
• Equipment conditions: socket wrench, copper hammer, etc.

• Preparation before disassembly: remove the gearbox and clutch, remove the flywheel,
flywheel housing, gear housing and oil pan
c. Disassemble
J 1) Remove the bolts (9, 10) around the crankcase; J

M 2) Remove the main bearing bolt (14); M
2 3) Remove gasket (13);
8 4) Remove cylinder head slave bolts (3);
_ 5) Remove main oil rifle threaded plug (17);
a6) Remove cylinder liner (2).
p
d. Install
_
The installation procedure is in reverse order to the removal procedure.
t
e. SERVICEsPOINTS
Point 1: Assembly
u
_ Tightening
22 N.m to 29 N.m Grade 8.8
Torque
e
Tightening Grade
29 N.m to 35 N.m
r Torque 10.9
Point 2: Assembly o
The main bearing boltsn 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.
Figure 4-3 Main Bearing Bolt Tightening Sequence
Tightening Torque 265 N·m ± 25N·m
Point 3: Assembly
The cylinder head slave bolts are tightened in the order shown in Figure 4-4 and reused up
to 2 times.
38
Figure 4-4 Cylinder head slave bolt tightening sequence

Point 4: Assembly
J Cylinder liner should be carefully inspected before assembly to see if there are crack J
M defects, and clean the cylinder liner, use special tooling to press into the cylinder bore, M
apply molybdenum powder on the surface of the cylinder liner before pressing.
2
8 4.2.2 Cylinder block pre-assembly disassembly and assembly
_ Disassembly diagram
a.
a
p
_
t
s
u
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n
Figure 4-5 Pre-Assembly Exploded View of Cylinder Block
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
39
J J
M M
2
8
_ Figure 4-6 Pre-Assembly Exploded View of Cylinder Block
a
10-Cylinder Block; 11-Bowl Plug; 12- Camshaft Bushing; 13-Crankcase; 14-Internal Threaded Pin;
p 15-Bowl Plug
_
• t
Equipment conditions: socket wrench, copper hammer, etc.
• s
Preparation before disassembly: remove the gearbox and clutch, remove the flywheel,
flywheeluhousing, gear housing and oil pan
c. Disassemble _
e threaded cylindrical pin (15);
1) Remove internal
r
2) Remove the camshaft bushing (2, 13);
o bolts and crankcase tightening bolts
3) Remove main bearing
4) Remove crankcasen(14).
5) Remove oil ruler assembly (5, 7, 8, 9).
d. Install
e. SERVICE POINTS
Point 1: remove
Use special tool to remove the camshaft bushing. Take care to protect the other bushings
during removal.
Assemble
Carefully inspect the inner surface of the camshaft bushing before assembly for any
scratches and replace if necessary. The camshaft bushing oil hole is aligned with the oil
hole of the camshaft bottom bore.
Point 2: Assembly
Clean the upper surface of the crankcase before assembly. The upper surface of the
crankcase should be coated with sealant.
40
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.
4.2.3 Removal and Installation of Piston Nozzle
J J
M M
2
8
_
a
p
_
t
s
u
_
e
r Figure 4-7 Exploded View of Piston Nozzle
o 2-Gasket; 3-Nozzle Assembly; 4-Elastic Cylindrical Pin
1- Banjo Bolt;
n
• Equipment conditions: socket wrench

• Preparation before disassembly: Remove the crankcase, crankshaft and other
components.
c. Disassemble
1) Remove banjo bolt;

2) Remove nozzle assembly;
3) Remove elastic cylindrical pin.
d. Install
The installation procedure is in reverse order to the removal procedure
e. SERVICE POINTS
Point 1: Assembly
41
Banjo bolt tightening torque

Tightening Torque 20 to 30N.m
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.
J J
4.2.4 Removal and Installation of Thrust Plate
M M
2 a. Disassembly diagram
8
_
a
p
_
t
s
u
_
e
r Figure 4-8 Exploded View of Thrust Plate
o 1-Lower thrust plate; 2-Upper thrust plate
n

• Preparation before disassembly: Remove the crankcase, crankshaft and other
components.
c. Disassemble
1) Remove the crankcase.

2) Remove the crankshaft.
3) Remove thrust plate (1, 2).
d. Install
1) Install crankshaft;
2) Install upper thrust plate (2);
3) Install lower thrust plate (1).
42
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.
J 4.2.5 Removal and Installation of Front/Rear Oil Seals J

M a. Disassembly diagram M
2
8
_
a
p
_
t
s
u
Figure 4-9 Exploded View of Front and Rear Oil Seals
_
1-rear oil seal; 2-front oil seal
e
r
o
• Preparation before disassembly: Remove the crankcase and flywheel housing.
n
c. Disassemble
1) Remove gear housing;

2) Remove front oil seal (2);
3) Remove the crankcase
4) Remove rear oil seal (1):
d. Install
The installation procedure is in reverse order to the removal procedure
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.
43
Remove
The oil seal is no longer used after removing it.
4.2.6 Removal and Installation of Gear Housing
J J
M M
2
8
_
a
p
_
t
s
u
_
e
Figure 4-10 gear housing exploded view
1- Timing Gear Housing r;2- Seal Ring ;3- Seal Ring ;4-Hex Flange Bolt; 5-Hex Head Plug; 6-Composite
o Washer; 7-Cylindrical Pin
n
Equipment conditions: socket wrench
Preparation before disassembly: Remove the front end accessories of the diesel engine
c. Disassemble
1) Remove gear housing fastening bolts; (4)

2) Remove screw plug and composite washer (5, 6);
3) Remove intermediate gear shaft;
4) Remove lubricating oil pump intermediate gear shaft and lubricating oil pump
intermediate gear bolts;
5) Remove gear housing; (1)
6) Remove ring seals; (2, 3)
44
d. Install
The assembly step is in reverse order to disassembly step.
e. SERVICE POINTS
Point 1: Assembly
Tighten the gear housing fastening bolts symmetrically in the order shown in Figure 4-11.
J Tightening J
44N.m to 58N.m
M Torque M
2
8
_
a
p
_
t
s
u
_
e
r
Figure 4- 11 gear housing bolt tightening sequence
o
Point 2: Assembly n
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.
4.2.7 Front end cover remove and install
45
J J
M M
2
8
_
a
p Figure 4-12 Front end cover Exploded View
_ 1-End Cap; 2-Flange Face Bolt; 3- Seal Ring
b Preparation before disassembly
t
• Equipment
s conditions: socket wrench
• u before disassembly: Remove the front end accessories of the diesel engine
Preparation
c. Disassemble _
e
1) Remove front end cover fastening bolts (2);
r
2) Remove Front end cover (1).
o
3) Remove front end cover seal ring (3).
n
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.
4.2.8 Removal and Installation of Flywheel Housing
46
J J
M M
2
8
_
a
p
_
t
Figure 4-13 Exploded View of Flywheel Housing
s
1- flywheel housing ;2- flywheel housing bolts; 3-flywheel; 4-starter; 5-studs; 6-nuts
u
_
• Equipment conditions:
e socket wrench
• Preparation before
r disassembly: remove the gearbox and clutch, remove the flywheel
c. Disassemble o
1) Unscrew the starternnut (6) and remove the starter (4).
2) Unscrew the fixed flywheel housing bolt (2).
3) Remove the flywheel housing (1).
d. Install
1) Apply sealant around the oil chamber.

2) Attach the flywheel housing (1) to the block.
3) Tighten the flywheel housing bolts (2).
4) Install the starter (4) on the flywheel housing and tighten the fixed starter nut (6)
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.
47
Tightening torque: 110 N.m~140 N.m
J J
M M
2
8
_
Figure 4-14 Flywheel Housing Bolt Tightening Sequence
a
Point 2: Assembly
p
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.
t
4.2.9 Removal and Installation of Oil Pan
s
a. Disassembly
u diagram
_
e
r
o
n
Figure 4-15 Exploded View of Flywheel Housing

1-gasket; 2-oil pan bracket; 3-hex flange bolt; 4-oil pan; 5-washer; 6-magnetic plug
• Preparation before disassembly: Drain the lubricating oil in the oil pan
48
c. Disassemble
1) Turn over the diesel engine with oil pan upward;

2) Remove the oil pan fastening bolt (3)
3) Remove oil pan carrier (2)
4) Remove the oil pan (4) and gasket (1);
J 5) Remove the magnetic threaded plug (5) and combination washer (6) J
M d. Install M
2 The installation procedure is in reverse order to the removal procedure
8
e. SERVICE POINTS
_
aPoint 1: remove
Drain
p 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
t
The oil pan tightening bolts are tightened in the order shown;
s
Tightening 22N.m to
u Torque 29N.m
_
e
r
o
n
Figure 4-16 Oil pan bolt torque sequence
4.2.10 Removal and Installation of Cylinder Head Cover
49
J J
M M
2
8
_
a
p
_
t
s
u
_
1. Cylinder Block; 2.eCylinder 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
r
bolt screw; 11. cylinder head main bolt; 12. clamping block; 13. clamping block;
o
Figure 4-17 Cylinder head disassembly diagram
n
• Equipment conditions: socket wrench or pneumatic wrench, torque wrench, open end
wrench;
• Preparation before disassembly: It is necessary to remove the cylinder head cover, the
hanging plate, the intake and exhaust piping, the water outlet pipe, the high pressure oil
pipe, and other parts that can be fixed on the cylinder head in advanced.
c. Disassemble
1) Loosen and remove the eyebolt and hanger plate at both ends of the engine;
2) Loosen the cylinder head slave bolt and nut and remove the clamping block. The
clamping block has four structures: one is a cylindrical clamping block assembled
between the two cylinder heads, and is mounted on a slave bolt; The second is a long
block-shaped clamping block that assembled between the two cylinder heads, and is
mounted on the two slave bolts. The third one is mounted on the ends of engine and
only mounted on a cylinder head, it is mounted on two slave bolts, where you can install
the eye bolt block; the fourth type is mounted on the ends of engine, and only mounted
on a cylinder head, it is mounted on a slave bolt;
50
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
J subsequent problem analysis.
J
M 6) Remove the cylinder head gasket. If multiple cylinder head gaskets are removed, the M
2 cylinder number shall be indicated on the cylinder head gasket for following problem
analysis.
8
7) If the cylinder head slave bolts need to be replaced, or if they need to be inspected,
_ remove the cylinder head slave bolts;
a8) Remove rocker lever seat, the intake and exhaust valves and other valve trains (see the
p 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
wallt of the valve stem seal sleeve, and remove the valve stem seal sleeve while rotating.
The valve
s stem seal sleeve is not recyclable.
d. Install u
1) Assemble_Cylinder head slave bolts
e
r
o
n
Figure 4-18 cylinder head sub bolt
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
51
J J
M M
2
8
_ Figure 4-19 cylinder head gasket
a① The cylinder head gasket can only be used once. If it is repaired, it must be replaced
p 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
t
corresponding pin hole;
④ Check s that the holes on the cylinder head gasket are aligned with the holes on the
cylinderublock, and check for the cylinder head gasket is assembled correctly.
3) Assemble_the stem seals
e
Spring
r
o
n
Figure 4-20 valve stem seal sleeve
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.
52
Guide Seal Installation Tool
J J
M M
2 Valve stem seals
8 Valve Guides
_ Cylinder Head
a
p
Figure 4-21 valve stem seal sleeve install
_
4) Assemble the cylinder head
t
① Carefully
s clean the cylinder head to ensure that there are no dirt, broken shoulders,
sand and other dirt, and then clean the surface under the cylinder head;
u
② Check that there are no foreign objects in the air passage and water passage of the
_ check that there are no foreign objects in the cylinder, and the surface of
cylinder head,
the cylinder head
e gasket and the cylinder head lower surface are clean;
r
③ Prior to the tightening of the cylinder head bolt, the cylinder head was pin-to-face
positioned;
o
④ Assemble the cylinder
n head.
5) Assemble clamping block
① Wipe the clamping block;
② After applying the cleaning lubricant on the support surface of the clamping block,
clamp it on the cylinder head at the position when disassembled, and apply oil to the
proper amount to prevent the lubricating oil from flowing into the gap between the
cylinder heads;
③ The clamping block is clamped so that the direction of the groove is the same as the
direction of the gap between the cylinder heads;
④ Screw the nuts of cylinder head slave bolts into the cylinder head slave bolts by hand.
6) Assemble the cylinder head bolt
53
J J
M M
Figure 4-22 cylinder head main bolt
2
① The cylinder head main bolt is allowed to be used 3 times;
8
② Center the cylinder head in sequence, apply a proper amount of clean lubricant to the
_ cylinder head main bolt thread and the shoulder bearing surface, then install on the
a cylinder head and the cylinder head slave bolt and clamping block. The cylinder head
main bolt is shown in Figure 4-23.
p
③ Use a torque wrench to tighten the cylinder head main bolt and the cylinder head slave
_
bolt & nut to (30~50) Nm;
t
④ Tap each clamping block to make it all seated in place;
s
⑤ Use a torque wrench to torque the nuts of slave bolts to 100 N·m in sequence and mark
u
on the nut;
_ wrench to torque the main bolt to 200 N·m in sequence and mark on the
⑥ Use a torque
bolt; e
⑦ Use a torque wrench
r to torque the sub-bolt & nut 90 in sequence, and mark the new nut
position;
o
⑧ Use a torque wrench to torque the main bolt additional 90, and mark the new position;
n
⑨ Use a torque wrench to torque the sub-bolt & nut additional 90° in sequence, while
tightening torque reaches (120~160) N·m;
⑩ Use a torque wrench to torque the main bolt additional 90°, while tightening torque
reaches (240~340) N·m;
The tightening sequence of the cylinder head bolt is shown in Figure 4-23, where the
number 1-21 is the cylinder head slave bolt and the number 22-45 is the cylinder head
main bolt.
Fan side Flywheel side

Figure 4-23 Cylinder head bolt tightening sequence
54
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.
J J
3) Check the valve recession before remove the valve mechanism, the valve recession is
M the vertical distance from the bottom surface of the valve to the bottom plane of the M
2 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
8 the valve seat. The valve recession can be measured using a depth micrometer, as
_ shown in Figure 4-24:
a
p
_
t
s
u
_ Figure 4-24 Depth micrometer
e for the valve recession required value. If the valve recession amount
Refer to Table 4-1
exceeds the allowable range, you need to confirm the wear of the valve and the valve seat.
r
The valve seat wear can be measured by measuring the amount of valve recession after
installing an unused o
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
n
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
55
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.
J J
Figure 4-25 Inside Diameter Micrometer
M M
2 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
8 after removal.
_ 8) Before removing, check the rubber lip of valve stem seal sleeve for any abnormalities,
a such as breakage and spring failure. However, always replace the valve stem seal
sleeve whenever it is removed.
p
4.2.11 Removal and Installation of Cylinder Head Cover
_
t
s
u
_
e
r
o
n
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
56
• Equipment conditions: socket wrench or pneumatic wrench;

• Preparation before disassembly: The engine is fixed and reliable, remove the parts
above the cylinder head.
c. Disassemble
J 1) Use a wrench to loosen the cylinder head cover bolts in sequence; J

M 2) Take the cylinder head cover and the cylinder head cover gasket vertically upwards, as M
shown in Figure 4-26.
2
3) Store the cylinder head cover and cylinder head cover gasket in place for inspection.
8
_ 4) To disassemble the split cylinder head cover, Loosen the hexagonal flange face bolts
that secure the upper and lower parts of the cylinder head cover as shown in Figure
a 4-26. Remove and inspect the upper and lower parts of the cylinder head cover and
the cylinder head cover gasket in the middle.
p
_
d. Install
1) Thet cylinder head cover pad is only allowed to be used once, and must be replaced with
a news 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.
u
2) Clean the upper surface of the cylinder head and assemble the cylinder head gasket in
sequence._
e head cover, and correctly install on the cylinder head.
3) Clean the cylinder
r head cover bolt and tighten. Install the mounting block and support
4) Install the cylinder
bracket in the corresponding
o positions as shown in Figure 4-26 and tighten the bolts.
e. SERVICE POINTS n
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.
4.2.12 Removal and Installation of Oil/Gas Separator
57
J J
M M
2
8
_
a
p
_
t
1. Eye bolt clamping block; 2. gas oil separator air intake connection; 3. bolt; 4. gas oil separator; 5. gas
oil separator
s air outlet tube; 6. Clamp; 7. Oil Separator Return Line; 8. Pipe Clamp; 9 Clamp; 10.
Connecting Pipe;
u
Figure 4-27 Disassembly diagram of gas oil separator
_
e
• Equipment conditions: socket wrench or pneumatic wrench, open end wrench.
r
c. Disassemble o
1) Remove the two fixing
n bolts on the air intake piping joint of the oil separator on the
cylinder block;
2) Remove the bolt that secures the oil separator to the eye bolt clamp block;
3) Remove the fixing bolts of the oil separator outlet pipe and the return line pipe clamps,
take off the air outlet pipe, remove the clamp of oil separator oil return hose and the
return line, remove the oil return hose;
4) If it is necessary to remove and check the oil return pipe that protrudes into the oil pan,
use a wrench to tighten the oil return pipe and then pull up the oil return pipe;
5) For other remove, remove them as shown in Figure 4-28.
d. Install
1) Install the oil separator and tighten the two fixing bolts on the air intake piping fitting of
the oil separator;
2) Installing a bolt that secures the oil separator to the front suspension plate;
3) If the connecting pipe at the end of the oil separator is removed, insert the connecting
pipe into the corresponding position of the crankcase and tighten the bushing to
complete the installation;
58
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
J pipe. If the airflow is not smooth, the impurities and oil in the oil separator can be J
removed by connecting the pressurized air to the oil separator. If the oil separator is
M still not smooth after the above operation, replace the new oil separator; M
2 3) If there is oil leakage at the joint between the air inlet and the cylinder block, check the
8 O-ring for damage and replace it.
_ 4) According to Figure 4-28, ensure that the position of each hose and each interface is
a correct, and pay attention to ensure that the rotation angle of the hose installation and
the fixture location match the diesel engine.
p
4.3 Crank and connecting rod mechanism
_
4.3.1 Disassembly and Assembly of Crank and Connecting Rod Mechanism
t
s View of Crank and Connecting Rod Mechanism
4.3.1.1 Exploded
u
Main Brg Capscrew
_
Main Bearing Shell
Crankcase
Crankshaft
e
Connecting rod big end cover
r Flywheel Ring Gear
Timing Gear Crankshaft
Shock Absorber
o
Flywheel
Pulley
n
Flywheel capscrew
Flanges Bearings
Pulley bolt Flywheel housing
Block
Piston & connecting rod Assy
Figure 4-28 Crank connecting rod mechanism disassembly diagram

4.3.1.2 Remove Procedure of Crank and Connecting Rod Mechanism
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
59
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.
4.3.1.3 Crank and connecting rod mechanism

J J
M assembly steps are the opposite of remove steps. M
2 4.3.2 Disassembly and Assembly of Piston/Connecting Rod Assy
8 4.3.2.1 Assembly Exploded View of Piston/Connecting Rod Assy
_
a
p Crankshaft
_
t
s
u Piston & connecting rod Assy
_
e
r
Figure o
4-29 Piston and connecting rod group assembly diagram
n First gas ring

Second gas ring
Piston Pin Oil Ring
Piston
Piston Pin Retainers
Connecting
rod body
Rod Cap Connecting Rod

Bearing Shells
Connecting rod bolts
Figure 4-30 Exploded View of Piston/Connecting Rod Assy
60
4.3.2.2. Disassembly Procedure of Piston/Connecting Rod Assy
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.
J 4.3.2.3 Inspection and Repair of Piston/Connecting Rod Assy J

M 1. Check the corner radius of piston and combustion chamber throat, piston pin retainer M
2 for crack; check piston skirt, piston head for cylinder score; check that the piston pin
hole wear is normal.
8
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.
a3. Check if the wear of outer circumference of the piston pin is abnormal;
4.p 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
t
bending of the connecting rod.
s
5. Check the connecting rod bearing shell for wear, and if there is signs of discoloration,
peeling,uslipping etc. on the alloy layer.
4.3.2.4 Assembly_Procedure of Piston and Connecting Rod Assy

e
1. Use a hole retaining ring pliers to fit a hole circlip into the retaining ring groove of piston
r
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.
o
2. Insert the small endnof 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.
61
First gas ring Second gas ring
Piston pin horizontal

orientation
J J
M M
Oil ring
2
Figure 4-31 Opening Angle Schematic of Piston Rings Assembly
8
_ 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
a connecting rod bolts. The separating surface of the connecting rod shall face the left
p 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
_ Apply cleaning lubricating oil onto the connecting rod bolt before installation;
body.
t connecting rod bolt: first screw in, then use the torque of 120N·m to tighten
7. Tighten
symmetrically,
s and finally angle tighten 90°±5° and meanwhile reach 170N·m ~250N·m.
Use the same method to install the remaining cylinders.
u
4.3.3 Crankshaft disassembly and assembly
_
e
4.3.3.1 Crankshaft assembly exploded View
r
o Main Brg Capscrew
n
Crankcase
Crankshaft Flywheel Ring Gear
Main Bearing Shell Flywheel

Bearings
Timing Gear Crankshaft
Retainer
Shock Absorber
Pulley
Flywheel capscrew
Flanges
Block
Pulley bolt
Figure 4-32 Assembly Exploded View of Crankshaft System
62
4.3.3.2 Crankshaft remove step

1. With the engine crankcase facing up, remove the main bearing bolts and place them in
order;
2. Remove the crankshaft and flywheel, and remove the front and rear thrust plates and
the flywheel end bearings. Take the oil seal out; Place the crankshaft on the bracket (if
the time is excessive, the crankshaft shall be placed vertically);
3. All parts removed shall be sorted as required.
J 4.3.3.3 Crankshaft check and repair J
M 1. Check crankshaft main journal, the corner radius of the connecting rod neck for M
2 cracked; check the crankshaft and the bearing shell, the oil passage for cracks and
other abnormal damage.
8 2. Check the main journal and the connecting rod neck for wear, and if there are line
_ shapes, metal peeling and cracks;
a3. Check the front and rear oil seals for wear;
4.p Check the main bearing bolt for failure such as damaged thread;
5. Check
_ if there is cracks at the bolt hole of the crankshaft flange surface;
6. Check
t wear degree of crankshaft journal , and if there is crankshaft bending and
distortion.
s
4.3.3.4 Crankshaft assembly step
1. Wipe uputhe bottom holes of the cylinder block;
2. Wipe bottom _ holes of the upper bearing cylinder off foreign material scraped from the
bearing. e
2.1. Before ther upper bearing shell is pressed in, it shall be strictly checked if there is
any bruise. If there is a bruise, it is not allowed to be repaired and reused.
o
2.2. The upper bearing shells shall align with the oil hole and oil groove on the cylinder
n If bias exceeds 1/5-1/4 of the oil holes, never assemble them;
block after installed.
the upper bearing shell needs to be fully engaged on the bottom hole of the
cylinder block.
3. Applying a proper amount of cleaning lubricating oil onto the inner surface of the upper
bearing shell;
4. Remove and wipe off oil from the lower surface of the cylinder block. It is required that
there is no oil or grease on the lower surface of the cylinder block;
5. Apply a bead of sealant onto the lower surface of the cylinder block, and then apply the
sealant evenly and continuously with a rubber roller;
6. Lift the crankshaft, blow the oil passage hole with compressed air, wipe up the main
journal and the connecting rod journal with a towel, and then gently drop into the
cylinder block. In this process, the crankshaft is required to be without bruise;
7. Wipe up the upper thrust plate and then press it into the cylinder block. The oil groove of
the upper thrust plate shall face outward (toward the crankshaft);
8. On the basis of ensuring that the oil seal is flat and free from distortion, the oil seal is
placed into the seal groove of the lower plane of the cylinder block with special tool;
9. Press the lower main bearing shell and the lower thrust plate (the oil groove toward the
crankshaft side) into the crankcase, to assemble the crankshaft;
63
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.
J J
M M
2
8
_
a
p Figure 4-33 Main Bearing Bolt Tightening Sequence
_
11. At the first time, use a low torque pneumatic wrench. The torque reaches 80 N.m at the
t time and the torque reached 250 to 280 N.m at the third time. Complete the
second
crankshaft
s assembly.
4.3.4 u and Installation of Flywheel and Ring Gear
Removal
4.3.4.1 Assembly_Exploded View of Flywheel

e
r Flywheel
o
Flywheel Ring Gear
n Capscrew, Hex Head
Bearings
Crankshaft
Flywheel capscrew
retainer
Studs
Locating Pin
Figure 4-34 Assembly Exploded View of Flywheel

4.3.4.2 Removal Procedure of Flywheel and Ring Gear
The removal procedure is in reverse order to the installation procedure
64
4.3.4.3 Inspection and Repair of Flywheel and Ring Gear
1. Flywheel bolts for failure such as broken thread.

2. Surface of flywheel for collapse.
3. Flywheel ring gear for damage.
4.3.4.4 Assembly Procedure of flywheel and ring gear

J 1. The flywheel ring gear is fastened to the flywheel by bolts. J
M 2. Insert the cylindrical pin into the rear end of the crankshaft, and be sure to tap the M
2 cylindrical pin to the bottom;
8 3. After inserting the flywheel guide bar into the threaded hole of the crankshaft, install the
flywheel component and pre-tighten the flywheel bolt in a crisscross diagonal pattern.
_
3-1 Apply lubricating oil to the threads and pressure bearing surfaces of the flywheel
a bolts.
p 3-2 flywheel bolt M14×1.5( Quantity: 9)
_
Hand tightening: After lubricating the thread and the pressure surface, insert the
t
flywheel bolt into the threaded hole and tighten them in a crisscross diagonal pattern,
and sthe tightening torque is 60+20
0 N·m; then turn two 90 ± 5° and simultaneously
moment reaches 230 N·m~280 N·m. Bolts that achieve a twist angle but do not reach
torqueu should be replaced. Can reused 2 times.
Tighten by_ automatic wrench: after apply the oil on the thread and the bearing surface
of the flywheel
e bolt, install it in the threaded hole and tighten diagonally, the tightening
torque is 60N·m; then turn 160°+5°, and the torque is simultaneously reached
230N·m-300N·m. r Bolts that achieve a twist angle but do not reach torque should be
replaced. Can reused
o 2 times.
4. Tighten the flywheelnbolts.
4-1. After applying lubricant to the threads and bearing surfaces of the flywheel bolts,
insert them into the threaded holes and tighten them in an opposite pattern. The
tightening torque is 60N.m to 80N.m, then turn two 90±5°, and the torque reaches
230N.m~280N.m at the same time. For bolts that reach the twist angle but the
torque does not meet the requirements, they should be replaced. the bolts can be
reused twice. Complete the flywheel assembly. Complete the flywheel assembly.
65
4.3.5 Disassembly and Assembly of Vibration damper, Crankshaft pulley
4.3.5.1 Vibration damper, crankshaft pulley assembly exploded view
Timing Gear
Flanges Crankshaft
J Shock Absorber J
M Pulley M
2
8
_ Pulley bolt
a
p Figure 4-35 Vibration damper, Crankshaft pulley assembly Exploded View
4.3.5.2 _
Vibration damper, Crankshaft pulley remove step
Unscrew
t the pulley bolt and remove the pulley and damper in sequence.
s damper, crankshaft pulley inspect and repair
4.3.5.3 Vibration
u
1. Check the damper for bruise, deformations, etc.
_
2. Check the pulley and for damage, and bolt part where holds tight for collapse;
e
3. Check for the pulley bolt is damage.
r
4.3.5.4 Vibration damper, crankshaft pulley assembly steps
o
After installing the timing
n gear housing, install the vibration damper and the pulley in
sequence, and fasten them on the crankshaft flange with the pulley bolts.
4.3.6 Disassembly and Assembly of Crankshaft Bearing Shell
4.3.6.1 Assembly Exploded View of Crankshaft Bearing Shell

Main bearing shell (Upper)
Crankshaft
Main bearing shell (Lower)
Figure 4-36 Assembly Exploded View of Crankshaft Bearing Shell
4.3.6.2 Removal Procedure of Crankshaft Bearing Shell

Push the bearing shell from the side by hand, and mark on the removed bearing shell
according to the block and the seat hole of the crankcase.
66
4.3.6.3 Inspection and Repair of Crankshaft Bearing Shell
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.
4.3.6.4 Assembly Procedure of Crankshaft Bearing Shell
1. First clean the main bearing shell and the bottom hole of the assembly, and wipe it
J clean; J
M 2. If reusing bearing shells, when assembling, install them into the block (upper shell) and M
the crankcase (lower shell) respectively in the order of removal of bearing shell. Pay
2 attention to distinguish the upper and lower shells, and the upper shells have oil groove;
8 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
a
4.4.1p Disassembly and Assembly of Valve Mechanism
4.4.1.1 _
Assembly Exploded View of Valve Mechanism
t
s Adjustment nuts
Flex Head Capscrews
u
Support arm
Intake Rocker Lvr
Adjusting Screw
Adjustment bolt assembly _
Adjustment nuts Valve lock collet
Rocker Lever Shaft

e Valve spring retainer, upper
Exhaust Rocker Lvr

r Inner valve spring
Adjusting Screw
o Outer valve spring
Valve spring retainer, lower
Valve cap n Valves
Drive Bar
Camshaft
Locating Pin
Tappet
Camshaft Timing Gear
Bowl plug
Hexagonal bolts
Capscrew, Hex Head
Thrust plate
Figure 4-37 Assembly Exploded View of Valve mechanism
4.4.1.2 Remove Step of Valve Mechanism

1) Remove the rocker arm and rocker arm shaft. See the removal procedures of rocker
arm and rocker arm shaft for details.
2) Remove the intake and exhaust valves. See the removal procedures of valves for
details;
3) Remove the tappet and the push rod. See the removal procedures of tappet and push
67
rod for details;

4) Remove the camshaft and camshaft timing gears. See the removal procedures of
camshaft and camshaft timing gear for details.
5) Remove the intermediate gear, see the intermediate gear remove step.
4.4.1.3 Assembly Procedure of Valve Mechanism
1) Assemble the intermediate gear, see the intermediate gear assembly steps;
J J
2) Assemble the camshaft and camshaft timing gears. See the assembly procedures of
M camshaft and camshaft timing gear for details; M
2 3) Assemble the tappet and the push rod. See the assembly procedures of tappet and
8 push rod for details;
_ 4) Assemble the intake and exhaust valves, see the assembly step of the intake and
exhaust valves;
a
5)p Assemble the rocker arm and rocker arm shaft. See the assembly procedures of rocker
arm and rocker arm shaft for details.
_
4.4.2 Disassembly and Assembly of Camshaft
t
4.4.2.1 Assembly
s Exploded View of Camshaft
u
_ Camshaft
e
Thrust plate
r
Camshaft bearing shell
o
Camshaft Timing Gear
n
Locating Pin
Flex Head Capscrews
Capscrew, Hex Head
Thrust plate hex head bolt
Figure 4-38 Assembly Exploded View of Camshaft

4.4.2.2 Removal Procedure of Camshaft
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;
68
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.
4.4.2.3 Inspection and Repair of Camshaft

J J
① Check the cam surface in contact with the tappet for wear and check if the main journal
M is stuck or worn; M
2 ② Measuring the camshaft spindle radial runout;
8 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)
a 0.04
No. 3 main journal (between cylinder two and cylinder three) 0.05
p
No. 4 main journal (between cylinder three and cylinder four) 0.06
_
No. 5 main journal (between cylinder four and cylinder five) 0.05
t (between cylinder five and cylinder six)
No. 6 main journal 0.04
s
③ Measure the actual maximum lift of the tappet (the distance between the inlet & exhaust
camshaft u tip and the base circle)
_ Table 4-3 Actual maximum lift measurement table of the tappet
Cam Lobes standard value Measured
e
Intake tappet MAX lift 8.481mm
Maximum exhaust tappet lift
r 9.492mm
o
④ Check for timing gear has tooth broken or the tooth surface has a heavy wear
phenomenon. n
4.4.2.4 Assembly Procedure of Camshaft
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.
69
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.
J ⑧ Screw the pre-coated hex bolts and tighten it symmetrically. The tightening torque is 40 J
M N·m~45 N·m. After tightening, mark with white mark on any bolt, inspect and record the M
gap between timing gear and intermediate wheel side.
2
⑨ The clearance between timing gear and intermediate gear side is 0.015~0.33, Insert the
8 cylindrical pin into the clearance between timing gear and intermediate gear side.
_
4.4.3 Removal and Installation of Rocker Arm and Rocker Shaft
a
4.4.3.1 Assembly Exploded View of Rocker Arm and Rocker Shaft
p
Capscrew,
_ Hex Head Adjustment nuts
t
Support arm
s
Adjustment bolt assembly
uIntake lever
assembly
_ Exhaust lever assembly
e
Rocker Lever Shaft
r
o
n
Figure 4-39 Assembly Exploded View of Rocker Arm and Rocker Shaft
4.4.3.2 Removal Procedure of Rocker Arm and Rocker Shaft
① Rotate the crankshaft to see if the rocker arm rotates freely.

② Measure each valve lash and check the valve lash change.
③ If the rocker lever is not flexible or the valve lash changes greatly, loosen the hex head
screw, then remove the support bracket, the rocker lever, the intake and exhaust rocker
lever assembly, mark them separately so as not to confuse the rocker levers of the
cylinders.
70
4.4.3.3 Inspection and Repair of Rocker Arm and Rocker Shaft

① Clean the rocker arm, and observe the appearance of the rocker arm, to find if there are
any defects such as cracks;
② Check the inner hole of the rocker arm for wear and abrasion, and measure its
diameter;
③ Inspect ball pin and rocker lever, check for the other end of the arc surface is worn.
J ④ Check that the oil passages are open. J
M ⑤ Measure the rocker lever bore diameter and the rocker lever shaft diameter to ensure a M
2 post-install clearance. See Table 4-4 below.
8 Table 4-4 Rocker lever bore diameter and rocker lever shaft diameter measurement table
Model Inspection Item Standard value (mm) Actual
_ Diameter of the rocker arm
923.972i23.993
a bore
WD615
Rocker Lever Shaft
p Diameter
923.927~923.960
4.4.3.4 _
Assembly Procedure of Rocker Arm and Rocker Shaft
t a small amount of oil onto the valve rocker seat shaft, then put the inlet and
① Apply
s rocker assembly on the rocker lever seat, loosely install the hex head bolts,
exhaust
ensure that there is a certain gap between the rocker lever and the rocker seat, and the
u can turn freely;
rocker lever
_
② After installing, rotate the crankshaft to see if the rocker arm rotates freely;
e
Check/adjust intake/exhaust valve lash.
r
① Crank the engine to the top dead center of cylinder 1, that is, the flywheel line and the
flywheel housing o
line are aligned, to determine the compression top dead center of
cylinder 1;
n
② Adjust the valve lash: No.1, 2, 4 cylinder intake valve, No.1, 3, 5 cylinder exhaust valve;
Intake valve lash: (0.3±0.03) mm, exhaust valve lash: (0.4±0.03) mm;
Adjusting Intake valve
Valve Intake valve rocker lever Screw rocker lever Valve cap
cap Adjusting Screw
Adjustment
Adjustment nuts Valve spring
nuts retainer, upper
Valve spring
Drive Bar Drive Bar
retainer, upper SPRING,VALVE
SPRING,VALVE
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°.
71
4.4.4 Removal and Installation of Tappet and Push Rod
4.4.4.1 Assembly Exploded View of Tappet and Push Rod
Drive Bar
J J
M Cylinder Head
M
2 Block
8
_
a
Tappet
p
_
t
s
u
_Figure 4-42 Assembly Exploded View of Tappet and Push Rod
e
4.4.4.2 Removal Procedure of Tappet and Push Rod
r
① Disassemble the rocker arm and the rocker arm shaft, and then directly take out the
o them in order;
push rods and place
n is removed (see the cylinder head remove step), remove the
② After the cylinder head
tappets and place them in order.
4.4.4.3 Inspection and Repair of Tappet and Posh Rod
① Clean the push rods and tappets;

② Check if the tappet and push rod oil passages are open;
③ Check if the push rod is bent and the outer surface is worn;
④ Check if the push rod head and the recess are worn;
⑤ Check the surface of the tappet and if the bottom surface is worn;
⑥ Check the inside socket of the tappet for wear.
72
4.4.4.4 Assembly Procedure of Tappet and Push Rod
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;
J J
④ After the cylinder head assembled (see the cylinder head assembly procedure), blow
M the pushrod with compressed air and check for the oil hole is blocked; M
2 ⑤ Apply clean lubricating oil onto the push rod, being sure that the ball joint and socket
8 head has sufficient lubricating oil;
_ ⑥ Install the pushrod and place the pushrod in the appropriate position.
a
4.4.5 Disassembly and Assembly of Valve
p
4.4.5.1 Assembly Exploded View of Valves
_
t Valve cap
Valve lock collet
s
Valve spring retainer, upper
u Inner valve spring Outer valve spring
_ Valve spring
retainer, lower
e
r
o
n
Valves
Figure 4-43 Assembly Exploded View of Valve

4.4.5.2 Removal Procedure of Valve
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.
4.4.5.3 Inspection and Repair of Valve
① Check the valve stem and valve stem end faces for wear;
73
② Check the valve cone for wear or damage;

③ Check the valve cone for carbon deposits;
④ Check the end face of the valve disc for carbon deposits and burns.
4.4.5.4 Valve assembly step
If the valve is worn or the carbon is seriously sintered, the valve needs to be replaced.
J ① Apply molybdenum disulfide paste evenly on the intake and exhaust valve stems, and J
M then install the intake and exhaust valves into the cylinder head to ensure that the M
intake and exhaust valves slide in the guides without any binding;
2
② Apply the thread locker evenly on the bottom surface of the exhaust valve spring, and
8 then attach it to the cylinder head. Check for the bottom surface of the exhaust valve
_ spring is seated, replace or repair if necessary.
a③ Install the intake valve spring lower seat. Put the valve stem protection sleeve on the
p 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.
t the valve inner spring and the valve outer spring, make ensure that the direction
④ Install
of the valve inner spring is opposite to the outer spring;
s
⑤ Install the
u 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
e
seat it. If collet or valve spring upper seat can not seat, check the cause and repair.
r
4.4.6 Intermediate gear disassembly and assembly
o
4.4.6.1 Intermediate gear assembly
n exploded View
Intermediate gear
Shim(s)
Shaft Bolts
Intermediate gear
Figure 4-44 Intermediate gear assembly Exploded View
74
4.4.6.2 Intermediate gear remove step
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.
J Remove four M10 hex head bolts on the intermediate gear and take off the washer. Use J
an M8 bolt to screw into the shaft in the middle of the gear and pull out the shaft, taking
M care to prevent the intermediate gear from falling; M
2 ⑤ The intermediate gear assembly and the intermediate gear shaft are removed with the
8 gear housing and taken out of the opening in the gear housing.
_
4.4.6.3 Intermediate gear overhaul
a
① Check for the bolt thread is good;
p
② Check for each gear has tooth surface peeling, broken teeth, the bolt bearing surface is
_
crushed, the threaded hole or the through hole on the gear is deformed;
t
③ Check for abnormal wear between the intermediate gear shaft and the intermediate
gear s
bushing. Check for each oil hole is clogged with dirty foreign matter.
u
4.4.6.4 Intermediate gear assembly step
_
① Install the lubricating oil pump, crankshaft and Lubricating oil pump intermediate gear
assemblies in e sequence
② Install the gear rhousing. Before installing the gear housing, place the intermediate gear
o
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
n
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
4.5.1 Disassembly and installation of Air Intake System
75
J 1. Air intake pipe washer J

2. Air intake pipe group
M 3. hex flange bolt M
4. hex flange bolt
2 5. hex flange bolt
6. Adjust the washer
8 7. Wave elastic washer
8. Hex Head Bolt
_ 9. Sealing washer
10. Hex Head Threaded
a Plug
p
_
t
s
u Figure 4-45 Air Intake System disassembly diagram
_ disassembly
b. Preparation before
e
• Equipment conditions: pneumatic wrench, sleeve, post, guide bar
r
• Preparation before disassembly: Remove the other peripheral parts that are installed on
the intake air line.o
n
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.
4.5.2 Exhaust system removal and installation
76
1. Shims
2. Rear Exhaust
manifold
3. Forward exhaust
manifold
4. Exhaust pipe seal
ring
J 5. Exhaust pipe bolt J
M M
2
8
_ Figure 4-46 exhaust system disassembly diagram
a
p
• Equipment conditions: pneumatic wrench, threaded sleeve, post, molybdenum disulfide,
_
lubricating oil, brush
• t
Preparation before disassembly: Remove the other peripheral parts that are installed on
the exhaust
s air line.
u
c. Disassemble
The removal _
procedure is in reverse order to the installation procedure
d. INSTALLATION. e
4) Adjust the seal rring (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.
o
5) Use an exhaust pipenbolt (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
77
1, turbocharger gasket
2. Turbocharger
3. Stud
J 4. Type 2 full metal hex lock nut
J
M 5. Turbocharger exhaust outlet M
plug
2 6. Stud
8
_
a
p
_
t Figure 4-47 Turbocharger system group disassembly diagram
s
u
_
e
r
o
n
1. Turbocharger oil inlet line shim
2, Turbocharger return line gasket
3. Turbocharger oil inlet line
4. Self-locking washer
5. Hex Socket Head Studded Screw
6. Bushings
7. Tube connector nut
8. Turbocharger return line component
9. Drain tube bolts
Figure 4-48 Turbocharger lubricating oil pipe system group disassembly diagram
78
4.5.4 Disassembly and assembly of turbocharger lubricating oil pipe system
• Equipment conditions: pneumatic wrench, sleeve, copper hammer, lubricating oil, brush
• Preparation before disassembly: Remove the other peripheral parts that are installed on
the turbocharger.
J J
c. Disassemble
M M
2
8 d. Install
_ Loosely install the turbocharger exhaust outlet block 3.5-3 (5) onto the turbocharger 3.5-3
a(2) with the studs 3.5-3 (6).
Use
p 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
t
pipe assembly 3.5-4 (3), and assemble the assembled parts to the cylinder block. Apply
567 sealant
s to the sleeve end. Tighten the union nut.
The turbocharger
u 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
e
outlet with the self-locking washer 3.5-4 (4) and the flange washer 3.5-4 (2).
Remove the protectiver cover at the inlet of the turbocharger. Use the turbocharger inlet
pipe bolt 3.5-4 (5) to oinstall 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.
n
79
4.6 Fuel System
4.6.1 Disassembly and Assembly of Fuel System
4.6.1.1 Assembly Exploded View of Fuel System

Injectors High Pressure
Supply Lines
J J
M M
2 Pump, Injection
8
_
a Fuel Filter(s)
Low Pressure Fuel
p Lines
_
Figure 4-49 Assembly Exploded View of Fuel System
t
4.6.1.2 Remove Procedure of Fuel System
s
a) The lowupressure fuel line is removed
b) Remove high
_ pressure oil pipe
e
c) Remove injector
d) Remove filter(s)r
o oil pump
e) Remove high pressure
n step
4.6.1.3 The fuel system install
Install step is in reverse order to the remove step.
80
4.6.2 Removal and Installation of Fuel Injection Pump

4.6.2.1 Injection Pump install exploded views
Injection Pump flange

Ring seal
Pump, Fuel Injection
Injection Pump Gear
J Fuel
J
M M
2
8
_
a LUBE OIL
PIPE,
p COMPL. Pump Support Bracket
Oil pump carrier
_
t Figure 4-50 Injection pump disassembly diagram
s Procedure of Fuel Injection Pump

4.6.2.2 Removal
u
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.
e
c) Remove injection pump locknut.
r
d) Remove the hex head bolt between the injection pump and the flange.
o
e) Remove injection pump flange.
n
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.
81
4.6.2.4 Injection pump assembly steps
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.
J J
M b) Finally, adjust the fuel injection pump waist groove to achieve the specified fuel supply M
timing.
2
c) Tighten the hex nut between the injection pump and the gear housing.
8
_
a
p
_
t
s
u
_ Gear scale
line
e Figure 4-51 Fuel pump engraving position
r
4.6.3 Removal and Installation of High Pressure Fuel Lines
o
4.6.3.1 Assembly ExplodednView of High Pressure Fuel Lines
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
82
4.6.3.2 Removal Procedure of High Pressure Fuel Line
a) Remove fixed high pressure tubing support bracket.

b) Remove pump-to-rail high pressure tubing.
c) Remove rail to fuel injector high pressure fuel line.
4.6.3.3 High pressure tubing assembly steps

J The installation procedure is in reverse order to the removal procedure. J
M Note: high pressure tubing tightening nut tightening torque: (30~40) N·m at fuel
M
2 injector end, (30~40) N·m at rail end and oil pump end
8 4.6.4 Removal and Installation of Injector
_
4.6.4.1 Assembly Exploded View of Injector
a
p
_
t
s
u
_
e
r
o
n
1-fuel injector; 2-gasket; 3- seal ring; 4- clamping plate; 5-hex head bolt
Figure 4-53 fuel injector assembly drawing
4.6.4.2 Removal Procedure of Injector
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.
4.6.4.3 Inspection and Repair of Injector
Fuel injector nozzle replacement must be carried out at Wuxi Weifu special repair location
83
4.6.4.4 Assembly Procedure of fuel injector
a) Fuel injector fastening bolt M8 (quantity: 2): symmetrical tightening and note that side
clearance is consistent (20~25) N·m.
4.7 Cooling System
4.7.1 Water pump disassembly and assembly

J 4.7.1.1 Assembly Exploded View of Water Pump J
M M
2
8
_
a
p
_
t
s
u
_
Figure 4-54 Assembly Exploded View of Water Pump
e
1- Water Pump Belt; 2- Crankshaft Belt; 3-Water Pump; 4-Nut; 5-Stud; 6-Stud; 7-Shim
r
4.7.1.2 Removal Procedure
o of Water Pump
See Figure 4-64: n
① Remove the crankshaft belt and the water pump belt;
② Remove the nut from the water pump;
③ Remove the water pump and remove the water pump gasket.
4.7.1.3 Inspection and Repair of Water Pump
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.
84
4.7.1.4 Water pump assembly step
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.
J 4.7.2 Removal and Installation of Thermostat J

M 4.7.2.1 Assembly Exploded View of Thermostat M
2
8
_
a
p
_
t
s
u
_
e
r
o
n
Figure 4-55 Exploded View of Thermostat

1-Water Pipe Joint; 2-Clamp; 3-Coolant Connection Hose; 4-Line Cap; 5-External Thermostat; 6-Hose
4.7.2.2 The thermostat remove step
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.
85
4.7.2.3 Inspection and Repair of Thermostat
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.
J J
4.7.2.4 Thermostat Assembly Steps
M M
2 ① Before assembly, inspect clamps, hoses, thermostats, and thermostat covers, make
ensure that there are no defects or damage to manufacturing and use.
8
② Clean the outlet pipe and the water pump outlet pipe to ensure that no foreign matter
_ enters.
a
③ The specific installation procedure is in reverse order to the removal procedure.
p
The thermostat opening temperature parameter table is shown in Table 4-5:
_
Table 4-5 Thermostat Opening Temperature Parameter Table
t Initial Opening Temperature Fully Opening Temperature
No.
(°C) (°C)
s
1 80 95
u
2 71 82
_
4.7.3 Disassembly
e and Assembly of Fan
r
4.7.3.1 Assembly Exploded View of Fan
o
n
Figure 4-56 Assembly Exploded View of Fan

86
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
4.7.3.2 Removal Procedure of Fan
See illustration:
J J
① Loosen six fan fastening nuts and remove the fan;
M M
② Loosen the hex head bolt that fix the gear housing to the clutch and support bracket
2 plate, remove the electromagnetic clutch;
8
③ Remove the harness and support plates.
_
4.7.3.3 Inspection and Repair of Fan
a
Check
p the fan and clutch for cracks and other damage.
4.7.3.4 _
Installation Procedure of Fan
t
① Before assembly, inspect the fan, clutch, and fastening bolts, make ensure that there
s defects or damages in manufacturing and use.
are no
u installation procedure is in reverse order to the removal procedure.
② The specific
4.7.4
_
Removal and Installation of Water Outlet Tube
e
r
o
n
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
87
• Equipment conditions: socket wrench or pneumatic wrench, open end wrench;

• Preparation before disassembly: Remove air intake piping, high pressure oil tubing
clamp retaining capscrew.
c. Disassemble
J 1) First remove the sensor harness on the outlet pipe and remove the clamp that connects J
to the water pump hose;
M M
2) Loosen the outlet pipe fixing bolts in sequence;
2
3) Remove the outlet pipe;
8
_ 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.
a
5) If further removal is required, remove the clamp connected to the thermostat and the
p hose as shown in Figure 4-27 to remove the hose and thermostat.
d. Install_
t
1) Assemble the thermostat, O-ring, thermostat cover gasket and thermostat cover and
s to the outlet pipe in sequence, and tighten the bolts;
flange
2) The air u
intake piping gasket is recommended to be used once, and it should be
replaced when
_ repaired;
3) Wipe the joint
e surface of the outlet pipe, install it on the cylinder head and install the
fastening bolts;
r
4) Tighten the fastening bolts;
o
5) Tighten the high pressure oil pipe clip fixing bolts;
n
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.
88
4.8 Lubricating Oil System
4.8.1 Lubricating oil pump disassemble and assembly
4.8.1.1 Assembly Exploded View of Oil Pump
J J
M GASKET-OIL PUMP M
2 Lubricating Pump
Hexagon flange face
8 toothed bolt
Hexagon flange face
_ toothed bolt
a
p
_
t Figure 4-58 Assembly Exploded View of Oil Pump
4.8.1.2 Removal
s Procedure of Oil Pump
Loosen theutwo hexagonal flanged toothed bolts on the lubricating oil pump and remove the
lubricating oil pump and the lubricating oil pump gasket as shown.
_
4.8.1.3 Inspection and
e Repair of Oil Pump
r for cracks and other damage, whether the inner cavity is smooth, if
① Check the oil pump
necessary, replace the oil pump;
o
② If there is a leaking lubricating
n oil phenomenon, check the lubricating oil pump gasket
for failure, and replace the lubricating oil pump gasket if necessary.
4.8.1.4 Lubricating oil pump assembly steps
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.
89
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
J J
M M
2
8 Oil pump intermediate gear
assembly
_ Intermediate gear shaft

Ring seal
a Capscrew, Hex
Head
p
_
t
Figure 4-59 Lubricating oil pump intermediate gear group assembly exploded view
s
4.8.2.2 Lubricating oil pump intermediate gear assembly remove step
u
① Loosen and remove the hex head bolts.
_
② Remove the e intermediate gear shaft with a special tool and then remove the lubricating
oil pump intermediate gear assembly.
r
4.8.2.3 Lubricating oil pump
o intermediate gear assembly inspection and repair
① Check lubricating oilnpump 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
4.8.2.4 Lubricating oil pump intermediate gear assembly assembly steps
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.
90
4.8.3 Remove and Installation of Oil Filter
4.8.3.1 Assembly Exploded View of Oil Filter
J J
M M
Lubricating oil
Lube oil cooler
2 assembly
filter head gasket
Wave elastic
8 washer
Hex Socket Head
_ Studded Screw
a
p
_
Hex Socket Head Studded Screw
t
s Figure 4-60 Assembly Exploded View of Oil Filter
u Procedure of Oil Filter

4.8.4.2 Removal
Loosen the 4 _bolts on the lubricating oil filter and remove the lubricating oil filter assembly
and the lubricating
e oil filter gasket as shown above.
4.8.4.3 Inspection andrRepair of Oil Filter
o
① Check the oil filter assembly for damage, if necessary, replace the oil filter assembly.
n
② Check the lubricating oil filter head gasket for damage, replace the filter head gasket if
necessary.
4.8.3.4 Installation Procedure of Oil Filter
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.
91
4.8.4 Lubricating oil cooler cover disassembly and assembly
4.8.4.1 Assembly Exploded View of Oil Cooler Cover
J J
M M
2 BLOCK
8 Hexagon flange
bolt
_
Sealing Shim
a Hex screw BLOCK BLOCK
plug
p
_ Lubricating oil cooler
cover gasket
t Hexagon flange bolt Oil cooler cover
s Figure 4-61 Assembly Exploded View of Oil Cooler cover

u oil cooler cover remove step
4.8.4.2 Lubricating
_ first drain the coolant from the engine, loosen the bolts on the lubricating
Before removing,
oil cooler cover,e
and remove the lubricating oil cooler cover and gasket, as shown above.
4.8.4.3 Lubricating oil rcooler check and repair

o
① Check the lubricating oil cooler cover for cracks and other damage. If necessary,
n oil cooler cover
replace the lubricating
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.
4.8.4.4 Lubricating oil cooler cover assembly step
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.
92
4.8.5 Disassembly and Assembly of Lubricating Oil Cooler
4.8.5.1 Assembly Exploded View of Oil Cooler
Ring seal
Lubricating Oil Cooler
J Wave elastic washer J
M Hex Socket Head
Studded Screw
M
2
8
_
a
p
_ Figure 4-62 Assembly Exploded View of Oil Cooler
t
4.8.5.2 Removal Procedure of Oil Cooler
s
Loosen the 4 bolts on the lubricating oil cooler and remove the lubricating oil cooler and
seal ring asushown above.
_ oil cooler check and repair
4.8.5.3 Lubricating
e
Check the oil cooler for cracks and other damage, and if necessary, replace the oil cooler.
r
4.8.5.4 Lubricating oil cooler assembly step
o
① Check the oil coolernbefore 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.
93
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
J J
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2
8
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s Main lubricating oil rifle pressure
relief valve
u
Figure 4-63 Assembly Exploded View of Main Oil Rifle Pressure Relief Valve
_
4.8.6.2 Removal Procedure
e of main lubricating oil rifle Pressure Relief Valve
r the main oil rifle pressure relief valve, as shown in the illustration.
Loosen and remove
4.8.6.3 Main LubricatingoOil Rifle Pressure Relief Valve Repair

n
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.
94
4.8.7 Lubricating oil cooler bypass valve disassemble and assembly
4.8.7.1 Lubricating oil cooler bypass valve assembly exploded view

Hex plug
Compound gasket
Safety Net Spring
Safety nets
J J
M M
2
8
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a
p
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s
u
Figure 4-64 Assembly Exploded View of Oil Cooler Bypass Valve
_
4.8.7.2 Lubricating oil
e cooler bypass valve remove step
Loosen and remove r the hex plug and remove the compound washer, relief valve spring
and relief valve in sequence as shown.
o
4.8.7.3 Lubricating oil cooler
n bypass valve check and repair
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.
4.8.7.4 Lubricating oil cooler bypass valve assembly step
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.
95
4.8.8 Disassembly and Assembly of Filter
4.8.8.1 Assembly Exploded View of Filter
J J
M M
2
8
_
a
p
_
t Shim(s)
Capscrew, Hex
Washer, Flat
s Head
Oil strainer
u
Figure 4-65 Assembly Exploded View of Strainer
_
4.8.8.2 DisassemblyeProcedure of Filter
r head bolts on the filter and remove the lubricating oil filter and gasket
Loosen the two hex
as shown above. o
n of Filter
4.8.8.3 Inspection and Repair
Check the filter and gasket for cracks and other damage, and if necessary, replace the filter
and gasket.
4.8.8.4 Assembly Procedure of Filter
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.
96
4.9 Starting System
4.9.1 Disassembly and Assembly of Starting System
4.9.1.1 Exploded View of Starting System
J J
M M
2
8
_
a 4 Ring gear
2 Stud
p
1 Starter 3. Hex Head Nut
_
t Figure 4-66 Assembly Exploded View of Starting System
s
4.9.1.2 Disassembly Procedure of Starting System
u
1) Remove the starter;
_
2) Remove the ring gear.
e
4.9.1.3 The starting system
r installation step is in reverse order to remove step.
Installation step is ino

reverse order to remove step.
4.9.2 Disassembly andnAssembly of Starter
4.9.2.1 Starter Assembly Exploded View
See starting system assembly exploded view
4.9.2.2 Starter remove step
1) Remove hex nut (3);

2) Hold the starter (1) with both hands and remove it in parallel with the direction of the
starter;
3) Remove stud (2)
4.9.2.3 Starter inspect and repair
Check the starter teeth for damage and replace if necessary.
97
4.9.2.4 Starter installation procedure is in reverse order to the removal procedure.
Installation procedure is in reverse order to the removal procedure.

4.10 Vehicle Accessory System
4.10.1 Removal and Installation of Alternator
4.10.1.1 Assembly Exploded View of Alternator

J J
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2
8
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e Figure 4-67 Assembly Exploded View of Alternator
r1- Water Pump Belt; 2-Generator; 3-Clamping Block;
o Head Bolt; 5-Hex Head Bolt; 6-Wave Washer
4-Hex
4.10.1.2 Removal Procedurenof Alternator
1) Remove the water pump belt.

2) Loosen two hex head bolts and remove the generator.
98
★Note: The disassembly and repair of the generator must be performed by a

professional. Check for each insulation pad, sleeve is good when installation,
replace if needed. The positive terminal must not be short circuit to the cylinder
block. Otherwise, It is strictly forbidden to load the generator to avoid causing
serious accidents.
4.10.1.3 Generator fault diagnosis and maintenance

4.10.1.3.1 Judgment Process for Alternator Faults
J J
When the user require warranty repair, first test on the vehicle to determine if it is a
M alternator failure. Tool: Test light, the flow is shown below. M
2
8 Turn on the vehicle power switch and connect the test
light to the B+ and E (negative) terminals of the
_ alternator.
a
p 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
t Yes
s Connect the E terminal to the D+
end of the alternator
u Yes
_ No It means that there is a problem
e Is the test light on? with the internal electrical circuit of
the D+ end of the alternator.
r
o Start Engine
n
Yes
Yes
Is the test light Alternator is
on?
No
No Faults with
alternator
Figure 4-68 Judgment Process for Alternator Faults
99
4.10.1.4.2 Troubleshooting & Repair of Charging System Malfunction
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
J running between 1V~3V; points.
J
M ② If the voltage at the alternator indicator terminal is zero, it means M
that the alternator end of excitation circuit has a short circuit to
2 ground, check the line.
③ If the voltage at the alternator indicator end is the battery voltage, it
8 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.
a b Detect whether the ① If the B+ voltage to ground is zero, check continuity in the positive
p voltage at the output of
the alternator B+ is
and negative leads between the alternator and the battery.
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
t damage.
Recommended detection method: connect a 2W indicator light between
s alternator output B+ and excitation terminal D+/L to observe the
working status of indicator light:
u 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.
e ② The brightness of the indicator is normal. After the engine is started,
r 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
o replaced.
3. The brightness of the indicator is normal. After the engine is started,
n 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
100
b) Charging voltage is too low

Fault 2: Charging voltage is too low
The battery is often Know whether alternator Measure the voltage of the B+ terminal of the alternator, usually
undercharged, the output power and vehicle between 27.8 and 28.4. If the voltage is normal, it indicates that there is
charging voltage is electrical appliances a problem with the voltmeter or voltmeter sampling point that needs To
low, and the voltage matches reasonably be repaired or replaced
drops significantly
J when loading. a Check the voltmeter for ① The idle speed of the alternator is recommended to be greater than J
damage 1600RPM.
M b Check alternator speed ② When the alternator is working with a high-power load such as air M
conditioner, the speed shall be ≥2000 rpm or the voltage shall be
2 around 27V.
8 c Check the quality and ① Check the quality of belts of the alternator and related gear train.
tension of belts of the The belts that are carbonized, missing teeth, broken, deformed, and
_ alternator and related loose to the bottom must be replaced.
gear train. ② Retighten the alternator and related gear train belts
a ★NOTE: If the system whose belt needs to be changed is a double belt
p drive, the double belt must be replaced at the same time when
replacing!
_ d Check the alternator Tension if loose
pulley
t
e Check if the wire is ① If the voltage difference is greater than 1V under heavy load
s used properly and conditions (the voltage drop is large due to the thin wire), replace
measure the voltage of the wire.
u the alternator and Less than 35A S ≥6mm2≥ Less than 70A S ≥12mm2≥
battery terminals. Less than 100A S ≥20mm2≥ Less than 150A S ≥25mm2≥
_ ② If the wire or connector is hot under heavy load conditions, replace
the wire or connector.
e
The battery is often f Check if the connection ① Polish the surface-oxidized tab and the surface of the housing
undercharged, the r
between the charging mounted with grounding bolt before reinstalling.
charging voltage is system wire and the ② Retighten the loose nuts and lugs, and the connectors need to be
low, and the voltage o
bolt is loose, oxidized, re-tightened.
drops significantly loose connected and ★After reinstalling or retightening, check whether there is still high heat
when loading. heat produced n
after running the engine with heavy load for 3〜5min.
g Detect the phase end If the phase end (W/R/AC) output voltage is significantly different from
output voltage of the the normal output value, there is a problem with the alternator rectifier
alternator (shall be bridge or stator, repair or replacement shall be considered.
about half of the
h Check if the battery is The charging current shall be reduced to about 10A after 10 minutes of
charging properly. charging, if the charging current is 30-90A for long time, the damaged
battery needs to be repaired or replaced.
101
c) Charging voltage is excessive

Fault 3: The charging voltage is too high
The voltmeter a Check the voltmeter for damage Measure the voltage of the B+ terminal of the alternator,
shows a high which shall normally be between 27V and 28.4V. If the
voltage voltage is normal, it indicates that the discrepancy of
calibrated value of the voltmeter is large and needs to be
repaired or replaced.
J J
b Check the wiring and connection parts ① If the contact is poor and the wiring is loose, it needs to
M of the charging system. Check whether be retightened, and the connector needs to be M
the wiring bolts are loose, loosely reconnected tightly.
2 connected, producing high heat, and ② If shorted, reconnect the wires.
whether the wires are short-circuited
8 with the alternator housing.
_ c Check if the battery is working ① Observe whether the battery has a large change in the
properly. charging current value during the charging process
a (50A drops to within 10A); if not, you need to consider
replacing the battery as soon as possible.
p ② Observe whether the surface of the battery is clean
and dry, and the binding posts and clamps are well
_ matched; if there is damage, it must be replaced as
soon as possible.
t
The voltmeter d Detect the phase end output voltage of If the phase end (W/R/AC) output voltage has a large
shows a high s the alternator (shall be about half of the difference from the normal output value, the voltage drops
voltage B+ output voltage) greatly when the alternator is under load, and the
u alternator rectifier bridge or stator has problems, and it is
considered to be repaired or replaced.
_
e If when the above checks are Replace alternator regulator, rotor or complete alternator.
e
completed, the symptoms do not
disappear
r
d) Charging voltage is
o unstable
n Fault 4: Charging voltage is unstable
When the engine is a Alternator or related gear train belts are too
Tensioning alternator and related belts
running normally, the loose or runout
voltmeter indicates
charging, but the pointer b Charging lines are connected loosely and Check the connections that fix the charging
swings left and right, and have poor contact line
the reading cannot be seen c Collector ring dirty, or excessive brush wear, Clean stains, or replace brush or brush
(or the charging indicator or brush spring is too soft or broken springs
keeps switching on and
off ) d Regulator damage Replace the regulator
102
e) Abnormal sound in alternator

Fault 5: Generator abnormal sound
a Alternator retaining bracket is deformed or Improve the strength of the mounting
too close to other external devices bracket and adjust the installation status
b Alternator belt is loose and slippery Replace the engine belt
c alternator pulley loose Fastening the pulley
J The alternator has
abnormal noise during
J
d Alternator bearing is short of oil or damaged Replace alternator bearing
M operation M
e Low noise inside the alternator Stator coil short circuit, replace
2 f Whistle inside the alternator, and sound It is the noise generated when the stator
changes with the speed core vibrates, and replace the stator
8 assembly if necessary.
_
4.10.1.4 Generator assembly step
a
The installation procedure of the alternator is in reverse order to the removal procedure.
p
_
t
s
u
_
e
r
o
n
103
4.10.2 Disassembly and Assembly of Air Compressor
4.10.2.1 Assembly Exploded View of Air Compressor
J J
M M
2
8
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s
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r
o
n
Figure 4-69 Assembly Exploded View of Air Compressor

1-Clamp; 2-Air Compressor Air Intake Pipe; 3-Hex Flange Face Bearing Toothed Bolt; 4-Single Pipe
Clamp Assembly; 5-Support Block; 6-Air Compressor Assembly; 7-Sealing Washer; 8-Air Compressor
Air Intake Pipe;9- Banjo Bolt ;10- Seal Ring ;11- Banjo Bolt ;12- Sealing Washer ;13-Air Compressor
Lube Pipe Assembly ;14-Hex Flange Face Bearing Toothed Bolt; 15- Hexagon Flange Face Bearing
Toothed Bolt; 16-Air Compressor Water Return Pipe
104
4.10.2.2 Removal Procedure of Air Compressor
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.
4.10.2.3 Inspection and Repair of Air Compressor

J 4.10.2.3.1 Air compressor was not pumping J
M M
Trouble phenomenon: There is no compress air going out from air compressor.
2
Cause:
8
a) The air compressor relief valve is stuck. The valve is deformed or broken.
_
b) Excessive carbon deposits in the intake and exhaust ports.
a
Troubleshooting and repair:
p
a) Check the relief valve assembly, and clean or replace the failed parts;
_
b) Remove
t and inspect the cylinder head. Inspect the valve disc, and replace the
deformed and broken valve disc;
s
c) Remove and inspect the cylinder head. Clean the valve seat plate and valve disc.
u
4.10.2.3.2 Insufficient air pressure
_
Trouble Phenomenon:
e 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. r
Cause: o
a) Air pressure gauge n
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
105
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.
J Based on the fault that is found, replace or repair damaged parts; J
e) Check if the air compressor cylinder liner and piston ring are excessively worn;
M M
f) Check and adjust the installation direction of the unloading valve to match the direction
2 of the mark (arrow).
8
4.10.2.3.3 Air compressor oil carryover
_
Trouble Phenomenon: The oil overflows from the air filter and the exhaust port, and
aexcessive oil overflows when the air storage tank (wet) discharges water.
p
Cause:
_
a) Inspiratory obstruction or poor air intake filtration;
b) Oil treturn is blocked;
s
c) The cylinder liner of the air compressor, the piston and the piston ring is worn out, or the
oil ring u
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;
e
f) The air compressor runs for too long.
r
g) The pressure in the engine crankcase is too high;
o
h) Engine oil pressure is too high.
n
i) Lubricating oil deterioration.
j) The air compressor is defective.
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
106
Note: Theoretical air discharge piston stroke×n÷109×the number of pistons, n is

the rated speed of the air compressor, and d is the cylinder diameter.
b) Ensure that the inside diameter of the exhaust pipe is larger than the minimum required
inner diameter.
Table 4-7 Minimum inner diameter of exhaust pipe
Compressed Air System Cycle Pipe Length Pipe I.D.
J Single cylinder air compressor (standard load cycle) ≤25% ≥3.6m 13mm J
M Single cylinder air compressor (high load cycle) 25%〜35% 3.6m to 4.6m 16 mm M
2 Twin cylinder air compressor (all duty cycle) ≤35% ≥4.6m 22mm
8 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
a accumulated on the fins. Replace any damage parts as necessary; inspect damaged
p 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
_ the pipe is 9.5 mm) and check the coolant flow of the air compressor. The minimum
of
allowable
t 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
s pipes and fittings.
cooling
u the water temperature cannot exceed 93°C. Check the air valves on the air
e) Check that
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
appropriatelyein front of the air tank.
f) In the case that rthe vehicle brake is not used, the leakage rate shall not exceed 6.9 kPa per
minute, and 20.7 kPao 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.
n
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;
107
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.
J J
a) Check for the connecting rod bearings, connecting rod bushing and main bearing are
M worn, strained or burnt, and the connecting rod bolt is loosen. Check for the main oil M
2 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
8 (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.
a
b) Check whether the groove type of main and auxiliary pulleys are the same. If they are
p inconsistent, replace them and adjust the belt tightness (press the belt with your thumb,
the
_ distance of sag shall be 10 mm);
c) Check
t 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
s and impurity content of the lubricant. If it exceeds the standard, it should be
quality
replacedu 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
e) For the geardriven air compressor, also check whether the gear is loose or the condition
r and fitted. Retighten the loose nut, or replace if there is any
that gear is installed
problem of engagement;
o
f) Remove foreign objects.
n
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.
108
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
J Trouble Phenomenon: The air compressor has a lubricant overflow on the outside. J
M Cause: M
2 a) Oil seal falls off or oil seal defects resulting in oil leakage;
8 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.
ad) Excessive tensioning of the belt causes the main bearing shell to wear.
e)p Casting or processing defects.
_
a) In the oil seal area, check the oil seal for cracks and the inner lip for cracks or flanging.
t of the above condition, it should be replaced: check the oil seal and the spindle
In one
joint s
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
u of the crankcase too high, resulting in the oil seal to leak or fall off. The
the pressure
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 iteif it does not meet the standard;
b) Forcefully mover the main shaft to check if the journal clearance is too large. If the
clearance is too large,
o replace the bearing shell and oil seal at the same time.
c) Inspect seal sealingnof 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.
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
109
or stuck, clean or repair the failed parts;

b) Check brake system components and piping. Replace failed components;
c) Poor lubrication between the piston and the cylinder liner, too small clearance or
cylinder scoring can cause overheating. In this case, the defective part shall be
inspected, repaired or replaced.
4.10.2.4 Air compressor install step is in reverse order to the remove step
J 4.10.3 Air filter system disassembly and assembly
J
M M
4.10.3.1 Air filter system assembly exploded view
2
8
_
a
p
_
t
s
Air Filters
u
Connection elbow
_
Capscrew, Hex Head
e
Wave elastic washer
r
Support, air cleaner
o
n Support Bolt
Figure 4-70 Assembly Exploded View of Air Filter System
4.10.3.2 Air filter system remove step

1) Remove the air cleaner connection elbow.
2) Loosen the connection clamp between the air cleaner and the air cleaner bracket and
remove the air cleaner.
3) Loosen the hex head bolt on the air cleaner bracket and remove the wave spring
washer and air cleaner bracket.
110
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.
4.10.4 Disassembly and Assembly of The Silencer System
4.10.4.1 Silencer system assembly explosion view

J J
M M
2
8
_
a Muffler
p
_
t Connection elbow
s Studs
Nuts
u
Washer
_ Bracket-Silencer
Block
e
Support Bolt
r
o
n
Figure 4-71 Assembly Exploded View of Silencer System

4.10.4.2 Silencer system remove step
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.
111
4) Remove the support bolts and support blocks between the silencer support bracket and
the cylinder head main bolt.
4.10.4.3 Silencer system assembly step

The silence system install step is in reverse order to the remove step.
J J
M M
2
8
_
a
p
_
t
s
u
_
e
r
o
n
112
Appendix A Matching Clearance of Main Parts of Diesel Engine

(Reference Value)
No. Item Theoretical Value (mm)
1 Main Bearing Clearance 0.095~0.171
2 Rod Bearing Clearance 0.059~0.135
3 Crankshaft End Clearance 0.102~0.305
J 4 Connecting Rod Horizontal Axial Clearance 0.15~0.35 J
M 5 Camshaft End Play 0.1~0.4 M
2 6 Valve Lash - Intake/Exhaust (cold) 0.3/0.4
8
_
a
p
_
t
s
u
_
e
r
o
n
113
Appendix B Evaluation Reference of Wear Amount of Main Friction Pair

in Diesel Engine
(Reference Value)
Wear Limit (mm) Clearance Limit (mm)
First ring closed gap 1.70 -
First ring height 0.10 -
J Second ring closed gap 1.50 - J

Second ring height 0.10 -
M M
Oil ring closed gap 1.50 -
2 Oil ring height 0.15 -
8 Piston Skirt Outside Diameter 0.25
0.60
_ diamer of liner
Inside 0.50
a Pin Outside Diameter

Piston 0.04
Piston Pin Bore Inside Diameter 0.08
p 0.10
Connecting rod small end bushing inner
0.08
diameter _
Camshaft Main t Journal Outside Diameter 0.06
0.10
inside diameter of camshaft bushing 0.06
s
Cam tip height 2.00 -
u
Cam base circle outer diameter 0.05 -
Crankshaft Connecting_Rod Journal Outside
0.12
Diameter 0.15
e
Connecting Rod Bearing Inside Diameter 0.10
r
Crankshaft Main Bearing Journal Outside
0.08
Diameter o 0.15
Main bearing inner diameter 0.10
n
Thrust Bearing Thickness 0.40 -
Intake Valve Recession 0.04*d(1)
Intake Valve Seal 0.75
Inlet valve seat insert 0.75
Exhaust Valve Recession 0.04*d(1)
Exhaust Valve Seal 0.85
Exhaust valve seat insert 0.85
Inside Diameter of Valve Guide - Intake 0.06
0.1
Valve Stem Outside Diameter - Intake 0.06
Inside Diameter of Valve Guide - Exhaust 0.06
0.1
Valve Stem Outside Diameter - Exhaust 0.06
Inside Diameter of Rocker Lever Shaft
0.10
Bushing 0.12
Rocker Arm Shaft Outside Diameter 0.05
114

WD10 two-valve China Stage II diesel manual

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WD10 two-valve China Stage II diesel manual

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WD10 two-valve China Stage II series diesel engine service manual

Weichai Power Co., Ltd.

WD10 two-valve China Stage II series diesel engine

3.2.18 Alternator Excessive Charging.........................................................................................31

4.6.3 Removal and Installation of High Pressure Fuel Lines ....................................................82

Section 1. Diesel Engine Operating Instructions

1.1 Exterior of Diesel Engine

1.2 Definition of Diesel Engine Model

u Firing Order 1-5-3-6-2-4

Bi. Life km 800,000

8 Fuel Injection Mechanical

1.4 Unpacking of Diesel Engine

Section 2. Diesel engine maintenance guide

2.1 Fuel, Lubricant, Coolant and Auxiliary Materials

2.1.1 Fuel oils

_ CH-4 10W-30 China Stage III Emission Diesel Engine:

2.1.3 Lubrication of the tensioner

J 2.1.4 Antifreeze additive for engine Cooling System J

a Category Product Type Package Size

Table 2-6 Reference for Diesel Engine Applying Sealant

2.2 Daily Maintenance

• Check oil level.

Figure 2-4 inspect fan blade

1 cylinder 2 cylinders 3 cylinders 4 cylinders 5 cylinders 6 cylinder

Figure 2-10 Drain the water collector

Replace water collector:

⑤ Install the screw by hand and tighten it with a tool.

• Checktthe air intake system

1. Paper filtering element

Figure 2-12 Air cleaner

High pressure air pipe

Section 3. Diesel engine typical failure and treatment

a◆ Fuel and lubricant oil grades are used improperly or unqualified.

Figure 3-1 Observation method Figure 3-2 Auscultation

2. For high-pressure oil pumps, turbochargers and other key components,

3.2.1 Diesel Engine Cannot Start

J Cause of Failure Troubleshooting Method J

(2) Fuel filter is plugged

3.2.3 Loss of power

Cause of Failure Troubleshooting Method

Cause of Failure Troubleshooting Method

J (9) Injection pump smoke limiter diaphragm damage Replace Repair J

_ oil pan lubricating oil level is too high

_ liner or piston wear or cylinder score

3.2.5 Black Exhaust Smoke

Cause of Failure Troubleshooting Method

_ The smoke limiter works incorrectly.

a White Exhaust Smoke, Blue Exhaust Smoke

3.2.7 Turbocharger Intake Port, Intake Pipe Stacking Oil

J 3.2.8 No Stability of RPM J

_ The governor (mechanical pump) heavy hammer and

3.2.10 Coolant Temperature High

Cause of Failure Troubleshooting Method

3.2.12 Louder Noise

Cause of Failure Troubleshooting Method

3.2.13 Starter Motor Does Not Work

Cause of Failure Troubleshooting Method

3.2.15 The Generator Does Not Generate Electricity At All

Cause of Failure Troubleshooting Method

(5) Regulatortadjusted voltage is too low Adjust

3.2.17 Charging _ Current Is Unstable

3.2.18 Alternator Excessive Charging