2 Engine System WEICHAIT2

Service Manual for LG959 Wheel Loader
CONTENTS
2 Engine System ..................................................................................................... 2-1
21 General................................................................................................................. 2-1
211 Engine Description ...................................................................................... 2-1
212 Engine Identification ................................................................................... 2-2
213 Product Model Composition and Significance............................................ 2-2
214 Cylinder Number ......................................................................................... 2-2
215 Engine Working Principle ........................................................................... 2-2
216 Engine Block Assembly .............................................................................. 2-3
217 Crank-Link Mechanism ............................................................................... 2-5
218 Valve Mechanism ........................................................................................ 2-7
219 Engine Technical Parameters ...................................................................... 2-7
22 Lubrication System .............................................................................................. 2-8
23 Fuel Supply System ............................................................................................. 2-9
231 Fuel Inlet Circuit.......................................................................................... 2-9
232 High Pressure Circuit ................................................................................ 2-10
233 Fuel Return ................................................................................................ 2-10
24 Cooling System.................................................................................................. 2-11
241 Function of Cooling System ...................................................................... 2-11
242 Thermostat ................................................................................................. 2-12
25 Intake and Exhaust System ................................................................................ 2-13
251 Intake System ............................................................................................ 2-13
252 Exhaust System.......................................................................................... 2-13
253 Turbocharger ............................................................................................. 2-14
26 Disassembly and Assembly of Engine .............................................................. 2-15
261 Disassembly of Engine .............................................................................. 2-15
262 Assembly of Engine .................................................................................. 2-25
27 Disassembly and Assembly of Fuel Tank ......................................................... 2-35
271 Disassembly of Fuel Tank ......................................................................... 2-35
272 Assembly of Fuel Tank ............................................................................. 2-37
28 Disassembly and Assembly of Radiator ............................................................ 2-40
281 Disassembly of Radiator............................................................................ 2-40
I
282 Assembly of Radiator ................................................................................ 2-43

29 Diagnosis and Troubleshooting of Engine Common Problems ........................ 2-47
291 Engine Fails to Start................................................................................... 2-47
292 Engine Power is not Sufficient .................................................................. 2-47
293 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke)............. 2-48
294 Engine Oil Pressure is too High or Too Low ............................................ 2-49
295 Large Consumption of Engine Oil ............................................................ 2-50
296 High Coolant Temperature ........................................................................ 2-50
II
2 Engine System
21 General
211 Engine Description
LG959 wheel loader is equipped with Weichai

WD10G220E21 engine.
Features of Weichai product are: reliable and
efficient, good adaptability, easy to cold start and
full load running, easy to be assembled on the
vehicle, low fuel consumption, low emission, low
noise and low vibration, etc. The engine also
featured with compact overall design and
convenient maintenance.
Fig. 2-1 Engine
1
212 Engine Identification
The serial number is printed on nameplate, which is

located on the engine cylinder block.
You must indicate the engine type and serial
number when ordering spare parts.
213 Product Model Composition and

Significance
WD10G220E21
Generation code
Emission standard
Rated power
For construction
machinery
Displacement
Water-cooling
diesel engine
214 Cylinder Number
The cylinders are numbered sequentially. Ignition

sequence: 1-5-3-6-2-4. From the point of view of
flywheel, the rotating direction of engine is
anti-clockwise.
Fig. 2-2 Cylinder No. 215 Engine Working Principle
The diesel engine is designed with four strokes,

every working cycle consists four processes, i.e.
intake, compression, power and exhaust.
Specifically speaking, during air intake, engine
inhales fresh air continuously until the piston
approaches the bottom dead center (BDC),
marking the end of intake. Then, the compression
stroke begins as the piston starts moving upwards,
Fig. 2-3 Schematic diagram of diesel during which the fresh air is compressed by the
engine structure
piston and its temperature rises. When the piston
2
approaches TDC, the diesel is atomized and then

injected into combustion chamber via injector,
where it is mixed with high temperature gas (i.e.
gas mixture is formed) and combusts automatically
and quickly. When the pressure generated from
self-combustion forces the piston to move
downwards, the power stroke begins, which will be
ended as the piston gets close to BDC. Following
this, the exhaust stoke starts as the piston moves
upwards by the force of inertia, and when it
approaches TDC, all remaining waste gas resulted
from mixture combustion is discharged, marking
the end of exhaust stroke.
That’s the whole working circle of the diesel
engine.
216 Engine Block Assembly
Engine block assembly mainly consists of engine

block, cylinder cover, cylinder cover shield,
cylinder gasket, main bearing cap and oil sump.
Engine block assembly is the support of engine, on
which the crank & connecting rod mechanism,
valve train, and main parts of each engine system
are installed.
Fig. 2-4 Engine block assembly

1 Cylinder cover shield
2 Cylinder cover 3 Cylinder gasket
4 Engine block 5 Oil sump
3
Engine block
The block, a casting that connects cylinder block
and crankcase, is usually casted by high strength
grey cast iron or aluminum alloy. Its construction
structure is related to cylinder arrangement,
Inline V type Boxer type cylinder structure and crankcase structure (the
Fig. 2-5 Arrangement of cylinders
cylinder arrangement types include inline (applied
for this engine), V-type and boxer type).
Cylinder cover
Cylinder cover is used to seal the top of the
cylinder and integrated with the piston crown and
the cylinder wall to form a combustion chamber.
Besides, cylinder cover, along with the water/fuel
passages in block and sump, is an integral part of
the cooling system and the lubrication system
Fig. 2-6 Cylinder cover respectively.
Cylinder gasket
Cylinder gasket acts as a seal between the top of
engine block and the bottom of cylinder cover,
which can ensure air tightness of cylinder and
avoid leakage of coolant/oil from the engine block
to the cylinder cover.
Cylinder gasket is subject to the pressure produced
from tightening of cylinder cover bolt, high
Fig. 2-7 Cylinder gasket
temperature/pressure of gas combustion in the
cylinder, and corrosion of oil/coolant.
4
217 Crank-Link Mechanism
Crank-link mechanism consists of components of

piston assembly, connecting rod assembly, and
crankshaft & flywheel assembly.
Functions: Transform the reciprocating movement
of piston into rotating movement of crankshaft, and
convert the force upon piston into the torque to be
Fig. 2-8 Crank-link mechanism output by crankshaft.
Crankshaft assembly
Crankshaft is used to convert the forces from
piston and connecting rod into torques, so as to
drive transmission system of vehicle, engine valve
train, and other auxiliary devices.
Fig. 2-9 Crankshaft assembly

1 Timing gear
2 Elastic cylindrical pin
3 Crankshaft
Flywheel assembly
The flywheel is a large disc-shape part with great
rotational inertia and functions as an energy
accumulator. The energy received by crankshaft
from engine in power stroke, except for the
purpose of external output, will be absorbed by the
flywheel, preventing the rotational speed from
rising too much. In intake, exhaust and
compression strokes, the flywheel will release the
Fig. 2-10 Flywheel assembly energy stored to compensate the power consumed
1 Gear ring 2 Flywheel therein, preventing the crankshaft rotational speed
3 Flywheel connecting ring
from decreasing too much.
5
Piston assembly
Piston is mainly used to bear the pressure from gas
combustion and then transfer it to the connecting
rod to drive the crankshaft.
There are three rings on the piston, i.e. trapezoidal
cross-section ring as the first, cone-shape ring as
the second (with the side with "TOP" mark
upwards), and the fuel ring with coil-spring as the
third. During installation, those three rings should
be staggered with 120ºapart, and the opening of
the first ring should be at 30ºor more to the piston
pin edge.
Structure and materials of piston:
Fig. 2-11 Piston assembly
1 Trapezoidal cross-section ring 1) The piston should not only have sufficient
2 Cone-shape ring rigidity/strength together with minimum
3 Trapezoidal steel fuel ring weight and suitable wall thickness, but also be
4 Piston
5 Piston pin shaped properly. The piston skirt should be
6 Elastic collar properly shaped to obtain the best fit
7 Connecting rod body clearance.
2) The piston should features small heating area
and good heat dissipation effect. The piston in
high-duty engine shall be cooled.
3) Piston shall be made of materials with small
thermal coefficient of expansion, good
heat-conducting property, small specific
gravity, good antifriction, and high thermal
intensity.
Connecting rod assembly
Connecting rod is used to transfer the pressure
upon piston to crankshaft, and transform the
Fig. 2-12 Connecting rod assembly
reciprocating movement of the piston into the
1 Connecting rod body
2 Connecting rod bush rotating movement of the crankshaft.
3 Elastic cylindrical pin Saw tooth is used to locate, 45° oblique cuts are
4 Connecting rod cap
marked in pairs.
5 Connecting rod bolt
6
218 Valve Mechanism

Valve assembly All the four-stroke engines are provided with a
Valve transmission
valve train consisting of valve assembly and valve
drive assembly.
assembly
Function: Open/close the intake/exhaust valves of
each cylinder regularly as per the working order
and working circle of engine, so as to allow fresh
air into the cylinder and exhaust waste gas out of it.
Components of valve mechanism
Fig. 2-13 Valve mechanism
219 Engine Technical Parameters
Table 2-1
Items Parameters Items Parameters
Model WD10G220E21 Number of cylinders 6
Type Supercharge Cylinder diameter/stroke (mm) 126/130mm
Min. fuel consumption

Rated power (kW) 162 215
(g/kWh)
Rated speed (r/min) 2200 Max. torque (Nm) 860
Displacement (ml) 9726 Emission standard China II
7
22 Lubrication System
Fig. 2-14 Route diagram of force-feed lubrication

Lubrication system consists of strainer, engine oil
pump, oil cooler, oil filter, pressure limiting valve,
etc. It is used for antifriction, washing, cooling and
rust prevention. The oil should be selected
according to the related company standards.
Multigrade oil is better for cold startup and should
be preferred consequently. The circulating route of
the lubrication system is as shown in Fig. 2-14.
Oil cooler and filter are connected to the filter seat
in parallel. Oil from the filter seat flows to the oil
cooler and the oil filter in sequence, back to the
filter seat again, and to the main oil passage finally.
Oil cooler is of plate-pin type. Oil filter is of
spin-on type and can only be used once. In the
lubrication system, pressure lubrication is provided
for main bearing, connecting rod bearing, cam
bearing, rocker arm bearing, intermediate gear
bearing, injection pump, turbocharger and air
compressor; while splashing lubrication is applied
for connecting rod small end, gear train, piston and
cylinder sleeve.
8
23 Fuel Supply System
Injector
Fuel
injection
pump
Fuel
fine
Fuel
filter
dilivery
pump
Oil-water
separator
Fuel tank
Fig. 2-15 Fuel system
Fuel supply system includes: fuel delivery pump,

fuel filler, injectors, and injection pump, etc.
231 Fuel Inlet Circuit
Firstly, the fuel pump pumps fuel from fuel tank to

fuel injection pump through inlet pipe of the
injection pump. Some of the fuel enters into
injection circuit, namely, injector–combustion
chamber, most of the fuel goes into the oil return
chamber in cylinder block via injection pump to
form fuel return circuit, stabilized pressure in low
pressure circuit is vitally important for engine
power output. If the situation of under-capacity of
9
engine occurs, check the fuel pressure first.

The fuel control valve is used to control oil
pressure in low pressure circuit. The major cause to
oil leak (cavitation) of injector is insufficient
pressure of low pressure circuit, so ensure the
cleanness of fuel filter and replace it if necessary.
232 High Pressure Circuit
The fuel in injection pump enters into the injector

via a short high pressure oil pipe, injector begins to
work to inject fuel into the combustion chamber.
233 Fuel Return
Due to the oil supply rate of fuel pump is more

than ten times larger than the capacity of injector, a
lot of excess fuel will return back to fuel tank via
the pressure control valve, leaked fuel from
injector during working gap returns to fuel tank too,
which has the effect of cooling the combustion.
Moreover, air in oil line can be bleed out under the
action of large amount of return fuel, self-bleeding
function is available.
10
24 Cooling System
The water pump intakes low temperature water

from an attached radiator through the thermostat,
the cooling water flows through engine oil radiator,
then enters into the water jacket in the cylinder
block to cool the cylinder sleeve, then the water
enters into water jacket of cylinder cover through
water channel, finally returns to the radiator.
Fan heater Fan heater
Thermostat
Water outlet pipe
Fan
Engine oil cooler

Radiator
Air compressor
Cylinder cover
Water
pump
Diesel engine block
Fig. 2-16 Cooling system
241 Function of Cooling System
When the engine is running, a large amount of heat

is generated by fuel combustion and friction
between moving parts, some parts are subjected to
strong heat, especially the parts exposed to burning
gas directly, without proper cooling, the normal
working of engine cannot be guaranteed. The
purpose of cooling system is to keep the engine
working under proper temperature.
11
WD10G220E21 is water cooling engine. Water is

the direct heat-transfer medium, then the heat is
passed down to air. That is, using a small amount
of water in engine water jacket to absorb excess
heat, in a continuously circulating way, and then
dissipate the heat in the radiator. Because of the
temperature difference between inlet and outlet of
water jacket is small, so the bottom of cylinder
wouldn’t be undercooled, besides, the cooling
intensity can be easily adjusted to keep the engine
working under normal temperature. In winter, hot
water can be used to preheat the engine.
242 Thermostat
The function of thermostat is to change the

circulating intensity (route and flow) along with
engine load and water temperature. Meanwhile, it
is also used to shorten the engine warm-up time, to
reduce fuel consumption and abrasion between
parts.
12
25 Intake and Exhaust System
251 Intake System

Compressed air
Engine Turbocharger
cylinder lubricating oil
inlet
Turbine
Compressor wheel
Air intake Exhaust
Compressor
impeller
Deflation
Lubricating oil outlet valve
Fig. 2-17 Intake and exhaust system

Air is absorbed in through air filter, and then flows
into turbocharger. After the air outflows from
turbocharger, the condensed air finally arrives at
the cylinder through the inlet manifold and intake
valve, mixes up with the fuel and burns.
252 Exhaust System
Firstly, the exhaust gas flows into the silencer

through turbocharger, discharge into the
environment through exhaust pipe at last.
13
253 Turbocharger
The turbocharger is driven by exhaust gas, the

exhaust gas flows through the turbine casing on its
way to DPF module.
Exhaust airflow drives the turbine rotor in the
turbine casing. The compressor rotor and turbine
rotor locate on the same shaft, the former located in
the housing that connected between air filter and
intake manifold.
When compressor rotor rotates, it will absorb air
from the air filter. The turbocharger is equipped
Fig. 2-18 Turbocharger
with an exhaust by-pass valve. The exhaust by-pass
valve is controlled by pressurized air, to allow a
small amount of exhaust gas bypass turbine rotor
under high engine speed (high pressurized air
pressure).
14
Preparation
Drain coolant and engine oil
Starter wiring harness Engine hood
261 Disassembly of Engine
A/C compressor wiring harness Remove radiator

Generator wiring harness Engine wiring harnesses
Sensor wiring harnesses Fuel absorption pipe
Fuel return pipe
engine needs to be replaced, examined or repaired.
Engine assembly
15
Fan heater water inlet and
return pipes
26 Disassembly and Assembly of Engine
A/C compressor pipes

Intake and exhaust pipes
Water inlet and return pipes
Air filter
Accelerator wire, flameout wire

Fan heater water valves
Water temperature sensor Air compressor pipes
Accessories
These following steps could be referred to disassemble the engine from the machine when the
1. Start the machine and drive it to the

maintenance position. Keep the bucket flat on
ground. Press the parking brake switch on the
operation box. Turn the key of the electrical
lock to shut down the engine, turn off the
electrical power of the whole machine 5min
later. Wedge the front and rear tires with wood
blocks.
1 2 ★ Do the following operations after the
Fig. 2-19
loader cools down. During the processes of
1 Wood block 2 Tire
disassembly, all the pipeline joints should
be wrapped up to avoid intrusion of
foreign matters.
2. Open the oil drain plug on engine sump and
drain the engine oil, contain them with a clean
vessel.
Engine oil
1 2
Fig. 2-20
1 Oil drain plug 2 Engine
3. Remove the engine hood. Refer to 8 Cab &

Covering Parts System for disassembly of
engine hood.
1
Fig. 2-21
1 Engine hood
16
4. Remove the radiator.

Refer to Disassembly of Radiator in this
chapter.
1
Fig. 2-22
1 Radiator
5. Remove the hydraulic oil tank.

Refer to 9 Working Hydraulic System for
disassembly of hydraulic oil tank.
1
Fig. 2-23
1 Hydraulic oil tank
6. Disconnect starter wiring harness.

★ ATTENTION
Don’t damage the wiring harness connector.
1
Fig. 2-24
1 Starter power wiring harness
17
7. Remove the electric generator wiring harness.
1 2
Fig. 2-25
1 Electric generator wiring harness
2 Electric generator
8. Disconnect the wiring harness between engine

and rear frame.
1
Fig. 2-26
1 Wiring harness
9. Disconnect engine oil pressure sensor wiring

harness.
1
Fig. 2-27
1 Engine oil pressure sensor
18
1 10. Remove the fixing bolts of compressor.
Fig. 2-28
1 Nut
11. Disconnect engine fuel absorption pipe and

fuel return pipe.
Oil may drop, protect the oil port to avoid
contamination.
1 2
Fig. 2-29
1 Fuel absorption connector
2 Fuel return pipe connector
12. Disconnect the fan heater rubber pipe.

★ Protect the pipe joint to prevent intrusion
of foreign matters.
1
Fig. 2-30
1 Rubber pipe
19
13. Disconnect the fan heater rubber pipe.

★ Protect the pipe joint to prevent intrusion
of foreign matters.
1
Fig. 2-31
1 Rubber pipe
14. Remove the clamp and disconnect the

connection between water inlet pipe of radiator
and engine.
1 2 3
Fig 2-32
1 Clamp 2 Water inlet pipe
3 Radiator
15. Disconnect radiator water return pipe from

engine.
1
Fig 2-33
1 Radiator water return pipe
20
16. Hang the engine with a lifting rope, remove

torque converter cover plate, remove the
connecting bolts between flywheel disc and
torque converter intermediate ring, remove the
connecting bolts and gaskets between flywheel
housing and torque converter.
1 2
Fig. 2-34
1 Connecting nut of torque converter
2 Connecting bolt of transmission box
17. Remove the accelerator wire.
1
Fig. 2-35
1 Accelerator wire
18. Remove the flameout wire.
1
Fig. 2-36
1 Flameout wire
21
19. Remove the air compressor pipe.
1
Fig. 2-37
1 Air compressor pipe
20. Remove the fixing bolts of engine support.
1
Fig. 2-38
1 Fixing bolt of engine support
21. Lift the engine and put it on proper place.

★ ATTENTION
Ensure all connecting parts are removed from
the engine, and no interference involved during
lifting. No one is allowed to stand under the
engine during the lifting.
1
Fig. 2-39
1 Engine
22
22. Disassembly of engine accessories

1 Disassembly of air filter
a) Remove the clamps, disconnect the
connection between the rubber hose and air
filter.
1 2
Fig. 2-40
1 Clamp 2 Clamp
b) Remove the fixing bolts of air filter and

take down the filter.
1 2
Fig. 2-41
1 Air filter fixing bolt
2 Air filter
2 Disassembly of fan heater water

inlet/return pipe.
a) Remove the water valve.
1
Fig. 2-42
1 Water valve
23
b) Remove the water valve.
1
Fig. 2-43
1 Water valve
c) Remove water temperature sensor.
1
Fig. 2-44
1 Water temperature sensor
24
Double end studs
Hang the engine
Starter wiring harness Speed changer-torque
A/C compressor wiring converter assembly
harness Engine support
262 Assembly of Engine
Engine wiring harnesses

Generator wiring harness
Fuel absorption pipe
Sensor wiring harnesses Fuel return pipe
Fan heater water inlet and
Refer to the following steps to recover the engine.
return pipes Engine assembly
25
A/C compressor pipes
Intake and exhaust pipes
Water inlet and return
pipes
Hydraulic oil tank
Air filter
Engine hood
Fan heater water valves
Accessories
Water temperature sensor Fill antifreeze
Fill engine oil
1. Hang up the engine and put it on the frame

properly so as to assemble the speed
changer-torque converter assembly.
★ Nobody is allowed to stand under engine
during the lifting.
1
Fig. 2-45
1 Engine
2. Connect speed changer-torque converter

assembly and engine.
1) Apply a layer of sealant on the end face of
engine. Remove the top cover plate of the
speed changer-torque converter assembly.
Connect the torque converter to the engine
with bolts and gaskets.
45±5Nm
1 2 2) Connect the flywheel to speed changer-torque

Fig. 2-46 converter assembly with nuts.
1 Connecting nut of torque converter
2 Connecting bolt of transmission box ★ Tighten the connecting bolts in
round-group way. Avoid debris entering
into the torque converter when connecting
the intermediate ring.
3. Install the top cover plate of torque converter.
After checking, assemble the top cover plate
and tighten it.
20-60Nm
1 2 3 4
Fig. 2-47
1 Flywheel housing
2 Cover plate 3 Cover plate bolt
4 Speed changer-torque converter assembly
26
4. Install and tighten the connecting bolts of

engine support.
120~200Nm
1
Fig. 2-48
1 Fixing bolt of engine support
5. Connect the starter power wiring harness.
1
Fig. 2-49
1 Starter power wiring harness
6. Connect generator wiring harness.
1 2
Fig. 2-50
1 Electric generator wiring harness
2 Electric generator
27
7. Connect the wiring harness between engine

and rear frame.
1
Fig. 2-51
1 Wiring harness
8. Connect engine oil pressure sensor.
1
Fig. 2-52
1 Engine oil pressure sensor
9. Connect engine fuel absorption pipe and return

pipe.
20~60Nm
1 2
Fig. 2-53
1 Fuel absorption connector
2 Fuel return pipe connector
28
10. Connect fan heater rubber pipe.

★ Fasten the clamp slowly until the rubber
hose is slightly deformed.
1
Fig. 2-54
1 Rubber pipe
11. Connect fan heater rubber pipe.
1
Fig. 2-55
1 Rubber pipe
1
12. Install the air compressor.
Fig. 2-56
1 Nut
29
13. Install the accelerator wire.
1
Fig. 2-57
1 Accelerator wire
14. Install the flameout wire.
1
Fig. 2-58
1 Flameout wire
15. Install the air compressor pipe.
1
Fig. 2-59
1 Air compressor pipe
30
16. Install radiator water inlet pipe.

1 2 3
Fig 2-60
1 Clamp 2 Water inlet pipe
3 Radiator
17. Connect radiator water return pipe.

1
Fig 2-61
1 Radiator water return pipe
18. Install hydraulic oil tank.

Refer to 9 Working Hydraulic System for
assembly of hydraulic oil tank.
1
Fig. 2-62
1 Hydraulic oil tank
31
19. Install engine hood.

Refer to 8 Cab & Covering Parts System for
assembly of engine hood.
1
Fig. 2-63
1 Engine hood
20. Install the radiator.

Refer to this chapter for assembly of radiator.
1
Fig. 2-64
1 Radiator
1 2 21. Fill coolant.

Coolant
Refer to 1 Repair & Maintenance for
selection of oil.
Fig. 2-65
1 Radiator
2 Coolant filling port
32
22. Fill engine oil.

Engine Oil
★ ATTENTION
Open the left side door of the engine hood and
fill prescribed engine oil from the engine oil
filling port. Run the engine at idle speed to
check whether the oil filter and oil drain plug
1 are leaky. Wait for 15 minutes after the engine
Fig. 2-66 flameout to let the oil flow back to the oil sump,
1 Engine oil filling port
and check the engine oil level again.
23. Assemble engine accessories.

1) Install the water valve of fan heater on
engine.
★ ATTENTION: Coat the water
valve with sealant start from the
second thread for about 3~5 threads.
AT545 sealant
1
Fig. 2-67
1 Water valve
2) Install the air filter.

a) Fix the air filter on engine.
1 2
Fig. 2-68
1 Air filter fixing bolt
2 Air filter
33
b) Fasten the rubber hose and with clamps.
1 2
Fig. 2-69
1 Clamp 2 Clamp
34
27 Disassembly and Assembly of

Fuel Tank
271 Disassembly of Fuel Tank
1. Start the machine and park it on level

capacious ground. Lower the bucket and flat it
on ground. Pull up the parking brake and
wedge the front and rear tires with wood
blocks, turn of main power 5min later.
★ ATTENTION: Do the disassembly
after the loader is cooled.
1 2
Fig. 2-70
1 Tire 2 Wood block
2. Loosen the screw plug on the bottom of fuel
tank and drain the fuel. Contain the fuel with
clean vessel and covers it to avoid falling
sundries.
★ ATTENTION: Fuel oil is inflammable.
In the processes of maintaining, the fire is
forbidden and the place should be far away
from fire. At the same time, prevent the
1 2 generation of fire, for example: Bumping
Fig. 2-71
brings spark.
1 Drain plug 2 Fuel Tank
3. Disconnect fuel level sensor connector.
1
Fig. 2-72
1 Fuel level sensor connector
35
4. Remove the hollow bolt and take down the

pipe from fuel tank.
1 2
Fig. 2-73
1 Fuel tank
2 Fuel absorption pipe
5. Remove the bolts and disconnect the fuel

return pipe from fuel tank.
1
Fig. 2-74
1 Fuel return pipe
6. Hang the fuel tank, remove the fastening bolts

to disconnect the connection between fuel tank
and rear frame.
7. Lift down the fuel tank.
★ ATTENTION
the tank, and no interference involved during
lifting.
1
Fig. 2-75
1 Fastening bolt
36
1
Fig. 2-76
1 Fastening bolt
272 Assembly of Fuel Tank
1. Lift and assemble the fuel tank.

Clean the fuel tank. Lift the fuel tank assembly
to rear-bottom site of the rear frame.
2. Fix the fuel tank on rear frame with bolts.
1
Fig. 2-77
1 Fastening bolt
1
Fig. 2-78
1 Fastening bolt
37
3. Connect engine fuel return pipe and tighten it.
1
Fig. 2-79
1 Fuel return pipe
4. Connect fuel absorption pipe to the tank.
1 2
Fig. 2-80
1 Fuel tank
2 Fuel absorption pipe
5. Install the fuel level sensor.
1
Fig. 2-81
1 Fuel level sensor connector
38
6. Fill fuel.
Fuel 90L
Keep away from open flame when filling.
1
Fig. 2-82
1 Fuel filling port 2 Fuel tank
39
28 Disassembly and Assembly of

Radiator
281 Disassembly of Radiator
1. Open the drain valve on the bottom of radiator.

Drain out the coolant and contain them with
clean vessel.
Coolant (antifreeze)
1
Fig. 2-83
1 Water drain valve
2. Hang the engine hood up.
Refer to 8 Cab & Covering Parts System for
disassembly of engine hood.
1
Fig. 2-84
1 Engine hood
3. Remove fan protecting wire net.
1 2
Fig. 2-85
1 Fan protecting wire net 2 Bolt
40
4. Disconnect the transmission oil hose from

radiator and disconnect the thermo switch
wiring harness as well.
1 2
Fig. 2-86
1 Transmission oil hose
2 Thermo switch
5. Disconnect the hydraulic oil inlet pipe from

radiator.
1
Fig. 2-87
1 Hydraulic oil inlet pipe
6. Disconnect the hydraulic oil return pipe from

radiator.
1
Fig. 2-88
1 Hydraulic oil return pipe
41
7. Disconnect the water inlet pipe from radiator.
1 2 3
Fig. 2-89
1 Clamp 2 Radiator water inlet pipe
3 Radiator
8. Disconnect the radiator water outlet pipe.
1
Fig. 2-90
1 Radiator water outlet pipe
9. Remove the fixing bolts.
1 2
Fig. 2-91
1 Radiator 2 Fixing bolt
42
10. Lift the radiator down.

★ ATTENTION
the radiator, and no interference involved
during lifting. No one is allowed to stand under
radiator during the lifting.
1
Fig. 2-92
1 Radiator
282 Assembly of Radiator
1. Clean the radiator, lift it up and place it on rear

frame for assembling.
1
Fig. 2-93
1 Radiator
2. Pre-tighten radiator fixing bolts.
1 2
Fig. 2-94
43
3. Install fan protecting wire net.
1 2
Fig. 2-95
1 Fan protecting wire net 2 Bolt
4. Connect the radiator water outlet pipe.

1
Fig. 2-96
1 Radiator water outlet pipe
5. Connect radiator and water inlet pipe.

★ Fasten slowly until the rubber hose is
slightly deformed.
1 2 3
Fig. 2-97
1 Clamp 2 Radiator water inlet pipe
3 Radiator
44
6. Connect the transmission oil hose to radiator

and connect the thermo switch wiring harness
as well.
1 2
Fig. 2-98
1 Transmission oil hose
2 Thermo switch
7. Connect hydraulic oil inlet pipe to radiator.
1
Fig. 2-99
1 Hydraulic oil inlet pipe
8. Connect the hydraulic oil return pipe.
1
Fig. 2-100
1 Hydraulic oil return pipe
45
9. Tighten the fixing bolts.
1 2
Fig. 2-101
10. Assemble the engine hood.

Refer to 8 Cab & Covering Part System for
assembly of engine hood.
1
Fig. 2-102
1 Engine hood
46
29 Diagnosis and Troubleshooting of Engine Common Problems
291 Engine Fails to Start

 Caused by starting system
1 Power shortage of storage battery.
Solution: Check the battery carefully, recharge or replace it.
2 Damaged starting motor.
Solution: Repair or replace the motor.
 Caused by oil supply system
1 There is air in the oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
2 Blockage of oil system.
Solution: Unchoke the oil circuit (such as blow with high pressure air), tighten all joints and
discharge air.
3 The diesel filter element is particularly dirty.
Solution: Replace the filter element.
4 Serious wear damage of plunger/delivery valve.
Solution: Repair the fuel supply pump professionally.
5 Damaged low pressure fuel supply pump.
Solution: Replace the fuel supply pump.
 Adjustment factors
1 Dislocated of fuel injection advance angle.
Solution: Adjust the fuel injection advance angle.
2 Change of valve clearance.
Solution: Check and adjust valve clearance.
3 Oil shortage when starting
Solution: Check the fuel injection pump professionally.
292 Engine Power is not Sufficient

1 Blockage of fuel filter or fuel supply pump oil inlet pipe connector filter screen.
Solution: Clean or replace it/them.
2 Low injection pressure or bad atomization.
Solution: Troubleshoot the injector or replace inject nozzle matching parts.
3 Serious wear damage of precise inject nozzle matching parts.
47
Solution: Regulate oil supply or troubleshoot plunger and barrel assembly.

4 Air infiltrate into the fuel system.
Solution: Discharge air of the fuel system.
5 Incorrect fuel injection advance angle.
Solution: Adjust the angle according provisions.
6 Nonuniform oil supply of each cylinder.
Solution: Adjust oil supply.
7 Blockage of air filter.
Solution: Clean or replace the filter element.
293 Exhaust Exceptions (Black Smoke, White Smoke, Blue Smoke)

 The engine gives off blue smoke
1 High engine oil level of engine pan.
Solution: Drain redundant engine oil, and make sure the oil level is within specified range.
2 Diesel flows into oil pan due to oil-fuel injector needle-valve untightly closed or stucked in
open position.
Solution: Clean and adjust the injector or replace the needle valve matching parts.
3 Damaged fuel supply pump plunger bushing sealing ring (P pump), or bad sealing between
plunger bushing and pump body, the fuel flows into oil pan along engine oil passage.
Solution: Replace the sealing ring.
4 Damaged valve oil seal or excessive clearance between the valve and tube.
Solution: Replace all faulted valves, pipes and oil seal (the oil seal must be replaced once being
disassembled; if the clearance meets the requirements after the valve is replaced, you can spare
the tube).
5 Damaged sealing ring of turbocharger, engine oil burns after enters into the combustion
chamber along air inlet passage.
Solution: Repair or replace.
 The engine gives off white smoke
1 There is moisture in the fuel system.
Solution: Clean the fuel tank and filter, and use qualified diesel oil.
2 Abrasion of cylinder valve.
Solution: Replace it.
3 Bad atomization of injected fuel, the fuel fails to burn in the combustion champ.
Solution: Adjust the injector and fuel supply advance angle.
 The engine gives off black smoke
48
1 Exhaust back pressure is too high or exhaust pipeline is blocked.

Solution: Reduce bend positions of pipeline; dust out the silencer.
2 The injection lags
Solution: Adjust fuel injection advance angle.
3 The injector doesn’t work normal or being damaged.
Solution: Dismantle, clean and check.
4 Poor quality of diesel or wrong brand.
Solution: Replace the diesel.
5 Severe wear of cylinder sleeve and piston group.
Solution: Replace worn parts
294 Engine Oil Pressure is too High or Too Low

 Engine oil pressure is too high
1 Malfunctioned engine oil display device.
Solution: Replace the display device.
2 High viscosity of engine oil
Solution: Choose specified brand engine oil, and take preheating action when starting the
machine in winter.
3 Too little gap in force-feed lubricating positions or blocked engine oil filter.
Solution: Adjust the gap, clean or replace the filter.
4 Misadjusted pressure restrict valve.
Solution: Readjust the spring force of the valve, so the engine oil pressure can drop to specified
value.
 Engine oil pressure is too low
1 Abrasions of engine oil pump or damaged sealing gasket.
Solution: Repair the pump and replace the gasket.
2 The absorbed oil reduces
Solution: Check oil capacity, add engine oil and clean the absorption filter.
3 Large engine oil leakage.
Solution: Check whether the lubricating pipe is broken; check and adjust the fitting clearance of
bearings in crankshaft and camshaft as required.
4 Blockage of engine oil filter or cooler.
Solution: Check and clean engine oil filter and cooler.
5 Low viscosity of engine oil
Solution: Choose specified brand engine oil.
49
6 Misadjusted pressure restrict valve.

Solution: Clean the valve; readjust or replace the spring.
7 Low displaced engine oil pressure.
Solution: Check and replace engine oil pressure sensor and pressure gauge.
295 Large Consumption of Engine Oil

1 Improper engine oil viscosity.
Solution: Choose proper engine oil.
2 High negative pressure in combustion chamber, result in engine oil spraying up to the chamber.
Solution: Examine the reason for high negative pressure and fix it.
3 Change of rotating speed and operating mode.
Solution: Test showed that with the increase of rotating speed, engine oil consumption rises
obviously, operate the engine according to the rules.
296 High Coolant Temperature

1 Improper selection of coolant or shortage of cooling water.
Solution: Choose suitable coolant and add to specified level.
2 Blockage of water radiator.
Solution: Put the radiating fins back to their original positions with stalloy carefully, after they
return to flat shape, clean them with compressed air or water gun.
3 Wrong indication of water thermometer or warning light.
Solution: Use the water thermometer to measure the temperature of water temperature sensor
area, see whether the measured temperature is consistent with actual value.
4 Low rotating speed of fan, the blades are deformed or installed backwards.
Solution: Loosened rubber belt will lead to slipping, which result in low rotating speed of fan.
Adjust the belt if necessary; if the rubber layer aged, damaged or fractured, replace it. If the
blades are deformed, replace them.
5 Malfunction of cooling-water pump.
Solution: Replace the pump.
6 Malfunction of thermostat.
Solution: Replace the thermostat.
7 Damaged cylinder cover gaskets.
Solution: Replace them.
8 Overloaded operation of diesel engine.
Solution: Lower the load of engine.
50

2 Engine System WEICHAIT2

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Service Manual for LG959 Wheel Loader

282 Assembly of Radiator ................................................................................ 2-43

211 Engine Description

LG959 wheel loader is equipped with Weichai

Fig. 2-1 Engine

212 Engine Identification

The serial number is printed on nameplate, which is

213 Product Model Composition and

214 Cylinder Number

The cylinders are numbered sequentially. Ignition

Fig. 2-2 Cylinder No. 215 Engine Working Principle

The diesel engine is designed with four strokes,

approaches TDC, the diesel is atomized and then

216 Engine Block Assembly

Engine block assembly mainly consists of engine

Fig. 2-4 Engine block assembly

217 Crank-Link Mechanism

Crank-link mechanism consists of components of

Fig. 2-9 Crankshaft assembly

218 Valve Mechanism

Components of valve mechanism

Fig. 2-13 Valve mechanism

219 Engine Technical Parameters

Type Supercharge Cylinder diameter/stroke (mm) 126/130mm

Min. fuel consumption

Rated speed (r/min) 2200 Max. torque (Nm) 860

Displacement (ml) 9726 Emission standard China II

Fig. 2-14 Route diagram of force-feed lubrication

23 Fuel Supply System

Fuel supply system includes: fuel delivery pump,

231 Fuel Inlet Circuit

Firstly, the fuel pump pumps fuel from fuel tank to

engine occurs, check the fuel pressure first.

232 High Pressure Circuit

The fuel in injection pump enters into the injector

233 Fuel Return

Due to the oil supply rate of fuel pump is more

The water pump intakes low temperature water

Fan heater Fan heater

Engine oil cooler

Fig. 2-16 Cooling system

241 Function of Cooling System

When the engine is running, a large amount of heat

WD10G220E21 is water cooling engine. Water is

The function of thermostat is to change the

25 Intake and Exhaust System

251 Intake System

Air intake Exhaust

Fig. 2-17 Intake and exhaust system

252 Exhaust System

Firstly, the exhaust gas flows into the silencer

The turbocharger is driven by exhaust gas, the

A/C compressor wiring harness Remove radiator

A/C compressor pipes

Accelerator wire, flameout wire

1. Start the machine and drive it to the

3. Remove the engine hood. Refer to 8 Cab &

4. Remove the radiator.

5. Remove the hydraulic oil tank.

6. Disconnect starter wiring harness.

7. Remove the electric generator wiring harness.

8. Disconnect the wiring harness between engine

9. Disconnect engine oil pressure sensor wiring