Wuxi Power Engineering WD327TAD68 User manual

Landi Serial Diesel Engine
Operation and Maintenance Manual
Wuxi Power Engineering Co., Ltd

FOREWORD
Landi series diesel engines are our company’s newly-developed
diesel engines. During the process of continuous development and
improvement, domestic and overseas advanced internal combustion
engine technologies are introduced.
In order to let customers know and use Landi series diesel engines
easily, legibly and fast, the edition of this manual places emphasis on the
method on using and maintenance and main faults and remedies during
normal using. Therefore, customers must read this manual carefully
before using. Customers must also read the attachment manual:《The
operation manual for turbocharger》. In this way, the diesel engine can be
properly used and maintained. Contact special manufacturer if you want
to know detailed technical parameters, specification and structure.
We may make some necessary amendments at appropriate time
with continuous innovation of our products without impartation in
advance.

CONTENTS
Chapter One Summary.............................................................................................................. 1
1. Diesel engine introduction .................................................................................................. 1
2. Explanation of power rating .............................................................................................. 1
Chapter Two Specification and parameter .............................................................................. 2
1. Specification of diesel engine .............................................................................................. 2
2. Main technical parameters ................................................................................................. 5
Chapter Three Operation instruction ...................................................................................... 6
1. Fuel, Lubricating oil and Cooling water ........................................................................... 6
A. Selection of fuel ........................................................................................................... 6
B. Selection of lubricating oil ......................................................................................... 6
C. Selection for cooling water......................................................................................... 7
D. Grease Lubricant ........................................................................................................ 7
2. Engine starting .................................................................................................................... 8
A .preparations before starting ...................................................................................... 8
B.Starting ......................................................................................................................... 8
C.Prewarming, run-in and operation ............................................................................ 8
Chapter Four Repair and maintenance ................................................................................. 11
1. Main items of maintenance .............................................................................................. 11
A. Daily maintenance .................................................................................................... 11
B. First order maintenance ........................................................................................... 12
C. Second order maintenance ...................................................................................... 13
D. Third order maintenance ......................................................................................... 14
2. Diesel engine bolt, nut tightening torque summary ....................................................... 14
Chapter Five Fault and solution ............................................................................................. 16
1. Diesel engine can't start .................................................................................................... 16
2. Diesel engine in normal operation situation suddenly send out the power of provisions
................................................................................................................................................ 17
3、Unordinary noise ............................................................................................................. 18
4、Abnormal exhaust color ................................................................................................. 18
5、Lubricating oil pressure abnormal ................................................................................ 19
6、Lubricating oil temperature too high, oil consumption too high and dilution of
lubricating oil ........................................................................................................................ 20
7. Oil level in engine sump rises ........................................................................................... 20
8. Engine outlet water temperature too high ...................................................................... 20
9. Injection pump faults and remedies ................................................................................ 21
10. Speed control faults and remedies ................................................................................. 21
11. Injector faults and remedies ........................................................................................... 22
12. Fuel feed pump faults and remedies .............................................................................. 22
Chapter six System and adjust .............................................................................................. 23
1. Adjustment of diesel engine .............................................................................................. 23
A.Fuel supply advance Angle adjustment ................................................................... 23
B. Valve clearance adjustment and distribution timing check .................................. 24

2. Fuel、speed control system .............................................................................................. 26
3. Lubrication system ............................................................................................................ 28
4. Cooling system ................................................................................................................... 29
5. Starting system .................................................................................................................. 29
6. Inlet and exhaust system ................................................................................................... 30
7. Diesel Engine Use Characteristic ..................................................................................... 31
appendix. power correction FACTOR ..................................................................................... 32

1
Chapter One Summary
1. Diesel engine introduction
Landi series diesel engines are, four strokes, direct injection, turbocharged
intercooled and water-cooling high speed diesel engine. It can be divided into
6-cylinder in-line and 12-cylinder V-type according to the arrangement mode of
cylinders . They are widely used in the field of diesel generating sets, agricultural
irrigation, construction machinery, emergency fire protection pump and industry.
Landi series diesel engines use the integrated crankshaft, the body for gantry
structure, cylinder head for one cylinder and one cap, each cylinder head has two inlet
valves and two exhaust valves, fuel injectors are located in the center of the cylinder.
Power is output from the flywheel end. Therefore, suitable power take-offs and
necessary accessories must be attached to the engine before it can be properly used.
Connection of the output end is SAE type and can also be modified to resilient
coupling. Cylinder number designation of model 12V diesel engine: Viewed from the
flywheel end, the right hand bank is the first bank and the left hand bank is the second
bank; counted from the free end, the order of the first bank is 1-6 , and the second
bank is 7-12; Cylinder number designation of 6-cylinder diesel engine is: counted
from the free end ,the order of cylinders is 1-6 . Our products adhere to the principle
of seriation, standardization and generalization, and the main components can be
exchanged.
2. Explanation of power rating
The power rating of Landi series diesel engines is the permissible effective
power output for the engine with the air cleaner, but without other accessories which
will affect its running such as fan, muffler, coupler, and gear box etc. to operate under
the atmospheric condition of 100kPa (750mmHg) barometric pressure, 25℃ ambient
temperature and 30% relative humidity. The engine can also be overloaded at 110% of
the 12 hour power rating for a short period of not over 1 hour discontinuously or
continuously during each 12 hour operation.
Output power of the diesel engine that the nameplate indicates includes the
power the fan has consumed when running with the fan but the output power of
engine (effective power) should deduct the power, the value of the power that the fan
consumed in different engines is: WD360TAD110\1200 is 35KW； WD327TAD92
\100 is 30KW; WD327TAD88 is 30KW ；WD327TAD68/78/82 is 25KW ；
WD164TAD43/45 is 15KW。
Because the output power will decrease with altitude, ambient temperature and
relative humidity increasing of the using area, so the customer should correct the rated
power according to the correcting method of standard GB/T6072.1 when the
barometric pressure, ambient temperature or relative humidity is different from the
above stated standard atmospheric condition.

2
Chapter Two Specification and parameter
1. Specification of diesel engine
Model WD327TAD68 WD327TAD78 WD327TAD82 WD327TAD88
Structure V-Type
Cylinder 12
Stroke 4
Intake Type Turbocharged Intercooled
Bore，mm 145 145 145 145
Stroke，mm 165 165 165 165
Compression Ratio
15 15.5 15.5 14.5
Displacement，L 32.7 32.7 32.7 32.7
Rated
power/Speed，
kW/ r/min
682/1500 780/1500 820/1500 880/1500
Rated Fuel
consumption
g/ kW·h
≤218 ≤218 ≤218 ≤218
Rated Oil
consumption
g/ kW·h
≤0.8 ≤0.8 ≤0.8 ≤0.8
Rated piston
mean speed，
m/s
8.25
Cylinder firing
order (from gear train)
1-12-5-8-3-10-6-7-2-11-4-9
Rotation
direction
(facing flywheel)
Anti-clockwise
Cooling Type Water cooling
Starting Mode 24V Electric Starting
Oil Volume (L） 90 90 90 90
Coolant Volume(L)
220 230 230 240

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Model WD327TAD92 WD327TAD100 WD360TAD110 WD360TAD120
Structure V-Type
Cylinder 12
Stroke 4
Intake Type Turbocharged Intercooled
Bore，mm 145 145 152 152
Stroke，mm 165 165 165 165
Compression Ratio
14.5 14.5 14 14
Displacement，L 32.7 32.7 36 36
Rated
power/Speed，
kW/ r/min
920/1500 1000/1500 1100/1500 1200/1500
Rated Fuel
consumption
g/ kW·h
≤218 ≤218 ≤218 ≤218
Rated Oil
consumption
g/ kW·h
≤0.8 ≤0.8 ≤0.8 ≤0.8
Rated piston
mean speed，
m/s
8.25
Cylinder firing
order (from gear train)
1-12-5-8-3-10-6-7-2-11-4-9
Rotation
direction
(facing flywheel)
Anti-clockwise
Cooling Type Water cooling
Starting Mode 24V Electric Starting
Oil Volume (L） 90 90 90 90
Coolant Volume(L)
240 240 250 275

4
Model WD164TWC40 WD164TAD43 WD164TAD45
Structure Straight
Cylinder 6
Stroke 4
Intake Type Turbocharged Intercooled
Bore，mm 145 145 145
Stroke，mm 165 165 165
Compression Ratio
15.5 15.5 14.5
Displacement，L 16.35 16.35 16.35
Rated
power/Speed，
kW/ r/min
400/1500 430/1500 450/1500
Rated Fuel
consumption
g/ kW·h
≤218 ≤218 ≤218
Rated Oil
consumption
g/ kW·h
≤0.8 ≤0.8 ≤0.8
Rated piston
mean speed，
m/s
8.25
Cylinder firing
order (from gear train)
1-5-3-6-2-4
Rotation
direction
(facing flywheel)
Anti-clockwise
Cooling Type Water cooling
Starting Mode 24V Electric Starting
Oil Volume (L） 70 70 70
Coolant Volume(L)
70 80 80
Note: ○1 Diesel engine net weight tolerance±80 kg.
○2 Rated power tolerance ±5%.
○3 Because of the product improvement, the above parameters and the
product model may change, product nameplate parameters shall prevail.

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2. Main technical parameters
(1) Various temperature ranges at rated power
The temperature at outlet of turbocharger ℃ ≤600
Temperature in oil sump ℃ (highest) ≤105
Cooling water outlet temperature ℃ (highest) ≤95
Cooling water inlet water temperature ℃ (minimum) ≥55
(2) Oil pressure
With rated power condition：
Main oil gallery pressure KPa 400~600
The supercharger inlet oil pressure ≥196
With idle speed
Main oil gallery pressure KPa ≥150
(3) Valve timing (according to crankshaft rotation angle)
Intake valve: Open initial point under cold condition (before TDC) 20°±3°
Closed end point under cold condition (after BDC) 56°±3°
Valve and rocker arm clearance under cold condition, mm 0.4~0.45
Exhaust valve: Open initial point (before TDC) 64°±3°
Closed end point (after BDC) 34°±3°
Valve and rocker arm clearance under cold condition, mm 0.5~0.55
(4) Fuel supply advance angle (according to crankshaft rotation angle) 24±1°CA
(5) Battery capacity Ah
Environmental
temperature 12-cylinder diesel engine
6-cylinder diesel engine
≥10℃ 1200 600
0℃~10℃ 1280 640
-18℃~0℃ 1800 900

6
Chapter Three Operation instruction
1. Fuel, Lubricating oil and cooling water
A. Selection of fuel
Selecting proper fuel is very important and should be according to the
environmental temperature the engine runs in. In the southern hot weather area, light
diesel fuel with high cloud point is ok, in the cold northern area, light diesel fuel with
low cloud point is necessary. For example, under ordinary ambient temperature, light
diesel fuel of grade 0 or -10 is ok; in the south with high temperature, light diesel fuel
of grade 10 is all right; and in the north with very low temperature, the light diesel
fuel of grade -35 or lower is needed.
Water content and mechanical impurities in the diesel fuel must be as little as
possible, or it possibly causes premature blockage of the fuel filter and rusting of the
engine parts etc. Poor quality diesel fuel mixing water, kerosene, gasoline up is
forbidden to be used.
Note: The fuel must be clean, it’s necessary to settle the fuel at least 7days or
filter it through silk cloth in order to remove the mechanical impurities
contained. The fuel without being settled or filtered is forbidden, otherwise, it
may easily cause fuel supplying problems.
B. Selection of lubricating oil
The lubricating oil for the engine should be grade CF-4 according to
GB11122-2006. For the users in the warm area, you can choose lubricating oil of
grade CF all year around which can be very helpful to improve lubricating conditions,
reduce mechanical wear and extend its lifetime.
For the users in cold area, special thickening oil with lower freezing point is
needed. Kind suggestion is as following: When the lowest ambient temperature is
-15℃, oil of grade 20W-40 is needed; if the lowest temperature is -20℃, oil of grade
15W-40 is needed; if the lowest temperature is -25℃, oil should be grade 10W-40; If
the lowest temperature is -30℃, oil should be 5W-40; If the lowest environmental
temperature is -35℃, please choose grade 0W-40.
Replacement cycle for the lubricating oil
(1) Lubricating oil should be changed in time after first 60 hours run-in operation
(2) Generally, lubricating oil should be renewed when the machine runs every
200h-250h. If the engine runs in a good environment, 300h-350h can be possible. The
oil should be exhausted when the machine is hot. You can exhaust the oil as soon as
the engine stops.
(3) For none compulsory lubrication type high pressure pump, the oil level in the
speed governor of oil pump must be checked before each use, and oil should be added
in time when the oil level is lower than the prescribed standard. Oil in the high pressure oil
pump should be renewed and the oil filter should be cleaned after oil pump’s running for 100h.

7
Note: This engine belongs to supercharged diesel engine with high strength
and intercooler; therefore, the lubricating oil shouldn’t be lower than grade CF
and mixed different grades together.
C. Selection for cooling water
As for cooling water for the engine, city supply water and clean river water is
recommended. Well water and other underground water containing too much minerals
should not be used, because scale will formed in the water jacket, affecting the
cooling efficiency and thus causing engine fault.
When the engine is operated under the environmental temperature of lower than
0℃, special care must be taken to prevent some concerning parts from being damaged
by frozen water. Therefore, please exhaust all the cooling water as soon as the engine
stops. However, proper antifreeze can be added into the cooling system. The formulas
of antifreeze are as following:
Name
Ingredient (%) Solidifying
point ethylene
glycol alcohol
glycerin water unit
Ethylene-Glycol
anti-freeze
60 40
Volume
ratio
-55
55 45 -40
50 50 -32
40 60 -22
Alcohol-
alcohol
anti-freeze
30 10 60 Weight
ratio
-18
40 15 45 -26
42 15 43 -32
Note: 100% antifreeze can’t be used as cooling water.
Seawater can’t be used as cooling water directly.
If there is too much scale and dirt accumulated in the cooling system, it should
be cleaned with cleaning solution, which can be made up in the proportion of 1L
water, 40g soda and 10g sodium silicate.
When cleaning the cooling system, first pour the cleaning liquid into the cooling
water jacket, start the engine and let it run until the outlet water temperature exceeds
60℃,keep it running for about 2 hours, then stop the engine and drain off the cleaning
solution. After the engine has cooled down, clean it with fresh water twice, then drain
off the water, fill it with cooling water, start the engine again and let it run until the
outlet water temperature exceeds 75℃, then stop the engine and drain off the dirty
water. Finally, refill it with fresh cooling water for operation.
D. Grease Lubricant
The grease lubricant for the engine’s roller bearing of fan pulley is the same as
the cars’ lithium grease (GB5671). The grease chamber has been fulfilled before
delivery, and users should check and refill it when maintaining the engine.

8
2. Engine starting
A .preparations before starting
(1) Check all components and systems to see whether they are in proper order.
Check the accessories to see whether they are firmly and reliably connected.
Eliminate any abnormality.
(2) Check the cooling system and fulfill cooling water.
(3) Fill the oil sump until the required oil level is reached.
(4) Check the fuel tank to see whether it’s enough.
(5) Check all electrical wiring connections of starting system to see whether they
are correctly and firmly connected. Check the batteries to see whether it fully charged.
(6) Feed fuel into the fuel system with hand pump on the fuel feed pump and at
the same time loose the vent screw on the injection pump or the vent plug on the fuel
filter to bleed air in the fuel system. When no bubble is found in the fuel flowing out
of the vent screw or plug, tighten the vent screw or plug. Thereafter, continue to pump
fuel until it spills into the overflow pipe, and then lock the hand pump.
(7) For a new engine or an engine not used for over five days, turn the crankshaft
for 3-5 revolutions before starting the engine.
(8) For the stand–by engine, it is recommended to start and run it once every
3-5days until its water and oil temperature exceed 60℃, so that when necessary, the
engine can be put into operation promptly.
B. Starting
After preparations, pressing “ON” button can start the engine under ordinary
ambient temperature. If fail at first time, can’t start it again until the motor stops
spinning.
Note: To protect the starting motor, the engine should be started within 5
seconds; if not, wait at least 2 minutes before starting the engine again.
At the beginning, let the engine run at a speed of 600-750r/min for a while, and
inspect the readings of the gauges, especially the oil pressure gauge. If the oil pressure
is never higher than 147Kpa, the engine should be stopped and checked and started
again after repairing.
Note: In order to protect the bearings of turbochargers from burning-out,
the speed of the engine can’t be increased until the oil pressure raises, especially
for those have replaced lubricating oil, oil filter or been closing down for 5 days.
Loosen the connecting parts of oil intake pipe till some oil outflows, then increase
the speed and load several minutes later.
C. Prewarming, run-in and operation
a. Prewarming for the engine.
After the engine has started, it takes some time to form oil layer between
crankshaft and bearing, pistons and cylinder jackets. Perfect clearance between
motion parts can be gained when all the parts reach their normal working temperature.

9
Therefore, as the heating of the engine, increase the speed from650r/min to
1000-1200r/min to warm the engine up. The engine is allowed to operate at full load
only when its outlet water temperature exceeds 55℃, oil temperature over 45℃.
b. Run-in for the engine
For a new engine or an engine after overhaul, the engine must run in for 60 hours
before it can be put into full load operation. Otherwise, it may greatly affect the use
and lifetime of the engine.
Users should do run-in as following chart(60h in total):
Sequence No. Speed(r/min)
Load
(rating power %)
Run-in time (h) Total time (h)
1 700-1500 0 0.25 0.25
2 1500 0 0.25 0.5
3 1500 25% 0.25 0.75
4 1500 50% 1.75 2.5
5 1500 75% 45 47.5
6 1500 90% 5.0 52.5
7 1500 100% 3.0 55.5
8 1500 75% 3.0 58.5
9 1500 50% 1.0 59.5
10 1500 25% 0.5 60.0
Note: 1, In run-in period, pay attention to the exhausted smoke, sounds and
heat condition. Settle abnormal situation immediately.
2, In run-in period, pay attention to the oil pressure, oil temperature and
exhaust cooling water temperature which should be accordance with
the instructions.
3, Inspect readings of the meter frequently.
4, Renew the lubricating oil after run-in period.
c. Operation for the engine
It is not allowed to operate the engine at 50% of rated power output for a long
time, as it can cause high fuel consumption, valve jammed etc.
If the temperature of cooling water becomes too low, the unburned fuel may thin
the oil in the oil sump, and affect lubricating efficiency.
Note: Any failures occur to parts, such as a sudden surge of oil temperature,
a sudden decline of oil pressure and abnormal sounds. Please stop the engine
immediately, check and repair it.
Before stopping the engine, run it at idling speed for 3-5 minutes, let cooling
water and lubricating oil take the heat away in the engine, which is very important for
turbocharged engine. Unless it is in urgent need, the engine shouldn’t be stopped
suddenly; otherwise, the turbochargers will overheat and cause their bearings to seize
up.
The operator should pay attention to the sounds of turbochargers to see whether
any impeller knocks at the housing at the moment that the engine is stopped. If a noise
of knocking is heard, please dismantle the turbocharger immediately to check the

10
bearing clearance.
Note: Under very cold situation, exhaust all the cooling water in the engine
and its accessories to protect the engine from freezing.
The intake and exhaust manifolds of the turbocharged engine must be free of
leakage; otherwise, its performance would be lower. Check the tightness of the
connecting nuts or bolts and the hose clamps frequently. If necessary, renew the
sealing gasket.
Note: When customers are to select proper engine, consideration should be
given to reasonable power of working machinery, as the engine shouldn’t be
operated at an excessive load or very low load for a long time. Otherwise, it may
lower reliability of the engine and cause some faults.
d.The output power for the engine
WD164 series engine outputs its power by flywheel and SAE connector which is
used to drive working machinery. Belt pulley can’t be fixed to the flywheel directly,
and the machine can’t be dragged in lateral direction, because they can damage the
engine’s crankshaft and main bearings easily.
The maximum output power of the engine’s front extension shaft should be
within 50kw, but some applications include bearings and clutch etc must be fixed to
support the shaft. The power it can bear to be dragged in lateral direction must be
controlled within 11kw to protect the main crankshaft and driving gears. For those
engines with a fan, dragged in lateral direction is forbidden.
Note: The engine shouldn’t be started with load, therefore, a engaging and
disengaging device should be fixed between the engine and those load devices
can’t be operated without load, and operator should start the engine when the
clutch is released.

11
Chapter Four Repair and maintenance
Correct maintenance of diesel engine, especially preventive maintenance,
though it is the easiest and most economical, it is the key of prolonging service life
time of diesel engine and decreasing its operation cost. First of all, daily records of the
engine operation should be well made so that necessary adjustments and regulation
can be performed accordingly. In addition to the daily records, users should refer to
the instructions in this section and work out their own particular maintenance
schedule in terms of their specific operating condition and experience.
Generally, the contents of daily records include:
Date, beginning time and end time of every shift; routine record of readings on
all meters; load of the engine; leakage and excessive consumption of fuel, lubricating
oil and cooling water; exhaust color and abnormal noise; problems and solutions.
1. Main items of maintenance
For reliable engine operation, all maintenance work must be carried out promptly,
carefully and correctly. Must carry out diesel engine technology maintenance system,
technical maintenance category below:
Daily maintenance (after every work-shift)
First order maintenance (after every100 accumulated operating hours).
Second order maintenance (after every500 accumulated operating hours)
Third order maintenance (after every1000-1500 accumulated operating hours or
every 1 year).
No matter what kind of maintenance is carried out, the dismantling, checking and
reassembling should always be done in a planned and sequential way. Be sure to use
suitable tools and exert proper strength. After dismantling, the surfaces exposed must
be kept clean and coated with anti-rusting oil or grease to prevent them from rusting.
Take care of the relative positions of the detectable parts, the structural features of the
parts which cannot be dismantled, the fit clearances and the adjusting methods. At the
same time, keep the engine and its accessories clean and complete.
A. Daily maintenance
1. Check lubricating oil level in engine sump. Oil level should meet the marks
indicated on the oil level scale. If insufficient, replenish to the specified limit.
2. Check oil, water and gas leakage.
3. Check rigidity and reliability of all components attached to the engine. Check
rigidity and reliability of engine foundation bolts and the connection between the
engine and the driven machinery.
4. Check all the meters to see whether the readings are normal. If abnormal,
replace or repair it.
5. Check injection pump connecting plate. If there is any alteration of injection
timing or the joint bolts are loose, check the injection timing and tighten the bolts.
6. Check the connecting screw between turbocharger and its bracket and bust of
connection between turbocharger and air inlet pipe to see whether they are loose.

12
7. Clean the engine and the surface of the attachment. Oil, water and dust
gathered on the engine surface, turbocharger, cylinder head cover and air filter can be
wiped clean with a dry rag or cloth dipped in a bit of diesel. Clean off the dust
gathered on the charging alternator, radiator, intercooler and fan by wiping or blowing
with compressed air.
B. First order maintenance
Besides the maintenance work given in “Daily maintenance”, add the following
items：
(1) Check the voltage of the battery and specific gravity of the battery acid. The
specific gravity of the battery acid should be within 1.28-1.29 (at ambient temperature
of 15 ) and should not be lower than 1.27. Check the level of the battery acid which ℃
should be 10-15 mm above the pole plates. If insufficient, add distilled water to
required level.
(2) Unscrewing oil drain plug on the the oil pan. Clean it in fuel. (If the oil is
rather clean, its change period can be prolonged.)
(3) Fill all grease nipples with the proper grade of grease and fill all oil cups with
lubricating oil.
(4) Diesel engine first run accumulate full 50 hours, must be replaced oil filter
element; After running accumulate full 150 hours, must be replaced oil filter element
to ensure that enter the high pressure oil pump of the diesel cleanness to use
requirement, when change, only diesel filter together with shell from the filter holder
unscrew and put on the new filter assembly to filter seat, to ensure the seal, when
install the new filter, can be on the top of the seal face coated with a small amount of
oil, and then screwing in filter in the seat.
(5) After the diesel engine’s running for first 50 hours, oil filter element of
turbocharger must be replaced; after the later 150 hours, oil filter element of
turbocharger must be replaced.
(6) Move the turbocharger rotor with hand. If the rotor cannot rotate freely and
smoothly or stop rotating soon, this means that the bearings may be worn excessively
or there occur collision or jam between rotor and its mountings or there may be
severe carbon deposit on the air sealing plate of turbo back. In such a case,
disassemble the turbocharger and check radial clearance and axial move of rotor to
analyze probable causes and remedy them.
(7) Check the tightness of bolts of busts on connection between turbine case and
middle case and tighten them if loose.
(8) Disassemble the compressor housing and clean impeller and passage of
compressor housing.
(9) Clean air filter and get rid of the dirt in the collector. Take out the
filter-element and clean off the dirt by vibrating or blowing with compressed air (its
pressure is 98~147kPa) from the center to the outside.
Maintenance about the air filter should be done regularly as the following
requirements:
① Open the back cover and clean dust gathered in dust collector for an interval

13
of every 50-100 operation hours (determined by working condition of diesel
engine).
② Take out the filter-element and clean it by vibrating or blowing with
compressed air (pressure is 98~147kPa) from the center to the outside for
every 100~200 operation hours.
③ Renew the filter-element for an interval of 500~1000 operation hours or the
exhaust smoke is over-rich and exhaust temperature is over-high caused by
filter-element choked.
④ Keep the filter-element dry and renew it while the filter-element is perforated
and polluted by water or oil.
⑤ Strictly forbidden to clean the filter-element with any kind of oil and water.
C. Second order maintenance
Apart from the items stated in “First order maintenance”, add the following：
(1) Check the injection pressure and spray pattern of the injectors. If necessary,
dismantle the injector, clean the parts and adjust. (This series of diesel injector for
injection pressure is 24 MPa)
(2) Check the calibration of the injection pump. If necessary, recalibrate it.
(3) Check valve timing and injection timing. If necessary, adjust these timings.
(4) Dismantle cylinder head. Check seal and wear of valves. Repair if necessary.
(5) Check leakage of fresh water pump. Repair or replace if necessary.
(6) Remove the oil sump and check the cylinder liners for water leakage. If
necessary remove the cylinder liner, the liner rubber seal rings should be renewed.
(7) Remove the timing gear case cover and check the transmission mechanism of
gear lubrication condition. If the nozzle hole is blocked, probe it with a wire of proper
size.
(8) Check the lubricating oil cooler and radiator for oil and water leakage. If
necessary, repair.
(9) Check the tightness of the connecting rod bolts, crankshaft bolts and nuts,
cylinder head studs and nuts, and main bearing cover bolt. If necessary, remove,
check and tighten the rules to torque again.
(10) Check the wiring contacts of the electric system. Burnt marks should be
removed.
(11) Clean piping of lubricating oil and fuel system including oil sump,
lubricating oil piping, lubricating oil cooler, fuel case and fuel piping. Clean off the
dirt and blow them dry.
(12) Clean the cooling system. Compounding and method is described in
SECTION II.
(13) Whether it is necessary to disassemble the turbocharger or not can be judged
by the running condition of the engine. If necessary, disassemble the turbocharger and
do the following work: clean air seal ring and air seal plate of turbo end, clean the dirt
and carbon deposits of turbo impeller and inlet shell, clean oil reservoir of middle
shell, check the wear of float bearing. Replace the parts if it is seriously worn. Check
the wear of oil seal ring and see whether it is distorted and sintered, replace the parts

14
if so.
D. Third order maintenance
Apart from the items stated in “Second order maintenance”, add the following：
(1) Check cylinder head assembly. Check wear of valves, valve seats, valve
guides, valve springs, as well as fitting surfaces between push rods and rocker arms. If
necessary, repair or replace worn parts.
(2) Check piston and connecting rod assembly. Check wear of piston ring,
cylinder liners, and connecting rod bearing and bushing. If necessary, replace worn
parts.
(3) Check the crankshaft assembly. Check wear of main journal, connecting rod
journal and spindle tile. If necessary, replace worn parts.
(4) Check drive mechanism and remove gearcase. Check wear of tooth surfaces
of drive gears and measure their backlashes. If necessary, repair or replace worn parts.
(5) Check fuel injection pump and governor. Check the tightness of oil pump
plunger matching parts and governor. If necessary, repair or replace worn parts.
(6) Check lubricating oil pump and fresh water pump. Check and measure parts
which are liable to wear. If necessary, readjust.
(7) Check gaskets of cylinder head and intake and exhaust manifolds. Any gasket
damaged or has lost its sealing effect should be replaced.
(8) Check charging alternator and starting motor. Clean all parts and bearings,
blow them dry and fill with new grease, check wear condition of starting motor pinion
and see whether transmission mechanism is running freely.
2. Diesel engine bolt, nut tightening torque summary
Table 1 The main thread connecting pieces of tightening torque
Tightening torque（N·m）
No. Name TWC40 TAD43
1 Cylinder head nuts M18×2 360 360
2 Main bearing cover bolts
M20×2 460 460
4 connecting rod bolts
M18×1.5 260 260
5 Flywheel bolts M18×1.5 360 360
6 Fuel injection pump drive
gear nuts M27×1.5 400 400
7 Oil sump bolts M8 30 30
Ordinary bolt, nut (drawing and technical document does not indicate tightening
torque, and used for screwing in steel or cast iron parts) of the tightening torque may
refer to the requirement listed in table below, see table 2.

15
Table 2 unit: N·m
Strength
M6 M8
M1
0
M12 M14 M16 M18
8.8 8±2.5 22±5 39±7 70±10 115±15 176±20 235±25
10.9 13±2.5 31±5 58±7 100±10 162±15 240±20 330±25
Note: 1. This form is applicable to level 6 precision thread, the oil or anaerobic
acid as lubricant.
2. Use galvanized thread, tightening torque should be reduced by 20%
3. Thread hole material is aluminum parts, tightening torque should be reduced
by 20%
Thread

16
Chapter Five Fault and solution
1. Diesel engine can't start
No. Probable causes Remedies
1 Fault in fuel system：
(1) Air trapped in fuel system
(2) Fuel piping blocked
(3) Fuel filter choked
(4) Feed pump supplies fuel
irregularly
(5) Fuel injected too little or no
fuel at all. Fuel spray not
atomized.
(1) Check fuel piping connections. If loose, tighten it. Loose the
vent screw on the injection pump and fuel filter, work the hand
priming pump till fuel flowing out of the vent screws is without air
bubbles, tighten the vent screws and the hand pump knob.
Loose the injector high pressure piping connector and actuate the
injection pump plunger by means of a screw driver till fuel flowing
out of the high pressure piping is without air bubbles. Tighten the
connector and pump plunger another few strokes so that the injector
is filled with fuel.
(1) Check and clean.
(3) Clean or renew element
(4) Check the inlet piping for leakage. If the fuel inlet pipe and its
connections are normal, dismantle the feed pump for check and
repair.
(5) Take the injector out of the cylinder head. Connect it with high
pressure fuel piping to observe its spray. Actuate the injection pump
plunger and check weather its spray is normal. If necessary, replace
couple.
2 Fault in starting system：
(1) Wires not correctly
connected or not in firm
contact.
(2) Battery not charged
(3) Bad contact between the
brushes and commutator of the
starting motor
(1) Check and correct
(2) Use fully charged batteries or temporarily series connect
another battery for starting.
(3) Repair or renew the brushes. Polish the commutator surface with
sand paper and blow clean.
3 Compression pressure
insufficient：
(1) Piston rings worn
(2) Valves leaked
(1) Renew. If the liner is also worn, renew it at the same time.
(2) Check valve lash, valves springs, valve guide and sealing of the
valves with their seats. If the valve seating line is not continuous,
lap the valve with its respective seat until a bright, even, continuous
band is obtained.