WEICHAI WD10 User manual

Service Manual for WD10 Diesel Engine
CONTENTS
1Usage Instructions for Diesel Engine.....................................................................1
11 External View of Diesel Engine.............................................................................1
12 Diesel Engine Model Composition and Significance.............................................3
13 Diesel Engine Main Technical Parameters.............................................................3
14 Unseal of Diesel engine..........................................................................................5
15 Lifting of Diesel Engine .........................................................................................6
16 Installation of Engine..............................................................................................6
17 Preparation before Starting Engine.........................................................................6
18 Start the Engine.......................................................................................................7
19 Run the Engine .......................................................................................................7
2Maintenance Guidelines for Diesel Engine............................................................9
21 Fuel Oil, Engine oil, Coolant and Auxiliary Materials ..........................................9
211 Fuel Oil...........................................................................................................9
212 Engine Oil.......................................................................................................9
213 Lubrication of Tensioning Wheel.................................................................10
214 Antifreeze Additive in Engine Cooling System...........................................10
215 Auxiliary Materials.......................................................................................11
22 Daily Maintenance................................................................................................12
221 Check Coolant Level and Temperature........................................................12
222 Check Engine Oil Level ...............................................................................13
223 Check Fuel Level..........................................................................................14
224 Check “Three Leakages” ..............................................................................14
225 Check Fan.....................................................................................................14
226 Check Belt ....................................................................................................14
227 Check Whether Exhaust Gas Color is Normal.............................................14
228 Check Whether Running Sound is Normal ..................................................15
229 Check Whether Rotating Speed and Vibration are Normal.........................15
23 Periodic Maintenance ...........................................................................................15
24 Maintenance for Long-Term Storage...................................................................20
241 Cleaning........................................................................................................20
242 Protection......................................................................................................20

Service Manual for WD10 Diesel Engine
3Diagnosis and Troubleshooting of Diesel Engine Common Faults.....................21
31 Diagnostic Methods..............................................................................................21
32 Fault Causes and Elimination Methods................................................................22
321 Diesel Engine Couldn’t Be Started ..............................................................22
322 Diesel Engine Stops Soon after Starting ......................................................23
323 Underpower..................................................................................................23
324 Large Fuel Consumption..............................................................................24
325 Engine Gives off Black Smoke ....................................................................25
326 Engine Gives off White and Blue Smoke ....................................................25
327 Turbocharger Intake Port and Intake Pipe Are Accumulated with Engine Oil
…………………………………………………………………………...26
328 Unstable Engine Speed.................................................................................26
329 Low Engine Oil Pressure..............................................................................26
3210High Cooling Water Temperature ..............................................................27
3211 Rapid Wear of Parts....................................................................................27
3212Excessive Noise..........................................................................................28
3213Starter Motor Doesn’t Work .......................................................................28
3214Underpowered Starter Motor......................................................................29
3215Generator Generates Nothing .....................................................................29
3216Generator Undercharging ...........................................................................29
3217Unstable Charging Voltage.........................................................................30
3218Generator Overcharging .............................................................................30
3219Generator Produces Abnormal Sound........................................................30
4Disassembly & Assembly of Diesel Engine.........................................................31
41 Overview...............................................................................................................31
411 Danger Signs.................................................................................................31
412 Safety Signs..................................................................................................32
413 Recommended Tools....................................................................................33
414 Notes for Health Protection..........................................................................33
415 Environmental Protection Measures ............................................................34
416 Notes for Disassembly and Assembly of Engine.........................................34
417 Explode View of the Whole Engine.............................................................35
42 Cylinder Cover Assembly ....................................................................................36
421 Disassembly and Assembly of Cylinder Cover Assembly ..........................36

Service Manual for WD10 Diesel Engine
422 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover
Shield............................................................................................................38
423 Disassembly, Inspection, Maintenance and Assembly of Water Outlet Pipe
…………………………………………………………………………...39
424 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator
…………………………………………………………………………...41
425 Disassembly, Inspection, Maintenance and Assembly of Hanger Plates.....42
426 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover..43
43 Engine Block Assembly .......................................................................................51
431 Disassembly, Inspection, Maintenance and Assembly of Engine Block
Assembly ......................................................................................................51
432 Disassembly, Inspection, Maintenance and Assembly of Engine Block
Module..........................................................................................................54
433 Disassembly, Inspection, Maintenance and Assembly of Engine Front Cover
…………………………………………………………………………...56
434 Disassembly, Inspection, Maintenance and Assembly of Gear Housing.....57
435 Disassembly, Inspection, Maintenance and Assembly of Flywheel Housing
…………………………………………………………………………...59
436 Disassembly, Inspection, Maintenance and Assembly of Oil Sump............60
437 Disassembly, Inspection, Maintenance and Assembly of Piston Nozzle.....62
438 Disassembly, Inspection, Maintenance and Assembly of Thrust Plates......63
439 Disassembly, Inspection, Maintenance and Assembly of Front and Rear Oil
Seals..............................................................................................................64
44 Crank-Rod Mechanism.........................................................................................66
441 Disassembly and Assembly of Crank-Rod Mechanism...............................66
442 Disassembly, Inspection, Maintenance and Assembly of Piston-Rod
Assembly ......................................................................................................67
443 Disassembly, Inspection, Maintenance and Assembly of Crankshaft .........70
444 Disassembly, Inspection, Maintenance and Assembly of Flywheel and Ring
Gear...............................................................................................................72
445 Disassembly, Inspection, Maintenance and Assembly of Damper and
Crankshaft Pulley..........................................................................................74
446 Disassembly, Inspection, Maintenance and Assembly of Crankshaft Bearing
Shell..............................................................................................................75
45 Valve Mechanism.................................................................................................76
451 Disassembly and Assembly of Valve Mechanism .......................................76
452 Disassembly, Inspection, Maintenance and Assembly of Camshaft............77

Service Manual for WD10 Diesel Engine
453 Disassembly, Inspection, Maintenance and Assembly of Rocker and Rocker
Shaft..............................................................................................................79
454 Disassembly, Inspection, Maintenance and Assembly of Valve Tappet and
Pushrod.........................................................................................................82
455 Disassembly, Inspection, Maintenance and Assembly of Valve .................83
456 Disassembly, Inspection, Maintenance and Assembly of Intermediate Gear
…………………………………………………………………………...85
46 Intake and Exhaust System...................................................................................87
461 Disassembly and Assembly of Intake and Exhaust System.........................87
462 Disassembly, Inspection, Maintenance and Assembly of Intake Pipe.........88
463 Disassembly, Inspection, Maintenance and Assembly of Exhaust Pipe......89
464 Disassembly, Inspection, Maintenance and Assembly of Turbocharger
System ..........................................................................................................90
47 Fuel System ..........................................................................................................93
471 Disassembly and Assembly of Fuel System ................................................93
472 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump
…………………………………………………………………………...94
473 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel
Pipes..............................................................................................................96
474 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector ......97
48 Cooling System.....................................................................................................99
481 Disassembly and Assembly of Cooling System...........................................99
482 Disassembly, Inspection, Maintenance and Assembly of Fan...................100
483 Disassembly, Inspection, Maintenance and Assembly of Water Pump.....101
484 Disassembly, Inspection, Maintenance and Assembly of Thermostat.......103
49 Lubricating System.............................................................................................105
491 Disassembly and Assembly of Lubricating System...................................105
492 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump
………………………………………………………………………….106
493 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump
Intermediate Gear...................................................................……………107
494 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Filter
………………………………………………………………………….108
495 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler
Cap..............................................................................................................109
496 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler
………………………………………………………………………….110

Service Manual for WD10 Diesel Engine
497 Disassembly, Inspection, Maintenance and Assembly of Main Oil Gallery
Pressure Limiting Valve.............................................................................111
498 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler
Bypass Valve..............................................................................................112
499 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer
………………………………………………………………………….113
410 Starting System.................................................................................................114
4101 Disassembly and Assembly of Starting System.......................................114
4102 Disassembly, Inspection, Maintenance and Assembly of Starter Motor .114
411 Engine Accessory System.................................................................................116
4111 Disassembly and Assembly of Engine Accessory System.......................116
4112 Disassembly, Inspection, Maintenance and Assembly of Generator.......122
4113 Disassembly, Inspection, Maintenance and Assembly of A/C Compressor
....................................................................................................................130
4114 Disassembly, Inspection, Maintenance and Assembly of Air Compressor
....................................................................................................................137
4115 Disassembly, Inspection, Maintenance and Assembly of Steering Pump146

Service Manual for WD10 Diesel Engine
51
43 Engine Block Assembly
431 Disassembly, Inspection, Maintenance and Assembly of Engine Block
Assembly
4311 Exploded View of Engine Block Assembly
Hexagon bolt
Rivet
Self-locking gasket
Bowl shape plug
Bowl shape plug
Hexagon socket head cap
screw
Cylindrical pin
Cylinder sleeve
Cylinder cover
auxiliary bolt
Elastic cylindrical pin
Pre-glued set screw
Engine block module
Fig. 4-19 Exploded view of engine block assembly

Service Manual for WD10 Diesel Engine
64
side with oil groove should be outward.
4384 Steps to Assemble Thrust Plates
(1) Install crankshaft;
(2) Install upper thrust plates (without lug);
(3) Install lower thrust plates (key point 1).
439 Disassembly, Inspection, Maintenance and Assembly of Front and
Rear Oil Seals
4391 Exploded View of Front and Rear Oil Seals
Rear oil seal Front oil seal
Fig. 4-31 Exploded view of front and rear oil seals
4392 Steps to Disassemble Front and Rear Oil Seals
(1) Remove gear housing (refer to section 434);
(2) Remove front oil seal (key point 1);
(3) Remove crankcase (refer to section 432);
(4) Remove rear oil seal (key point 1);
4393 Inspection and Maintenance of Front and Rear Oil Seals
Key point 1:
Assembling:
Clean up the oil seals and fitting holes before assembling, no dirt is allowed. Apply lubricating oil
on the oil seal and the dedicated press-fitting tool first, and then press-in the seal slowly with the

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77
(3) Install valve tappet and pushrod, refer to assembly of valve tappet and pushrod for details;
(4) Assemble intake and exhaust valves, refer to assembly of valves for details;
(5) Install rocker and rocker shaft, refer to assembly of rocker and rocker shaft for details;
452 Disassembly, Inspection, Maintenance and Assembly of Camshaft
4521 Exploded View of Camshaft
Locating pin
Camshaft timing gear
Hexagon screw
Thrust plate
Camshaft
Camshaft bearingshell
Hexagon bolt
Thrust plate hexagon bolt
Fig. 4-42 Exploded view of camshaft
4522 Steps to Disassemble Camshaft
(1) Rotate camshaft to check whether camshaft and timing gear are flexible and smooth;
(2) Measure camshaft axial movement with a dial gauge, compare it with required range
0.1~0.4mm;
(3) Check timing gear backlash;
(4) Rotate crankshaft until camshaft timing gear is in cylinder 1 TDC. Remove the hexagon bolts
of camshaft timing gear and take down the gear and locating pins;
(5) Remove the hexagon bolts of camshaft thrust plate, take down the plate;
(6) Take down camshaft.
4523 Inspection and Maintenance of Camshaft
(1) Check whether there is wear trace on cam working surface, check main journal for seizure and

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(10)Remove engine oil cooler bypass valve.
4913 Steps to Assemble Lubricating System
Assembling steps are contrary to disassembling ones.
492 Disassembly, Inspection, Maintenance and Assembly of Engine Oil
Pump
4921 Exploded View of Engine Oil Pump
Engine oil pump
Engine oil pump gasket
Hexagon flange bearing
surface toothed bolt
Hexagon flange bearing
surface toothed bolt
Fig. 4-66 Exploded view of engine oil pump
4922 Steps to Disassemble Engine Oil Pump
Remove the two hexagon flange bearing surface toothed bolts, take down engine oil pump and
gasket, as shown in Fig. 4-66.
4923 Inspection and Maintenance of Engine Oil Pump
(1) Check the engine oil pump for crack damage, check whether its inner cavity is smooth, replace
it if necessary.
(2) Check engine oil pump gasket for oil leakage, replace the gasket if necessary.
4924 Steps to Assemble Engine Oil Pump
(1) Check the pump and pump gasket before assembling, make sure there is no manufacturing
defect and damage.
(2) Clean up the fitting surface between oil pump and crankcase.
(3) Install engine oil pump gasket.

Service Manual for WD10 Diesel Engine
107
(4) Install engine oil pump.
(5) Install and tighten the two toothed hexagon bolts.
493 Disassembly, Inspection, Maintenance and Assembly of Engine Oil
Pump Intermediate Gear
4931 Exploded View of Engine Oil Pump Intermediate Gear
Seal ring
Hexagon bolt
Intermediate gear shaft
Engine oil pump
intermediate gear module
Fig. 4-67 Exploded view of engine oil pump intermediate gear
4932 Steps to Disassemble Engine Oil Pump Intermediate Gear
(1) Screw off the hexagon bolt;
(2) Pull out the intermediate gear shaft with dedicated tool, and then remove engine oil pump
intermediate gear module.
4933 Inspection and Maintenance of Engine Oil Pump Intermediate Gear
(1) Check whether there is crack on intermediate gear and intermediate gear shaft. Replace if
necessary.
(2) Check the seal ring for breakage and replace it if so.
4934 Steps to Assemble Engine Oil Pump Intermediate Gear
(1) Before the assembly, check engine oil pump intermediate gear module, intermediate gear shaft,
hexagon bolt and seal ring, make sure there is no manufacturing and use defect and damage.

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(2) Clean up engine oil cooler bypass valve and valve fitting hole on engine block.
(3) Install safety valve, safety valve spring and compound gasket orderly.
(4) Install the hexagon plug and tighten it.
499 Disassembly, Inspection, Maintenance and Assembly of Engine Oil
Strainer
4991 Exploded View of Engine Oil Strainer
Hexagon bolt
Engine oil stainer
Flat washer
Gasket
Fig. 4-73 Exploded view of engine oil strainer
4992 Steps to Disassemble Engine Oil Strainer
Screw off the two hexagon bolts, take down the oil strainer and gasket, as shown in Fig. 4-73.
4993 Inspection and Maintenance of Engine Oil Strainer
Check the strainer and gasket for crack damage, replace if necessary.
4994 Steps to Assemble Engine Oil Strainer
(1) Check the strainer and gasket before assembling, make sure there is no manufacturing defect
and damage.
(2) Clean up fitting surface between oil strainer and engine oil pump, clean up the strainer inner
cavity.
(3) Install the strainer and gasket.
(4) Install and tighten the hexagon bolts.

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Fig. 4-81 Assembly of A/C compressor
(2) Install A/C compressor V-belt.
(3) Adjust the location of compressor and tension the V-belt with the draw-in rod, tighten
compressor fixing bolts and nuts, as shown in Fig. 4-81.
Assembly of air compressor and its pipelines
(1) Place the O-shape seal ring in compressor ring groove. Make sure compressor main axis is
perpendicular to engine timing gear housing fitting surface, and push the compressor into the
mounting hole gently, ensure the helical gears are normally engaged and air compressor flange
face should be parallel with engine fitting surface, loose-fit the compressor with three M10
hexagon bearing surface toothed bolts, and tighten the bolts with 13mm open end wrench (or
double offset ring spanner).
(2) Install air compressor water inlet pipe, water outlet pipe, oil inlet pipe and intake pipe, fix the
pipes with clamps. As shown in Fig. 4-82.

Service Manual for WD10 Diesel Engine
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Fault 2: Low charging voltage
Phenomenon
Fault detection
Troubleshooting
Battery is
occasionally
underpowered,
low charging
voltage, and the
voltage declines
markedly once
loaded.
Check whether generator
output power is reasonably
matched with electrical
appliances.
a. Check whether
voltmeter is damaged.
b. Check generator speed.
c. Check the quality and
tensioning situation of
generator belt and
relevant pulley belts.
d. Check generator
pulley.
e. Check whether electric
wires are reasonably
connected, measure the
voltage of generator
and battery.
f. Check whether wires in
charging system are
loose, oxidized and
producing too much
heat, check whether
bolt connections are
loose.
g. Measure output voltage
of generator W/R/AC
terminal (should be
about half of B+
terminal voltage).
h. Check whether battery
charging is normal.
Measure generator B+ terminal voltage,
which should be within 27.8~28.4V, if the
voltage is normal, then it means voltmeter
failure or voltmeter sampling point is in fault,
repair or replace.
a. It is recommended the generator idling
speed should exceed 1600rpm.
b. Generator speed should be 2000rpm and
above, or the voltage should be about 27V
when high power load appliance like air
condition is working
c. Check the quality of generator belt and
relevant pulley belts, for belt involved
severe coking, breakage, deformation or
wear should be replaced.
Tension generator belt and relevant pulley
belts.
ATTENTION: If the to-be replaced belt is
in twin-drive belt system, then the belts
should be replaced together.
d. Tension it if it is loose.
e. If voltage drop is bigger than 1V in heavy
load condition (thin wire results in big
voltage drop), the wire should be replaced.
0~35A S≥6mm235~70A S≥12mm2
70~100A S≥20mm2100~150A S≥25mm2
If the wire or connector gets too hot in
heavy load condition, then the wire or
connector should be replaced.
f. Oxidized lead foot and the housing that
used to install grounding bolts should be
polished before reassembling.
Retighten the loose nuts and lug plates,
re-plug the loose connectors firmly.
ATTENTION: Reassembled or
retightened parts should be run in heavy
load and will be overheat, check whether
the overheat is still there 3~5min later.
g. If there is big difference between terminal
W/R/AC output voltage and normal range
and big voltage drop happened after the
engine loaded, then it means failure in
generator rectifier bridge or stator, repair
or replace.
h. If charging current drops to about 10A
10min later, or charging current reaches to
30-90A for a long time, then the battery is
damaged, repair or replace the battery.

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3) Check measure wear condition and fitting condition of air compressor cylinder sleeve, piston
and piston ring, severely worn parts should be replaced.
4) For compressor air cooling parts, please: Clean up accumulated oil dirt, soot and other dirty
materials on cooling fin. Check the cooling fin and should replace the damaged parts. For
compressor water cooling parts, please: Check the cooling pipe size (recommended minimum
pipe diameter is 9.5mm), Check the flow rate of air refrigerant, minimum allowed flow rate is
5L/min when the engine is running. If refrigerant flow rate is small, check whether cooling pipe
and accessories are rusted or twisted.
5) Check and ensure water temperature is under 93oC; check the air valve on gasholder and ensure
it can work normally. It is suggested to equip the machine with automatic exhaust valve and air
drier.
6) When the brake is not used, air leakage (pressure drop) should not exceed 6.9kPa/min, and
when depressing the brake, that value is 20.7kPa/min. If there is severe leakage, check the
system and remove the fault. Check whether unloading system is working and repair it.
7) Check whether oil pressure in crankcase is too high, replace or repair ventilating device of
crankcase if so. If the oil dipstick is loose or partially raised, then oil pressure in crankcase is in
problem.
8) Check engine oil pressure (air compressor oil inlet port), compare it with rated pressure.
9) Replace with qualified lubricating oil (engine oil).
Only after ruling all the causes above out should the air compressor be repaired or replaced.
(4) Air compressor produces abnormal sound.
Fault phenomenon: Metal crash, rhythmic knock or grinding squeal
Possible causes:
1) Connecting rod sleeve or bearing shells are severely worn, connecting rod bolts are loose, main
bearing shell is worn or damaged that result in crash noise.
2) The belt is too loose, driving and driven pulley groove type is not uniform, which lead to
slipping squeal.
3) No engine oil is supplied to air compressor, dry friction of metal leading to squeal.
4) Loose fixing bolts.
5) Loose gear fastening nuts results in oversized tooth space, which will bring rhythmic knock.
6) Foreign matter in piston head.
Troubleshooting:
1) Check whether connecting rod bearing shells, connecting rod sleeve and main bearing shell is

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152
surface, and push the pump (with a sealing gasket) into the mounting hole gently, ensure the
helical gears are normally engaged and steering pump flange face should be parallel with the
fitting surface, loose-fit the pump with two M10 hexagon bolts and wave spring washers, and
tighten the bolts diagonally with 16mm open end wrench (or double offset ring spanner) to
50~60Nm, make sure not to damage the sealing gasket in this process. As shown in Fig. 4-93.
(2) Two applicable connecting types of oil inlet and outlet joints: copper washer (or combination
flat gasket) and O-shape ring. Thread seal tape or thread sealant is strictly prohibited.
(3) Steering pump oil inlet and outlet joint screwing-in length should be suitable, neither too short
nor too long. Refer to Fig. 4-94 and Fig. 4-95.
Screwing-in
length is too
long, oil inlet
channel is
blocked
Screwing-in
length is
suitable
Fig. 4-94 Oil inlet joint screwing-in length is too long
Screwing-in
length is too
long, damping
hole is blocked
Screwing-in
length is
suitable
Fig. 4-95 Oil outlet joint screwing-in length is too long