Service Manual For WP10 Two-Valve Stage-II Series Diesel Engine

Service Manual for WP10 Two-valve Stage-II Series Land-use Diesel Engine for Power Generation
Service Manual for WP10 Two-valve Stage-II Series
Diesel Engine
Service Manual for WP10 Two-valve Stage-II Series Land-use Diesel Engine for Power Generation
Weichai Power Co., Ltd.

Service Manual for WP10 Two-valve Stage-II Series Land-use Diesel Engine for
Power Generation
1
Special Notice
 Before the operations, the operator of the diesel engine must carefully read this service manual
and strictly abide by the operation and maintenance practices specified in this manual.
 The diesel engine has tested strictly in accordance with the testing specification of our company
at the time of delivery. It’s prohibited to adjust the fuel injection pump or increase the power of the
diesel engine without permission. Otherwise, all our three-guarantee warranty commitments will be
voided.
 Oil pump and fuel injector are of high precision parts. Do not disassemble these parts by self,
otherwise all our three-guarantee warranty commitments will be voided.
 The turbocharger rotor shaft is one high precision and high speed rotating part. It’s prohibited
to remove or collide it, otherwise all our three-guarantee warranty commitments will be voided.
 The strict torque and angle requirements are specified for the main bearing bolts and
connecting rod bolts of the diesel engine. Please do not loosen or disassemble any bolt by self. The
connecting rod bolts are of one-time bolts and can’t be reused, otherwise all our three-guarantee
warranty commitments will be voided.
 The oil and fuel added to the diesel engine must be of the designations specified in this service
manual. Dedicated clean filters must be used for the addition. Before addition, the fuel shall settle
for 72 hours. Before driving the vehicle, check that the coolant and oil levels meet the requirements.
 It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply of
non-filtered air into the cylinders.
 After the cold start of the diesel engine, slowly increase the engine speed, instead of running at
high speed suddenly or long-term idling (not more than 3min). After the running under heavy load,
run the engine at low speed for 5~10min before stopping the engine, instead of stopping the engine
suddenly (except special cases);
 After the engine is stopped, if the temperature of working environment is probably below 0℃
and the coolant without antifreeze additive is used, fully drain the coolant from the water tank and
diesel engine.
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 The checking and repair for all parts of the electrical system must be fulfilled by the
professional electric technicians.
 The diesel engine is oil sealed at the time of delivery to prevent rusting. The oil sealing period
for diesel engine is generally one year. At the expiration of one year, check and take necessary
supplemental measures.
 Please add specified fuel at authorized gas stations. Damage to the fuel system of the diesel
engine due to poor fuel quality shall not be covered by the warranty offered by Weichai.
 Special diesel fuel shall be used for this diesel engine. Failure to do so could cause excessive
emissions, for which Weichai shall not be responsible.
 The Disassembly, checking, and repair shall be fulfilled by the designated service stations of
Weichai. Ensure to use designated spare parts of Weichai during repair. Weichai will not be liable
for any damage of diesel engine arising from the use of parts other than designated spare parts.
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Foreword
WP10 stage-II series land-use diesel engine with two valves per cylinder, in generating set is a high-
speed diesel engine developed by Weichai Power Co., Ltd. with the application of all-new design
concept. The diesel engine is featured by a compact structure, reliable use, good technical indicators
like power performance, economy and emission level, rapid start, simple operation, and easy
maintenance.
This manual briefly describes the technical specification, performance indexes, structural
characteristics, and operation and maintenance precautions for WP10 stage-II series land-use diesel
engine with two valves per cylinder, in generating set. While the user is using this diesel engine, the
true fulfillment as per the requirements specified in this manual will surely prolong the service life
of engine remarkably.
This manual describes the basic model of WP10 stage-II series land-use diesel engine with two
valves per cylinder, in generating set. Following the continuous development of the product, the
product structure will be subject to improvement and the contents contained in this manual may
become obsolete. For latest product information, the user (or dealer) may access Weichai website at
http://www.weichai.com.
Recommendations and opinions on further product improvement from you are welcome.
October, 2016
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Table of Contents
Chapter I General Information.....................................................................................................................1
1.1 Exterior View of Diesel Engine....................................................................................................1
1.2 Model Meaning of Diesel Engine................................................................................................2
1.3 Main Technical Specification of Diesel Engine...........................................................................2
1.4 Unsealing of Diesel Engine..........................................................................................................3
1.5 Hoisting of Diesel Engine............................................................................................................4
1.6 Installation of Diesel Engine........................................................................................................4
1.7 Pre-start Preparations of Diesel Engine.......................................................................................4
1.8 Start of Diesel Engine...................................................................................................................5
1.9 Running of Diesel Engine............................................................................................................6
Chapter II Maintenance Guide.......................................................................................................................8
2.1 Fuel Oil, Lubricant, Coolant, and Auxiliary Materials for Diesel Engine...................................8
2.1.1 Fuel Oil.................................................................................................................................8
2.1.2 Lubricating Oil.....................................................................................................................8
2.1.3 Coolant.................................................................................................................................9
2.1.4 Auxiliary Materials.............................................................................................................10
2.2 Routine Maintenance..................................................................................................................11
2.3 Periodic Maintenance.................................................................................................................14
2.3.1 Replace Engine Oil.............................................................................................................14
2.3.2 Replace Engine Oil Filter...................................................................................................14
2.3.3 Check and Adjust the Clearances of Intake and Exhaust Valves......................................14
2.3.4 Replace Fuel Filter Element...............................................................................................15
2.3.5 Check the Intake and Exhaust System...............................................................................18
2.3.6 Check the Air Filter Element..............................................................................................18
2.4 Maintenance for Long-term Storage..........................................................................................20
2.4.1 Clean...................................................................................................................................20
2.4.2 Protection............................................................................................................................20
2.4.3 Oil Seal...............................................................................................................................20
Chapter III Typical Faults and Solutions......................................................................................................22
3.1 Diagnostic Method.....................................................................................................................22
3.2 Common Faults and Troubleshooting........................................................................................23
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3.2.1 Diesel Engine can't Start....................................................................................................23
3.2.2 Stop of Engine Shortly after Start......................................................................................23
3.2.3 Low Power..........................................................................................................................24
3.2.4 Excessive Fuel Consumption.............................................................................................25
3.2.5 Black Exhaust Gas..............................................................................................................25
3.2.6 White or Blue Exhaust Gas................................................................................................26
3.2.7 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger......................26
3.2.8 Unstable Speed...................................................................................................................26
3.2.9 Engine Oil Pressure Too Low............................................................................................27
3.2.10 High Coolant Temperature.................................................................................................27
3.2.11 Excessive Wear of Parts.....................................................................................................28
3.2.12 Excessive Noise..................................................................................................................28
3.2.13 Working Failure of Starter Motor.......................................................................................29
3.2.14 Weak Starter Motor............................................................................................................29
3.2.15 Generally Cannot Generate Electricity at All....................................................................29
3.2.16 Inadequate Charging Current of Alternator.......................................................................30
3.2.17 Instable Charging Current..................................................................................................30
3.2.18 Excessive Charging Current of Alternator.........................................................................30
3.2.19 Abnormal Sound from Alternator......................................................................................31
Chapter IV Disassembly and Assembly of Engine.......................................................................................32
4.1 Overview....................................................................................................................................32
4.1.1 Danger Sign........................................................................................................................32
4.1.2 Safety Sign..........................................................................................................................33
4.1.3 DisassemblyTool................................................................................................................34
4.1.4 Precautions for Health Protection......................................................................................34
4.1.5 Precautions for Environment Protection............................................................................35
4.1.6 Precautions on Disassembly and Installation of Engine....................................................35
4.2 Engine Block Group...................................................................................................................37
4.2.1 Disassembly and Assembly of Engine Block Group.........................................................37
4.2.2 Disassembly and Assembly of Cylinder Block Preassembly............................................40
4.2.3 Disassembly and Assembly of Front End Cover...............................................................42
4.2.4 Disassembly and Assembly of Gear Chamber...................................................................43
4.2.5 Disassembly and Assembly of Flywheel Cover.................................................................45
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4.2.6 Disassembly and Assembly of Oil Pan..............................................................................47
4.2.7 Disassembly and Assembly of Piston Nozzle....................................................................49
4.2.8 Disassembly and Assembly of Thrust Halfring.................................................................50
4.2.9 Disassembly and Assembly of Front and Rear Oil Seal....................................................51
4.2.10 Disassembly and Assembly of Cylinder Head Group.......................................................52
4.2.11 Disassembly and Assembly of Cylinder Head Cover........................................................54
4.2.12 Disassembly and Assembly of Oil-gas Separator..............................................................56
4.2.13 Disassembly and Assembly of Engine Lifting Plate.........................................................57
4.2.14 Disassembly and Assembly of Cylinder Head...................................................................58
4.3 Crank Connecting Rod Mechanism...........................................................................................67
4.3.1 Disassembly and Assembly of Crank Connecting Rod Mechanism.................................67
4.3.2 Disassembly and Assembly of Piston Connecting Rod Group..........................................69
4.3.3 Disassembly and Assembly of Crankshaft-flywheel Group..............................................72
4.3.4 Disassembly and Assembly of Flywheel and Gear ring....................................................74
4.3.5 Disassembly and Assembly of Vibration Damper and Crankshaft Pulley........................76
4.3.6 Disassembly and Assembly of Crankshaft Bearing Shell..................................................77
4.4 Valve Mechanism.......................................................................................................................78
4.4.1 Disassembly and Assembly of Valve Mechanism.............................................................78
4.4.2 Disassembly and Assembly of Camshaft...........................................................................79
4.4.3 Disassembly and Assembly of Rocker Arm and Rocker Arm Shaft.................................81
4.4.4 Disassembly and Assembly of Tappet and Push Rod........................................................84
4.4.5 Disassembly and Assembly of Valve.................................................................................86
4.4.6 Disassembly and Assembly of Intermediate Gear.............................................................88
4.5 Intake and Exhaust System........................................................................................................89
4.5.1 Disassembly and Assembly of Intake and Exhaust System...............................................89
4.5.2 Disassembly and Assembly of Intake Pipe........................................................................91
4.5.3 Disassembly and Assembly of Exhaust Pipe.....................................................................92
4.5.4 Disassembly and Assembly of Turbocharger System........................................................93
4.6 Fuel system.................................................................................................................................96
4.6.1 Disassembly and Assembly of Fuel System......................................................................96
4.6.2 Disassembly and Assembly of Fuel Injection Pump.........................................................97
4.6.3 Disassembly and Assembly of High-pressure Fuel Pipe...................................................99
4.6.4 Disassembly and Assembly of Fuel Injector....................................................................100
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4.7 Cooling System........................................................................................................................101
4.7.1 Disassembly and Assembly of Cooling System...............................................................101
4.7.2 Disassembly and Assembly of Fan..................................................................................103
4.7.3 Disassembly and Assembly of Water Pump.....................................................................104
4.7.4 Disassembly and Assembly of Thermostat......................................................................105
4.7.5 Disassembly and Assembly of Water Outlet Pipe............................................................106
4.8 Lubrication System...................................................................................................................108
4.8.1 Disassembly and Assembly of Lubrication System.........................................................108
4.8.2 Disassembly and Assembly of Oil Pump.........................................................................109
4.8.3 Disassembly and Assembly of Engine Oil Intermediate Gear Assembly........................110
4.8.4 Disassembly and Assembly of Engine Oil Filter.............................................................112
4.8.5 Disassembly and Assembly of Oil Cooler Cover.............................................................113
4.8.6 Disassembly and Assembly of Oil Cooler.......................................................................114
4.8.7 Disassembly and Assembly of Main oil-way Pressure Control Valve............................115
4.8.8 Disassembly and Assembly of Engine Oil Cooler Bypass Valve....................................115
4.8.9 Disassembly and Assembly of Engine Oil Suction Filter................................................117
4.9 Starting System.........................................................................................................................118
4.9.1 Disassembly and Assembly of Starting System...............................................................118
4.9.2 Disassembly and Assembly of Starter..............................................................................118
4.10 Electrical system.......................................................................................................................119
4.10.1 Disassembly and Assembly of Alternator........................................................................119
Appendix A Fit Clearances for Main Parts of Diesel Engine.......................................................................128
Appendix B Wear Evaluation References for Main Friction Pairs in Diesel Engine..................................130
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Chapter I General Information
1.1 Exterior View of Diesel Engine
1- Air Inlet Port of 4- Water temperature

2- Fuel return port 3- Fuel inlet port
Engine sensor
6- Adjustment 7- Speed sensor
5- Filler port
handle interface
1- Alternato
2- Oil dipstick 3- Compressor air outlet port
r
Figure 1-1 Exterior View of Diesel Engine
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1.2 Model Meaning of Diesel Engine
Variant code
Emission phase
Power code
Application code
Product series code
1.3 Main Technical Specification of Diesel Engine
Table 1-1Main Technical Specification of Diesel Engine I
Liquid cooled, 4-stoke, brake with exhaust valve, direct

Type injection, and turbocharged and intercooled, with
exhaust valve brake
Bore/Stroke (mm) 126/130
Displacement (L) 9.726
Compression ratio 17:1
Ignition order 1-5-3-6-2-4
Fuel system Mechanical pump
Cold valve clearances (mm) Intake valve: 0.3, Exhaust valve:0.4
Opening of intake valve: 34° ～ 39° prior to top dead
center.
Closing of intake valve: 61° ～ 67° after bottom dead
Valve timing
center.
(Valve clearance: The intake valve is 0.3mm and the
Opening of exhaust valve: 76° ～ 81° prior to bottom
exhaust valve is 0.4mm.)
dead center.
Closing of exhaust valve: 26° ～ 31° after top dead
center.
Startup method Electric startup
Lubrication method Pressurized lubrication
Lubricating oil capacity(L) 23
Cooling method Water-cooling and forced recirculation
Engine oil pressure (kPa) 350～550
Engine oil pressure of idling speed (kPa) 100～250
Allowed vertical
Front / Rear Long terrm 10/10 Short terrm 30/30
inclination (°)
2
Allowed transversal Near exhaust pipe/fuel
Long terrm 45/15 Short terrm 45/30
inclination (°) injection pump
Crankshaft rotating direction (seeing from free end) Clockwise
Table 1-2Main Technical Specification of Diesel Engine II
Item WP10D
Engine type 200E200 238E200 264E200 200E201 238E201 264E201 288E201
Valve number of per 2
cylinder
RatedPower (kW) 182 216 240 182 216 240 ——
Rated speed (r/min) 1500 1800 ——
Overload Power (N.m) 200 238 264 200 238 264 288
Overload Speed (r/min) 1800
Fuel supply advance angle 14° 12° 9° 17° 14° 14°
1.4 Unsealing of Diesel Engine
After the diesel engine is unpacked, the user shall firstly count the diesel engine and its accessories
as per the delivery packing list, check the exterior of diesel engine for presence of damage and the
connectors for presence of looseness, and then fulfill the following works:
（1） Wipe the anti-rusting layer and anticorrosive agent on the exposed parts.
（2） Drain the sealing oil from the inside of fuel filter and the parts of fuel system (It’s allowed
to start the engine without draining the sealing oil from the fuel system. However, it’s permitted to
run the engine under loaded condition only when the sealing oil in the fuel system is used up and
the diesel is supplied to the engine).
Notice: The oil sealing period for diesel engine is one year. At the expiration of one year, conduct
checking and take necessary supplemental measures. Refer to section 2.4.3, for the precautions on
the use of new oil seals.
（3） Rotate the flywheel and spray solvent into the intake pipe, till the sealing oil in the cylinder
is completely removed.
（4） Spray solvent to the intake and exhaust orifices of the turbocharger, till the sealing oil is
completely removed.
（5） According to the agreement concluded between the manufacturer and the user, the oil pan
shall be filled with specified engine oil by the user if it is empty when the engine is delivered out of
factory. If the oil pan is filled with engine oil containing running-in accelerant when the engine is
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delivered out of factory, the user should change engine oil after the vehicle has travelled 2,000km
(or run 50h, whichever comes earlier).
（6） In accordance with the agreement concluded between Weichai Power and the user, if
required by the user, the diesel engine shall be filled with the specified coolant. Be sure to check the
coolant performance after unpacking the diesel engine. The coolant that has an anti-freezing
capacity of -30ºC or -35ºC, PH value of 7-8 (neutral) and total hardness of 5-15ºd [9-15ºf
(hardness)] can be used. If the coolant fails to meet these requirements, drain it out of the diesel
engine and add the coolant that contains anti-freeze.
1.5 Hoisting of Diesel Engine
During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist in
tilted or unidirectional manner. Hoist up and down slowly. See Figure 1-2.
True False
图1-2 Diesel Engine Hoisting
1.6 Installation of Diesel Engine
For supply installation, ensure that the crankshaft centerline of the diesel engine is coaxial with the
axis of input shaft of drive unit (gearbox, transmission, or alternator) and ensure that the crankshaft
is free of additional axial force due to installation.
1.7 Pre-start Preparations of Diesel Engine
（1） Check the coolant level

If the engine is already installed on a machine, check the coolant level of expansion tank before
starting the engine each time. If the coolant is insufficient, add coolant through the filler port cap.
The filler cap is equipped with a pressure relief valve and a bleeding button. Before opening the
filler cap, press the bleeding button to open the cap in the case of a hot engine. If the diesel engine
remains hot, do not add a great deal of coolant. Dramatic temperature change could cause damage
4
to the parts. Start the engine. While the engine is running (1,000 r/min), continue to add the coolant
to specified location, till the coolant level is stable, and finally install the filler port cap.
（2） Check the fuel level
If the engine is already installed on a machine, turn on the power supply switch, and check fuel
level from the fuel gauge or check the fuel tank.
（3） Check the engine oil level
The engine oil level shall be between upper and lower markings of the oil dipstick. If necessary, add
engine oil through the engine oil filler port.
（4） Check all accessories of diesel engine for reliable connections and solve any abnormal
phenomenon.
Check the starter system for normal wiring and check and ensure that the battery is sufficiently
charged. Open the valve fuel tank. Loosen the bleeding screw of the fuel coarse filter. By operating
the manual pump, bleed air from the fuel coarse filter.
1.8 Start of Diesel Engine
（1） Start the diesel engine after the start preconditions of the machine are met.
（2） If starting conditions are met, the engine fails to start within 5 to 10 seconds, wait for 30
seconds then repeat the starting process. If the engine can’t be started by three consecutive attempts,
stop the attempt and find out and solve the malfunction before retry. After the start of diesel engine,
observe the readings of all instruments. The engine oil pressure gauge shall indicate the pressure
immediately. Do not have the cold engine running at high speeds after start. Have it running at idle
speeds at first for a not very long time.
（3） The auxiliary starter shall be used to start the diesel engine under cold temperature. By
running the electric heating flange via relay, the engine can start successfully under -30ºC
environment.
1.9 Running of Diesel Engine
(1) After start-up, idle the engine for 3 minutes, then apply partial load. Do not have it running
under full load until the outlet coolant temperature is above 60ºC , engine oil temperature is above
50ºC and the engine oil pressure shall be higher than 120kPa. Apply load and increase the speed
gradually. Avoid the sudden loading and unloading whenever possible.
(2) In the 50h run-in period, the diesel engine is better to run under a moderate load.
5
(3) It’s inappropriate to run the engine under low-speed and low-load condition for a long time,
otherwise it will easily lead to oil permeation problem.
(4) During normal use, it’s permissible to run the diesel engine continuously at rated power and
rated speed. After the unloading, idle the diesel engine for (1~2)min before stop.
(5) Parameters and checking locations to be observed at all times during operations are as below:
Main oil-way pressure of lubricating oil: 380 kPa ~580 kPa.
Main oil-way engine oil temperature: 85℃~105℃;
Outlet temperature of coolant no more than 98 ℃;
Exhaust temperature after turbine: ≤550℃;
Air intake temperature after inter cooling: 50-55 ℃
Check the exhaust fume color, to estimate the performances of the injectors and the load of the
engine. If the color of exhaust gas is serious black or white, stop and check the engine.
Notice to check the diesel engine for presence of water, air, and fuel leakages. If any, stop the
engine for troubleshooting.
(6) The operator shall understand the following characteristics of diesel engine:
1 The fuel consumption is relatively low at maximum torque output and is increased along with
the increasing of speed.
2 The torque output reaches best value at the moderate speed range of the engine
(1,200~1,600r/min).
3 The power output of the engine increases along with the increasing of the speed and reaches
rated value at the rated speed.
(7) Precautions for running under cold environments:
1 Fuel: Choose diesel of different trademarks depending on the environmental temperature in
winter.
2 Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons.
3 Coolant: Add antifreeze additive into the cooling system and choose the coolant of different
trademarks and quantities depending on the ambient temperature.
4 Start: The auxiliary starter can be adopted if necessary in winter. After the start of the diesel
engine, wait for the oil pressure and water temperature to turn normal before running at high speed
under loaded condition.
5 Before the approach of the cold season, make sure to check the level and viscosity of
6
electrolyte and unit voltage of the battery. If the diesel engine is not to be used for a long time and is
under extremely low temperature, disassemble the battery and store in a warm indoor place.
6 Stop: To stop the engine under cold weathers, unload the engine, idle the engine for (1~2) min,
and wait for the water temperature and oil temperature to cool down before stop. Please be noted
that it’s disallowed to drain the coolant containing antifreeze additive after the stop of the engine. If
the coolant contains no antifreeze additive, make sure to open the water drainage valves or water
plugs on the engine block, oil cooler cover, radiator, and water inlet pipe to fully drain the coolant,
in order to prevent the frozen cracking of the engine.
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Chapter II Maintenance Guide
2.1 Fuel Oil, Lubricant, Coolant, and Auxiliary Materials for Diesel Engine
2.1.1 Fuel Oil
Use 0# diesel (GB 252) when the air temperature is above 5ºC and use -10# light diesel (GB 252)
when the air temperature is above -5ºC. Use -20# diesel when the outdoor temperature is below
-15ºC and -35# diesel when the outdoor temperature is below -30ºC.
The fuel used must conform to the requirements in section D.1 of Appendix D to national standard
GB 20891-2014.
2.1.2 Lubricating Oil
For Weichai Power Naitonal II series diesel engines, CF-4 grade engine oil shall be used. For details, refer to
Table 2-1.
Table 2-1 Selection Specification of Weichai Special Engine Oil
Packing
Variety Product category Applicable model
specification
10W/30 Naitonal -II diesel engines: WD615,
Diesel 4L, 18L,
CF-4 15W-40 WD10, WD618, WD12, WP4 and WP6
engine oil 170kg
20W-50 series, etc.
Choose the viscosity of Weichai special engine oil based on the temperature, with reference to Table
2-2.
Table 2-2 Relationship Table between Viscosity and Environmental Temperature
Applicable environmental
SAE viscosity grade
temperature (ºC)
10W-30 -25~35
15W-40 -20~40
20W-50 -15~50
Notice:
（1） Before starting the diesel engine, ensure to check the engine oil level within oil pan.
（2） Do not check the oil level while the diesel engine is running.
（3） Never mix special engine oil of Weichai Power with engine oils of other manufacturers.
For the added volumes of engine oil and numbers of filters of Weichai Power engines. See Table 2-
3.
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Table 2-3 Added Volumes of Engine Oil and Numbers of Filters of Weichai Power Engines
Number of filters
Added
Diesel engine
volume
Model Engine Diesel filter
of engine
oil Coarse
oil (L) Fine filter
filter filter
WP10 22~26 2 1 1
Remark:
1） The added volumes listed in the table are only for reference.
Actual added volumes shall be decided with the oil dipstick.
2） If the vehicle is equipped a highly-cold-resistant filter or
moisture-removing filter as developed by Weichai Power, they
shall also be replaced when the fuel is replaced.
3） Number of filters are only for reference. The actual model
shall prevail.
2.1.3 Coolant
The freezing point specification for Weichai special coolant includes -25ºC, -35ºC, and -40ºC.
Please choose Weichai special coolant of different freezing points based on the local environmental
temperature in such manner that the freezing point is less than local air temperature by
approximately 10ºC, with reference to Table 2-4.
Table 2-4 Weichai Special Heavy-Duty Engine Coolant
Packing
Variety Product category
specification
HEC-Ⅱ-25
Heavy-duty
HEC-Ⅱ-35 4kg, 10kg
engine coolant
HEC-Ⅱ-40
Notice:
（1） Make sure to periodically check the coolant and, to prevent the corrosion and damage,
timely replace depending on actual situation.
（2） It’s prohibited to use water or low quality coolant as the engine coolant.
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2.1.4 Auxiliary Materials
Table 2-5 Auxiliary Materials Used for Diesel Engines
SN. Name Color Purpose and location

Applied on flat and smooth metal surfaces to
prevent seize
1 Molykotte Pulver Black
For example, applied onto outer surfaces of
cylinder liners
Lubrication before the lubricating oil pressure
2 Molykotte G.u.plus Dark grey builds up.
For example, applied onto the intake valve stem
Table 2-6 Reference Table for Sealant Application of Diesel Engine
List of locations for application of

Mark Main use Supplement
sealant
Flywheel cover bolt
Camshaft thrust halfring bolt
Camshaft timing gear bolt
Intermediate idler bolt
Front end cover bolt
It’s applied onto the Engine oil filter base bolt
threads to prevent Oil cooler bolt
Loctite
being vibrated to Screw plug, control valve, engine
242
looseness, with oil cooler, Alternatively, the thread
moderate strength. Bolt, fuel return pipe fixing device, pre-application sealant
fuel pump, DriLoc204 can be pre-
Air compressor shaft end thread applied.
Suction filter bolt
Bolts of sensor and harness fixing
device
Applied onto outer
threads for locking,
Loctite
sealing, preventing Auxiliary bolt, cylinder head
262
vibration from
causing looseness
Loctite Preventing looseness,
Cup plug, oil drain hole
271 fixing
Loctite For sealing between
Other cup plug
277 element and bore
Loctite Sealing cylinder head
Push rod -cylinder head
270 top
10
Loctite It’s applied onto Interface between cylinder block
518 shining metal surfaces and crankcase
(modifie for sealing purpose. Plates connecting engine body
d from front end face to front end cover,
Loctite and connecting engine body rear
510) end face to flywheel cover
Interface between engine oil filter
base and crankcase
Interface between water pump rear
cover and engine body front end
face
Interface between flywheel cover
and its connecting plate
Interface between cylinder block
and engine oil cooler cover
Interface between cylinder block
and engine oil filler cap cover
2.2 Routine Maintenance
（1） Check the coolant level and temperature.
Observe the coolant level through glass sight hole. If the coolant is insufficient, open the filler port
cap and add coolant. See Figure 2-1.
Notice:
While opening the filler port cap, make sure to push down the air bleeding button, in order to
prevent the coolant from causing personal injuries under hot state of engine. Location of the coolant
filler cap is shown in Figure 2-2.
Figure 2-1 Bleeding Button
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（2） Check the oil level.
It’s prohibited to start the diesel engine when the oil level is below lower marking of oil dipstick or
is above upper marking of oil dipstick. See Figure 2-3.
After the diesel engine is stopped, wait for at least 5min and then check the oil level, in order to
enable the engine oil to flow into the oil pan sufficiently.
The oil amount difference between lower marking and upper marking of oil dipstick is 3L.
Figure 2-2 Correct engine oil level
（3） Check the fuel level
Check the fuel level indication from the instrument panel. Add fuel if necessary.
（4） Check for presence of water, airand oil leakage.
Check the diesel engine surface for signs of water, airand oil leakage.
（5） Check the fan
Visually check the blades of fan for presence of damage and check connecting bolts for secure
fastening. See Figure 2-4.
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Figure 2-3 Check the fan visually.
（6） Check the belt
The belt is tensioned by belt tensioner. Check the tension of belt by pushing the belt with hand. See
Figure 2-5.
Figure 2-4 Check the belt.
（7） Check the color of exhaust gas.
The normal color of exhaust gas is light grey. Upon detection of change in color, check and solve
the cause.
（8） Check the sound
（9） Check the revolving speed and vibration
13
2.3 Periodic Maintenance
2.3.1 Replace Engine Oil
Before replacing old engine oil, remove the drain plug at the bottom of oil pan, and drain the old
engine oil. Then tighten the drain plug. See Figure 2-7.
Open the engine oil filler cap, as shown in Figure 2-8. Add fresh engine oil until the oil level meets
the requirement. Then tighten the filler cap.
Figure 2-7 Engine oil filler port Figure 2-8 Drain plug location
Notice: Waste engine oil must be put in the specified container at the specified place.
2.3.2 Replace Engine Oil Filter
(1) Remove the used engine oil filter.

(2) Fill the new filter completely with clean engine oil.
(3) Before installing new engine oil filter, apply engine oil onto the rubber gasket.
(4) After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal.
(5) Start the diesel engine and check for presence of oil leakage.
2.3.3 Check and Adjust the Clearances of Intake and Exhaust Valves
(1) Under the cold status of diesel engine, turn the engine (along the rotation direction of engine) to
the compression top dead center of 1st, 6th cylinder. In such case, the notch on the flywheel is
aligned with the pointer on the sight glass cover plate.
(2) Remove the valve rocker cover from the cylinder head and judge whether the 1st or 6th
cylinder is at compression stroke (there is a gap between exhaust valve and rocker for the cylinder
under the compression stroke).
14
(3) Using the feeler gauges, check the clearance between valve bridge top and valve rocker arm.
For the WP10 diesel engine with two valves per cylinder, the intake and exhaust valve clearances
shall be 0.3mm and 0.4mm, respectively. If the clearance is too large or too small, adjust the
adjustment bolt on the rocker to meet the above-mentioned clearance requirement.
(4) After the checking of 1st cylinder or 6th cylinder, turn the engine for 360º to adjust the 6th or
1st cylinder to power stroke and then check and adjust the remaining valves.
Table 2-7 Sequence for adjusting valve
Position 1st cylinder 2nd 3rd cylinder 4th 5th 6th cylinder
cylinder cylinder cylinder
1st cylinder Intake and Intake Exhaust Intake Exhaust Non-
compression exhaust valves valve valve valve valve adjustable
stroke
6th cylinder Non-adjustable Exhaust Intake valve Exhaust Intake Intake and
compression valve valve valve exhaust valves
stroke
2.3.4 Replace Fuel Filter Element
(1) Remove the used fuel filter element; If the water collector installed on the coarse filter can be
reused, please take out the water collector;
(2) Lubrication seal.
(3) Screw the filter by hand, till the seal comes into contact with the port.
(4) Continue to screw the filter by hand, till the filter is securely installed (for approximately 3/4
turn).
(5) Bleed the air, till there is no presence of air bubble.
(6) Conduct the leakage test.
15
Figure 2-9 Fuel filter
Notice:
After replacement of the spin-on fuel coarse filter, bleed the new spin-on fuel coarse filter. After re-
installation of the fuel delivery pipe, bleed the spin-on fuel coarse filter.
Steps:
(1) Shut off the engine.
(2) Remove the bleeding screw.
(3) Operate the manual pump until only fuel comes out of the bleeding screw.
(4) Install the bleeding screw.
Notice: Water must be drained from the water collector when the water collector is full or the spin-
on coarse filter is replaced with a new one.
Water draining is shown in Figure 2-10.
(1) Open the drain plug (2) at the bottom of water collector (1).
(2) Refit the drain plug.
16
Figure 2-10 Draining water from the water collector
Water collector replacement is shown in Figure 2-11:
(1) Stop the engine.
(2) Drain water from the water collector.
(3) If possible, manually remove the screw (1) from the water collector. If the water collector is too
tightly connected to be removed manually, use the Disassembly tool that is provided along with the
new water collector.
(4) Apply several drops of lubricating oil to the seal ring (2) of the new water collector.
(5) Manually tighten the screw. Then using the tool, tighten it in place.
(6) If the water collector is installed to a new spin-on filter, check the water collector for damage
before installation.
(7) Using the torque wrench, tighten the water collector to the torque of 20N.m.
Figure 2-11 Replacing Water Collector
17
2.3.5 Check the Intake and Exhaust System
Check the intake hose for presence of aging or cracking and check the clip for presence of
looseness. When necessary, tighten or replace parts to ensure air-tightness of intake system.
2.3.6 Check the Air Filter Element
Type I radially sealed air filter

When the intake resistance indicator alarms (turns red), stop the engine and maintain the external
filter element of the air filter (Notice: It’s prohibited to disassemble or clean the safety filter
element).
Pay attention to the following items during maintenance:
1) Check the inner surfaces of external filter element and the outer surfaces of safety filter element
for presence of dusts. If yes, it indicates that the external filter element is damaged or improperly
installed. In such case, high attention shall be paid.
2) Blow away the dusts from the external filter element by blowing with clean air of <0.5MPa
from inside to outside. It’s prohibited to clean filter element by oil or water.
Notice:
It’s prohibited to disassemble or clean the safety filter element.
It’s prohibited to blow the external filter element from outside to inside. If the outer surfaces of
filter element are deposited with heavy dusts, flap by hand to fall off the dusts. It’s prohibited to
disassemble or clean the internal filter element (safety filter element). Make sure to replace it along
with the external filter element.
Figure 3-13 Cleaning of Filter Element
Type II 93# desert filter
18
1) Fully loosen the connecting circlip between rear cover and housing, take out the rear cover, and
thoroughly remove the dusts from the rear cover.
Caution: During the checking under parking status, timely remove the dusts by the dust discharge
valve. The damaged or lost dust discharge valve shall be timely replaced.
2) Rotate counter-clockwise the yellow sealing cap to disassemble it. In such case, the external
filter element is visible.
3) Hold the rear cover hanger of external filter element to pull the external filter element out from
the air filter housing.
4) Maintain the external filter element as per the maintenance instructions of the air filter.
5) Remove the dusts from the internal chamber of filter and the internal threads before
reinstallation of external filter element. Thoroughly remove the dusts by a brush or rag, ensure the
smoothness of the threads, and guard the external filter element against the ingress of dusts.
6) Reinstall all parts as per reverse sequence. Take cautions to install correctly to ensure sealing
performance and do not miss any part.
Figure 3-14 93# desert filter
Notice: It’s absolutely prohibited to run the diesel engine without the air filter, otherwise the ingress
of dusts and impurities into the diesel engine will lead to earlier wear of diesel engine.
2.4 Maintenance for Long-term Storage
2.4.1 Clean
(1) After the engine warm-up, drain the engine oil, clean engine oil filter, and add anti-rusting oil.
(2) Drain the fuel and add anti-rust oil mixture.
19
(3) Drain the coolant and add coolant with anti-rust agent.
(4) Start the engine and idle for (15~25) min.
(5) Fully drain the engine oil, fuel, coolant and urea solution.
(6) Take protection measures for other portions.
2.4.2 Protection
Plug with caps or wrap with plastic film for all oil, gas, and water inlets and outlets and seal up the
entire diesel engine with weather anti-rusting film. If the transport is required, the external package
shall be supplemented.
2.4.3 Oil Seal
Generally the period of validity of oil sealing is one year for the diesel engine in storage. If the
storage period exceeds one year, oil sealing processes shall be performed again as follows:
(1) The oil sealing processes shall be performed in a clean environment. Before doing so, remove
rust, oil stain, and dust from the engine and parts.
(2) Depending upon actual requirements, oil sealing processes may be dipping in, spraying,
daubing, and filling with oil.
(3) Oil sealed locations: Inlet and outlet of turbocharger, inlet of air compressor, and intake pipe
mouth. The pneumatic spray gun is shown in Figure 2-16.
1Oil sealing of the intake and exhaust system: While the diesel engine is being driven by the starter
or other driving device, spray JB-1 pump calibration fluid towards the intake pipe mouth for at least
15 seconds using the pneumatic spray gun.
2Oil sealing of turbocharger: While the diesel engine is not running, or is being driven by the
driving device, spray JB-1 pump calibration fluid towards the inlet and outlet of the turbocharger
for at least 5 seconds using the pneumatic spray gun.
3Oil sealing of air compressor: While the diesel engine is running at idle speed, or is being driven
by the driving device, spray JB-1 pump calibration fluid towards the inlet of air compressor for at
least 5 seconds using the pneumatic spray gun.
20
Figure 2-16 Pneumatic Spray Gun
21
Chapter III Typical Faults and Solutions
WP10 series diesel engine is designed and manufactured under strict quality assurance system and
each delivered diesel engine passed the specified tests. In addition, the diesel engine is a kind of
high precision machinery and the long-term guarantee of its functionality is closely related to the
normal maintenances. The causes leading to earlier failure of diesel engine are generally as below:
(1) Operations against rules or improper management and operations.
(2) Failure to fulfill maintenance as specified or even repair instead of maintenance.
(3) Poorly manufactured parts, especially the counterfeit products procured due to temptation of
cheap prices, which will greatly shorten the service life of diesel engine.
(4) Inappropriate trademark of fuel or lubricating oil or disqualified fuel or lubricating oil.
3.1 Diagnostic Method
The common diagnosis methods for malfunctions of diesel engine are generally as below:
(1) Observation method: Judge the malfunction situation by observing the malfunction symptom,
such as exhaust smoke of diesel engine. See Figure 3-1.
(2) Listening diagnosis method: Judge the characteristic and extent of the malfunction portion by
listening as per the abnormal sound of diesel engine. See Figure 3-2.
Figure 3-1 Observation Method Figure 3-2 Listening Diagnosis Method

(3) Cylinder interruption method: Interrupt the working of certain cylinder to judge whether the
malfunction occurs in such cylinder. Generally, the cylinder interruption method is to cut off the
fuel supply to the suspiciously malfunctioned cylinder and compare the status changes of the diesel
engine before and after the interruption of cylinder, in order to narrow the scope for further
determination of the malfunction location or cause.
(4) Comparison method: For some assemblies or parts, the replacement method is adopted to
determine the presence of malfunction.
22
Notice:
(1) Judging the malfunction cause of diesel engine is a really precise work. Before the cause is
basically identified, do not disassemble the diesel engine casually, or it will not only eliminate the
malfunction, but also lead to more serious malfunction due to improper assembly after Disassembly.
(2) Inspection and Maintenance on critical components such as high-pressure fuel pump and
turbocharger shall be performed by experienced personnel using special instruments. If having no
such experience or instruments, the customer shall not remove or adjust these components.
3.2 Common Faults and Troubleshooting
3.2.1 Diesel Engine can't Start
Cause Troubleshooting
In event of working failure, firstly exclude the malfunctions of

(1) If the Starter works
electric circuits.
(2) Air temperature too low Add startup aid equipment measures
Bleed the air, check sealing performance of connectors, and restore
(3) Air content in fuel system
accordingly
(4) Blockage of fuel delivery pump inlet
Check and remove dirt and check fuel cleanliness.
filter screen or fuel lines (such as hoses)
Check plunger and fuel outlet valve and repair or replace damaged
(5) Malfunction of fuel injection pump
parts.
(6) Damage or leakage of valve or fuel
Check and adjust
supply pipes
(7) Damage and leakage of high pressure
Restore and replace
fuel pipes
(8) Malfunction of fuel injector Check the injectors for atomization
(9) Insufficient compression pressure of Check sealing performance of valves and cylinder gasket, check
cylinder wear of piston rings, and repair or replace damaged parts.
3.2.2 Stop of Engine Shortly after Start
Check the sealing performance of fuel pipes and connectors, check

（1） Air content in fuel system. and ensure the tightening of bleeder screw, and bleed the remained
air.
Remove the filter body, remove internal contaminant and water,
（2） Blockage of fuel filter.
and when necessary replace element.
（3） Poor fuel quality and high water

Clean filter and replace fuel
content
23
（4） Working failure of fuel delivery
Check piston and valve of fuel delivery pump, clean and restore
pump
（5） Low regulated idling speed Re-adjust
3.2.3 Low Power
Check air filter and intake pipe and clean dirt or replace filter
(1) Intake blockage (blockage of air filter)
element
Check valve timing, check exhaust pipeline for blockage, and
(2) Over-high exhaust backpressure
adjust and repair
(3) Insufficient pressure of turbocharger
Check and solve leaks at pipeline connections.
system
(4) Abnormal working of turbocharger Replace assembly
4-1) Blockage of air compressor or turbine
Clean or replace
runner by dirt
4-2) Failure of floating bearing Replace
4-3) Carbon deposit and oil sludge at back
Clean
gap of turbine and compressor
(5) Damage and air leakage of inter-cooler Replace or repair
Check the tightness of oil pipe and joint, filter pollution and fuel oil
(6) Leakage or blockage of fuel pipe
pipe restoreor clear the fouling, replace the filter element.
(7) Poor fuel quality Clean fuel tank, filtration parts and fuel pipes, and replace fuel
(8) Excessive wear of fuel injection pump
Repair or replace
or speed regulator
(9) Damaged diaphragm of fume
Repair and replace
restriction device of fuel injection pump
(10) Leakage of fume restriction device due
Replace
to air pipe breakage
(11) Poor atomization of fuel injection Check the injection pressure, injection nozzle carbon deposit;
nozzle conduct adjustment or repair
(12) Incorrect valve or fuel supply timing Check and adjust
(13) Under-low high-speed adjustment of
Check speed governor behavior and adjust
speed regulator
(14) Over-high oil level of oil pan Check oil dipstick and drain excessive engine oil
Check compression pressure during warm-up and replace damaged
(15) Air leakage of cylinder gasket
cylinder gasket
(16) Wear and breakage of piston rings and
Replace worn parts or overhaul the engine
excessive gap of bearing shells
(17) Wear or scuffing of cylinder liner or
piston
24
3.2.4 Excessive Fuel Consumption
(1) Blockage of intake pipe Check air filter and intake pipe and clean
(2) Over-high exhaust backpressure Check exhaust pipeline and brake valve and clean accordingly.
(3) Poor fuel quality Replace the fuel oil as required
(4) Blockage of fuel pipe Check and restore
(5) Leakage of fuel pipe Check and restore
(6) Poor atomization of fuel injector Check and adjust or restore
Adjust valve clearance and fuel supply advance angle as per
(7) Incorrect valve or fuel supply timing
specification
(8) Air leakage of cylinder gasket Check the compressed pressure
(9) Excessive gap of bearing shells. The
Check and overhaul
overhaul is required for the engine.
(10) Piston cylinder expanding Replace the cylinder sleeve, piston, and piston ring
system
(12) Abnormal working of turbocharger Check and replace
3.2.5 Black Exhaust Gas
(1) Blockage of intake pipe or excessive

Clean
exhaust backpressure
(2) Poor fuel quality Clean and replace
(3) Incorrect valve or fuel supply timing Adjust as required
(4) Poor atomization of fuel injection
Check, restore or restore
nozzle
(5) Excessive fuel volume of fuel injection
Check and adjust
pump
system
(7) Abnormal working of turbocharger Check and replace assembly
(9) Incorrect application point of smoking
Re-adjust
limiter
25
3.2.6 White or Blue Exhaust Gas
(1) Poor fuel quality and high water

Replace fuel
content
Check working temperature of thermostat and replace when
(2) Under-low coolant temperature
necessary.
(3) Wear of turbocharger seal rings Check and replace
(4) Wear of turbocharger thrust bearing Check and replace
(5) Blockage of turbocharger oil return
Clean or repair
pipe
Check and restore
nozzle
(7) Incorrect valve or fuel supply timing Check and adjust
(8) Low compression pressure, incomplete Check piston rings, cylinder liner, and cylinder gasket and
combustion, and piston expanding restoreaccordingly
(9) Improper run-in of piston rings and
Continue the run-in
cylinder liners
(10) Non-staggered openings of piston
Adjust and reassemble
rings
(11) Failure of piston oil rings Replace
(12) Large fit clearance between piston and
Repair and replace
cylinder liner
3.2.7 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger
(1) Turbocharger sealing failure Repair or replace turbocharger

(2) Failure of oil-gas separator Replace
(3) Over-high oil pan level and Check whether proper engine oil is discharged to meet the
excessively added engine oil stipulations
3.2.8 Unstable Speed
(1) Poor fuel quality, with water or

Replace fuel
paraffin content
Check sealing performance of fuel pipes and connectors and bleed
(2) Air ingress of fuel suction pipe
air
(3) Abnormal working of speed regulator
(Mechanical pump) counterweight and Check and adjust
speed regulation spring
26
(4) Non-uniform fuel supply Check and adjust
(5) Unstable atomization of fuel injector
Check and restore
nozzle
Check and clean air compressor runner, dredge blockage, and
(6) Spray vibration of turbocharger
remove carbon deposit from exhaust passage
(7) Damage of turbocharger bearing Replace
3.2.9 Engine Oil Pressure Too Low
(1) Under-low oil pan level or oil shortage

Replace engine oil as required and choose an appropriate oil
(2) Inappropriate engine oil trademark
trademark
(3) Over-high water temperature of
cooling system and over-high engine oil Check the cooling system for normal working
temperature
(4) Excessive resistance of engine oil filter Replace with new filter element
(5) Blockage of oil cooler Check and clean
(6) Check coarse filter, engine oil pipeline,
Check and clean air compressor runner, dredge blockage, and
and connector gaskets for presence of
remove carbon deposit from exhaust passage
blockage and cracking
(7) Leakage of oil pump inlet pipe Check the oil pipes and connectors and restoreor replace
(8) Malfunction of main oil-way pressure
Check valve and clean and restore
regulator valve
(9) Blockage of main oil-way Check and clean
(10) Excessive gap of bearing shells or
Check and replace
damage of bearing shell
(11) Excessive wear of parts and need
Check engine operation and need overhaul
overhaul
3.2.10 High Coolant Temperature
(1) Under-low level in water tank Check water leaks and add water
(2) Blockage of water tank radiator fins Clean water tank radiator fins.
(3) Loose water pump belt Adjust tension as per specification
(4) Damage of water pump gasket and
Check and restoreor replace
wear of water pump impellor
(5) Damage of water pipe and ingress of Check water pipes, connectors, and gaskets and replace damaged
air parts
(6) Thermostat malfunction Replace
(7) Blockage of water tank Check water tank and clean or restore
27
(8) Under-low oil pan level or oil shortage Check oil level and oil leaks, restore, and add oil
3.2.11 Excessive Wear of Parts
(1) Disqualified or damaged air filter

Check and replace with qualified filter element
element
Check intake pipe, gasket, and connecting pipe sleeve and restoreor
(2) Short-circuit of intake system.
replace
(3) Failure for timely replacement of
Replace as per specification
engine oil filter element
(4) Under-low oil pan level or oil shortage Check oil level and oil leaks, restore, and add oil
(5) Inappropriate oil trademark Replace with specified oil
(6) Use of disqualified engine oil Use qualified oil trademark
(7) Blockage of oil-way Clean oil-way
(8) Breakage or wear of piston ring Replace damaged parts
Remove and check piston and cylinder liner and restoreor replace
piston
(10) Crankshaft misalignment with driven
Check mounting bracket and repair
shaft
(11) Excessive wear of parts. The overhaul
Check current mileage and determine overhaul
is required.
3.2.12 Excessive Noise
(1) Poor fuel quality Replace fuel

(2) Under-low coolant temperature Check thermostat and replace when necessary
(3) Incorrect valve or fuel supply timing Check, restore, and adjust
Check, restore, and adjust
nozzle
(5) Excessive fuel volume of fuel injection
Check and adjust
pump
Check for damage, check state of connecting bolts, and replace
(6) Wear of vibration damper
damaged parts
(7) Air leakage or improper adjustment of
Remove and check valves and adjust
valve
(8) Excessive gear backlash or broken
Check and replace damaged parts
teeth
Check and restoreor replace
piston
(10) Bending or breakage of push rod and Replace
28
breakage of rocker
(11) Breakage or wear of piston ring Check or replace damaged parts
3.2.13 Working Failure of Starter Motor
(1) Burnt fuse Replace fuse

(2) Poor contact of connecting wires Clean circuits and tighten wiring posts
(3) Insufficiently charged battery Check and charge or replace battery
(4) Short-circuit of starter motor Check and repair motor or replace assembly
(5) Poor contact of electric brush Clean electric brush surfaces or replace electric brush
3.2.14 Weak Starter Motor
(1) Insufficiently charged battery Charge or replace battery

(2) Wear of bearing bushing Replace assembly
(3) Poor contact of electric brush Clean electric brush surfaces or replace electric brush
(4) Dirty or burnt commutator Remove oil dirt and polish with sand paper or replace assembly
(5) Loose weld of wire ends Re-weld
(6) Poor contact of switch Check and restoreswitch
(7) Slip of friction clutch Adjust working moment of clutch or replace assembly
3.2.15 Generally Cannot Generate Electricity at All
(1) Open circuit, short circuit, or loosen Check alternator and ampere meter for loose connection.
connection Reconnect conductor if necessary.
(2) Open circuit, short circuit, or earthing
Repair or replace assembly
of rotor coil or stator coil.
(3) Rectifier damaged Replace assembly
(4) Terminal paper insulation damaged, or
Restore
conductor disconnected
(5) Regulator voltage setting too low Restore
(6) Regulator contact fusion Restore or replace assembly
3.2.16 Inadequate Charging Current of Alternator
(1) Open circuit, short circuit, or loosen

Restore
connection
29
(2) Open circuit, short circuit, or earthing
Restore or replace assembly
of rotor coil or stator coil.
(3) Loose alternator belt Check and adjust belt tension
(4) Rectifier of alternator damaged;
Restore
battery loose connection
(5) Regulator voltage setting too low Adjust
(6) Regulator coil or resistor disconnected Restore or replace
(7) Insufficient battery electrolyte, or old
Add electrolyte, or replace battery
battery
3.2.17 Instable Charging Current
(1) Open or short circuit is to occur for

Restore or replace
stator coil or rotor coil
(2) Poor contact of electric brush Restore
(3) Terminal comes loose or poor contact Restore
(4) Damage of voltage regulator Restore
(5) Improper voltage regulation Check and adjust
3.2.18 Excessive Charging Current of Alternator
(1) Internal short circuit of battery Restore or replace

(2) Regulator voltage too high Restore and adjust
(3) Regulator insecure earthing Restore
(4) Regulator contact failed, voltage coil
Restore or replace
disconnected, or resistor disconnected
3.2.19 Abnormal Sound from Alternator
(1) Improper alternator installation Restore

(2) Rotor comes in contact with stator Restore or replace
(3) Damaged bearing Replace bearing
(4) Short circuit of rectifier Replace
(5) Short circuit of stator coil Restore or replace
30
Chapter IV Disassembly and Assembly of Engine
4.1 Overview
During Disassembly and Assembly of engine, please follow operating instructions in this manual
strictly and pay attention to operation steps containing danger and safety marks, so as to ensure
personal safety and avoid accidents.
4.1.1 Danger Sign
This sign is a worldwide recognized warning sign. In the

manual, this sign is used to stress the importance of the
following information. Please make sure that you know what
potential risks are and how to ward off such risks. In case of
any behaviors in violation of the warning information, it may
result in damage to property, personal injury and even death.
Some common danger signs are usually used for ordinary
warnings. Warning information in this manual is classified
into different types (slight injury, serious injury and death)
according to severity of possible consequences.
This warning sign indicates a potential danger, which, if not
Warning
warded off, may lead to slight injury or property loss. It is also
used to warn against dangerous operations.
This warning sign indicates a potential danger, which, if not
Notice
warded off, may lead to severe injury, death or major property
loss.
The instructions herein are provided to explain how to correctly operate and safely use the engine of
our company.
Simply reading through this document will not prevent risks from happening. But only through
adequate understanding can these instructions will be correctly applied.
The warning information provided herein may not cover all possible situations!
If you decide to use a procedure or a method that is not recommended, please make sure that such
operation will not bring harm to yourself, any other person or the equipment.
31
4.1.2 Safety Sign
Sign Description
During use of the engine, many potential dangers occur without any signs. Hence, this manual
cannot give warning instructions for all kinds of potential danger. If the procedures taken by you are
not recommended ones, please ensure the same procedures are safe to operate and do not result in
any damage to property.
32
4.1.3 DisassemblyTool
Should any method or tool used is not recommended in this manual, the user must first ensure
personal safety, and avoid jeopardizing the life of the user or other personnel, as well as guarantee
that the use, maintenance or repairing method will not cause damage risks or jeopardize personal
safety.
4.1.4 Precautions for Health Protection
The following “Precautions for health protection” are to reduce pollution risks.
(1) Avoid the long-term repeated touch of used engine oil.
(2) If possible, please wear the protective clothing and water-proof gloves.
(3) Never place any oil-immersed rag into your pocket.
(4) Guard your clothing, especially the underwear, against the oil contamination.
(5) Wash your working clothing frequently. Throw away oil-immersed clothing and shoes that
can’t be cleaned.
(6) In event of cuts or injuries, please immediately take the emergency treatment. In the case of
serious injury, seek medical aid immediately.
(7) Make sure to apply to apply the protective paste before operations, which will make the
Disassembly of oil easier if your skin is contaminated by mineral oil.
(8) Use soap and hot water or use liquid soap and fingernail brush to wash hands, in order to
completely remove oil dirt. If the naturally secreted grease on your skin is removed during the
33
hand-washing, a product with wool fat content can replace this naturally secreted grease to help
moisturize the skin.
(9) Do not clean the skin by gasoline, kerosene, fuel, thinner, or solvent.
(10) Upon detection of skin irritation, please immediately seek for medical treatment.
(11) If possible, deoil the parts before the handling of parts.
(12) Please use goggles or face mask whenever your eyes are endangered. Make sure to prepare the
eye flushing fluid at all accessible places.
(13) During the repair of engine, never splash oil or other liquid onto the ground. In event of
accidental leakage of hydrocarbon or other liquid, take all necessary measures to quarantine this
area to keep clean the environment and guard personnel against injuries.
(14) The handling, storage, and recovery of hydrocarbon, ethylene, glycol, and petroleum must
abide by the safety and environmental standards of the country in which the operations are fulfilled.
4.1.5 Precautions for Environment Protection
Please observe relevant environmental protection laws and regulations with respect to disposal of
waste oil and hydrocarbons. For details, consult local officials.
4.1.6 Precautions on Disassembly and Installation of Engine
Most accidents in connection with use, maintenance and service of engine are resulted from failure
to observe safety rules and basic precautions. So, you should know risks you face and take
corresponding preventive measures to avoid occurrence of accidents. Operation, maintenance, and
repair of the engine shall be performed by personnel who have received required trainings and have
proper skills using proper tools.
Failure to follow relevant instructions given in this manual may result in serious accidents, even
endangering the operator's life. Weichai Power Co., Ltd. cannot foresee all potential risks. Similarly,
guidelines and instructions specified in this manual are not exhaustive.
Before proceeding with maintenance or repairing, a signboard containing “Don’t Use” or a similar
sign should be placed on the starter switch.
Before use of the barring rod, necessary preventive measures should be taken.
Ensure that the maintenance site and surrounding environment are suitable for safe operation.
Ensure the maintenance workshop or area around the engine is clean and neat.
Before work, remove ring, necklace and watch, and wear well-fitted working clothes.
34
Before working, please check whether corresponding protection equipment (goggles, gloves, shoes,
masks, working uniform, helmet, etc.) are within effective life.
Do not use faulty or unsuitable tools.
Stop the engine during maintenance or service.
35
4.2 Engine Block Group
4.2.1 Disassembly and Assembly of Engine Block Group
4.2.1.1 Exploded View for Assembly of Engine Block Group
The engine body group consists mainly of the cylinder block preassembly, cylinder head, cylinder
head cover, main and auxiliary bolts of cylinder head, oil pan, flywheel cover, front end cover, front
and rear oil seals, oil-gas separator, and cup plug. Main parts are shown in Figure 4-1 and Figure 4-
2.
Auxiliary bolt, cylinder headCylinder liner Cylinder pre-assembly
Flexible parallel pin

Sealant pre-applied set screw
Parallel pin
Cup plug
Self-plugging rivet
Cup plug
Lock washer
Hex socket-head screw

Hexagon bolt
Figure 4-1 Exploded View I for Assembly of Engine Block Group
36
Combination washer
Rear screw plug of main oil line
Cup plug
Self-plugging rivet
Seal ring
Main bearing bolt
Figure 4-2 Exploded View II for Assembly of Engine Block Group
4.2.1.2 Engine Block Group Disassembly Procedures
(1) Remove the bolts on the peripheral of crankcase (point 1).

(2) Remove the main bearing bolts (point 2).
(3) Remove the seal ring.
(4) Remove the auxiliary bolts of cylinder head (point 3).
(5) Remove the screw plug of Main oil-way.
(6) Remove the cylinder liners (point 4).
4.2.1.3 Inspection and Maintenance of Engine Block Group
Point 1:
Assembly: Tighten the bolts on the peripheral of crankcase to the torque of 22N·m～29N·m (for
grade 8.8 bolts), or 29N·m～35N·m (for grade 10.9 bolts).

Point 2:
37
Assembly: Tighten the bolts on the peripheral of crankcase to the torque of 22N·m～29N·m (for
grade 8.8 bolts), or 29N·m～35N·m (for grade 10.9 bolts). Before installation, apply clean
lubricating oil to the supporting face of crankcase and the threads of main bearing bolts.
11 10 3 2 5 8 13
Ⅶ Ⅵ Ⅴ Ⅳ Ⅲ Ⅱ Ⅰ
14 7 6 1 4 9 12
Figure 4-3 Tightening Sequence of Main Bearing Bolts

Point 3:
Assembly: Tighten the bolts on the peripheral of crankcase to the torque of 22N·m ～ 29N·m (for
grade 8.8 bolts), or 29N·m～35N·m (for grade 10.9 bolts). The auxiliary bolts can be used at most
twice.
18 12 5 6 7 13 19
17 11 4 1 8 14 20
16
Ⅵ 10
Ⅴ 3
Ⅳ 2
Ⅲ 9
Ⅱ 15
Ⅰ 21
Figure 4-4 Tightening Sequence for Cylinder Head Auxiliary Bolts

Point 4:
Before installation, check carefully the cylinder liners for cracks. Clean the cylinder liners. Apply
molybdenum power to the outer surface of cylinder liner. Using the special tool, press the cylinder
liner into cylinder bore. Before doing so, apply molybdenum powder to the outer surface of cylinder
liner.
4.2.1.4 Engine Block Group Assembly Procedures
Assembly of engine body group is in the reverse order of disassembly.
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4.2.2 Disassembly and Assembly of Cylinder Block Preassembly
4.2.2.1 Exploded View of Cylinder Block Preassembly
The cylinder block preassembly consists mainly of the cylinder block, crankcase, camshaft
bushings, oil dipstick subassembly, and cup plug. Main parts are shown in Figure 4-5 and Figure 4-
6.
Figure 4-5 Exploded View I of Cylinder Block Preassembly

1- Cylinder 2- Cup 3- Crankcase; 4- Hex socket-head 5- Bushing; 6- Cup
block; plug; screw; plug
39
Oil dipstick tube head Oil dipstick
Cup plug
Oil dipstick tube
Cup plug
Camshaft bushing
Oil dipstick Oil

tubedipstick tubeThreaded
bushing connecting pipe
Figure 4-6 Exploded View of Cylinder Block Preassembly II
4.2.2.2 Cylinder Block Preassembly Disassembly Procedures
(1) Remove the parallel pin with internal threads.

(2) Remove the camshaft bushings (point 1)
(3) Remove the main bearing bolts and crankcase fixing bolts.
(4) Remove the crankcase (point 2).
(5) Remove the oil dipstick combination (point 3).
4.2.2.3 Inspection and Maintenance of Cylinder Block Preassembly
Point 1:
Disassembly: Using a special tool, remove the camshaft bushing. While doing so, be careful not to
cause damage to other bushings.
Assembly: Before installing the camshaft bushing, check the inner surface of camshaft bushing for
scratches. If any, replace it. Align the lubricating oil hole in the camshaft bushing with that for
camshaft in the engine body.
Point 2:
Assembly: Before installation, clean and apply sealant to the upper plane of the crankcase.
Point 3:
Assembly: Connect the oil dipstick to the sleeve. Apply sealant to the lower section of the sleeve.
Using a copper hammer, tap the sleeve into the mounting hole in the crankcase.
40
4.2.2.4 Cylinder Block Preassembly Assembly procedures
Assembly of the cylinder block preassembly is in the reverse order of disassembly.
4.2.3 Disassembly and Assembly of Front End Cover
4.2.3.1 Exploded View for Assembly of Front End Cover
The front end cover subgroup consists mainly of the front end cover, seal ring, and fixing bolts. See
Figure 4-7.
Figure 4-7 Exploded View for Assembly of Front End Cover

1- Corrugated 2- Seal 3- Front end 4- Stud bolt; 5- Nut; 6- Hex socket-
gasket; washer; cover; head screw;
7- Hexagon bolt; 8- Nut; 9- Stud bolt; 10- Air 11- Gasket; 12- Corrugated
41
compressor gear gasket
cover.
4.2.3.2 Front end cover Disassembly Procedures
(1) Remove the front end cover fastening bolt;

(2) Remove the front end cover;
(3) Remove the front end cover seal ring.
4.2.3.3 Inspection and Maintenance of front end cover
Point 1:
The removed front end cover shall be put in a clean place. Before assembling the front end cover,
check its inner side for dirt. Remove it if any.
Point 2:
Before installing the front end cover, apply sealant to the mating face of engine body. Ensure that
the sealant strips are continuously without interruption.
Point 3:
Check the seal ring for damage. Replace the damaged seal ring with a new one. Press the seal ring
completely in the groove of front end cover.
4.2.3.4 Front End Cover Assembly Procedures
Assembly of the front end cover is in the reverse order of Disassembly.
4.2.4 Disassembly and Assembly of Gear Chamber
4.2.4.1 Exploded View for Assembly of Gear Chamber
The gear chamber subgroup consists mainly of the gear chamber, screw plug, gasket, and bolts. See
Figure 4-8.
42
Figure 4-8 Exploded View for Assembly of Gear Chamber
1- Engine block; 2- Pin; 3- Gear chamber; 4- Combination
washer;
5- Hexagon screw plug; 6- Front seal seat and front 7- Corrugated 8- Hexagon bolt;
seal; gasket;
9- Hex head tooth-flanged 10- Hex head tooth-flanged 11- O-type seal ring; 12- Seal ring
bolt; bolt;
4.2.4.2 Gear Chamber Disassembly Procedures
(1) Remove the gear chamber; fixing bolts (point 1).

(2) Remove the plug and combination washers.
(3) Remove the intermediate gear shaft.
(4) Remove the intermediate gear shaft and intermediate gear shaft bolt of the engine oil pump.
(5) Remove the gear chamber (point 3).
(6) Remove the seal ring (point 2).
4.2.4.3 Inspection and Maintenance of Gear Chamber
Point 1:
43
Assembly: Diagonally tighten the gear chamber fixing bolts in the sequence shown in Figure 4-9.
Tightening torque: (44-58) N·m.
Figure 4-9 Sequence for tightening the gear chamber; fixing bolts
Point 2:
Assembly: Before installing the seal ring, check it for scratches and other defects. If any, replace it
with a new one. Before installing the seal ring, apply lubricating oil to it, and then press it fully in
the groove, avoiding damage caused by the groove.
Point 3:
Disassembly: Remove first the gear chamber fixing bolts, then the intermediate gear shaft of the
gear chamber, and the intermediate gear shaft of the engine oil pump. These individual components
must be placed in a clean environment.
Assembly: Install the intermediate gear shaft to the intermediate gear; then put them in the gear
chamber. Apply sealant to the coolant inlet and outlet in the cylinder block, and then press the seal
rings in place.
4.2.4.4 Gear Chamber Assembly Procedures
Assembly of gear chamber is in the reverse order of disassembly.
4.2.5 Disassembly and Assembly of Flywheel Cover
The flywheel cover subgroup consists mainly of the flywheel cover, observation hole cover plate,
locating parallel pin, stud bolts, washers, and nuts. See Figure 4-10.
44
Stud bolt
Spring washer
Type 1 hexagon nut Flywheel cover
Flywheel cover bolt
Observation hole cover plate

Hexagon bolt
Parallel pin
Figure 4-10 Exploded View for Assembly of Flywheel Cover
4.2.5.1 Flywheel CoverDisassembly Procedures
(1) Remove the flywheel cover fixing bolts (point 1).

(2) Remove the flywheel cover observation hole cover plate fixing bolts and the observation hole
cover plate.
(3) Remove the flywheel cover (point 2).
4.2.5.2 Inspection and Maintenance of Flywheel Cover
Point 1:
Assembly: The flywheel cover bolts shall be tightened symmetrically according to the order given
in the figure 4-11, tightening torque is (110-140) N·m. Before assembly, paint oil on the bolt flange
face. The flywheel cover bolts can be used for two repeated times.
45
Figure 4-11 Tightening sequence of flywheel cover bolts
Point 2:
Assembly: Apply uniformly sealant to junction plane between cylinder block and flywheel cover
and guard flywheel cover against knocking damage during hoisting.
4.2.5.3 Flywheel Cover Assembly Procedures
Assembly of the flywheel cover is in the reverse order of Disassembly.
4.2.6 Disassembly and Assembly of Oil Pan
4.2.6.1 Exploded View for Assembly of Oil Pan
The oil pan combination consists mainly of the oil pan, gasket, magnetic plug assembly, fixing
bolts, washers, and supporting block. See Figure 4-12.
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3- Hexagon flange
1- Crankcase 2- Sealing gasket; 4- Spacer block;
bolt
5- Oil pan
6- Washer 7- Magnetic plug
assembly;
Figure 4-12 Exploded View for Assembly of Oil Pan
4.2.6.2 Oil Pan Disassembly Procedures
(1) Turn over the diesel engine with the oil pan facing up (point 1).
(2) Remove the oil pan fixing bolts (point 2);
(3) Remove the oil pan supporting block.
(4) Remove the oil pan and sealing gasket;
(5) Remove the magnetic plug and combination washers.
4.2.6.3 Inspection and Maintenance of Oil Pan
Point 1:
Disassembly: Oil pan should be discharged before disassembly. Place the container containing oil
beneath the drain plug of the oil pan, and use a screw plug wrench to loosen the drain plug to empty
oil.
Point 2:
Assembly: Tighten the bolts in the sequence as shown in Figure 4-13 to the torque of (22 ~29) N·m.
47
Figure 4-13 Sequence for tightening the oil pan fixing bolts
4.2.6.4 Oil PanAssembly Procedures
Assembly of the oil pan is in the reverse order of disassembly.
4.2.7 Disassembly and Assembly of Piston Nozzle
4.2.7.1 Exploded View for Assembly of Piston Nozzle
The piston nozzle combination consists mainly of the nozzle assembly, bolt, washer, and flexible
parallel pin. See Figure 4-14.
Hollow bolt
Sealing washer
Nozzle assembly
Flexible parallel pin
Figure 4-14 Exploded View for Assembly of piston nozzle
4.2.7.2 Piston Nozzle Disassembly Procedures
(1) Remove the hollow bolt (point 1).

(2) Remove the nozzle assembly.
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(3) Remove the flexible parallel pin (point 2).
4.2.7.3 Inspection and Maintenance of Piston Nozzle
Point 1:
Assembly: The hollow bolt shall be tightened to the torque of (20~30)N·m.
Point 2:
Assembly: Check the locating pin for damage. Replace the damaged locating pin. Aligning the
locating pin with the pin hole in the engine body, tap the nozzle body using a copper hammer, until
the locating pin fully enters the hole.
4.2.7.4 Piston Nozzle Assembly Procedures
Assembly of the piston nozzle is in the reverse order of Disassembly.
4.2.8 Disassembly and Assembly of Thrust Halfring
4.2.8.1 Exploded View for Assembly of Thrust Halfring
The thrust halfring combination consists mainly of the upper and lower thrust halfrings. See Figure
4-15.
Upper thrust halfring
Lower thrust halfring
Figure 4-15 Exploded View for Assembly of thrust halfring
4.2.8.2 Thrust Halfrings Disassembly Procedures
(1) Remove the crankcase;

(2) Remove the crankshaft;
(3) Remove the thrust halfrings (point 1).
49
4.2.8.3 Inspection and Maintenance of Thrust Halfrings
Point 1:
Assembly: Thrust halfrings must be used in pairs. Install the crankshaft to the engine body. Install
the upper thrust halfring (no lug). Apply grease to the lower thrust halfring; then press slightly it to
the crankcase. The lower thrust halfring is installed along with the crankcase. Thrust halfrings shall
be installed with their lubricating oil grooves facing out.
4.2.8.4 Thrust Halfring Assembly Procedures
(1) Install the crankshaft.

(2) Install the upper thrust halfring (no lug).
(3) Install the lower thrust halfring (point 1).
4.2.9 Disassembly and Assembly of Front and Rear Oil Seal
4.2.9.1 Exploded View for Assembly of Front and Rear Oil Seal
The installation unit of front and rear oil seals consists mainly of the front and rear oil seals. The
rear oil seal is shown in Figure 4-16.
Figure 4-16 Exploded View for Assembly of rear oil seal

1- Rear oil seal; 2- Front oil seal
4.2.9.2 Front and Rear Oil SealDisassembly Procedures
(1) Remove the gear chamber (see this chapter).
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(2) Remove the front oil seal (point 1).
(3) Remove the Crankcase;
(4) Remove the rear oil seal (point 1).
4.2.9.3 Inspection and Maintenance ofFront and Rear Oil Seal
Point 1:
Assembly: Before installation, remove dirt (if any) from the mounting hole and oil seal. Using a
special tool, press steadily the oil seal in place. Before installation, apply lubricating oil to both the
special tool and the oil seal.
Disassembly: It will no longer use the oil seal after disassembled.
4.2.9.4 Front and Rear Oil SealAssembly Procedures
(1) Install the crankcase.

(2) Install the rear oil seal.
(3) Install the gear chamber.
(4) Install the front oil seal.
4.2.10 Disassembly and Assembly of Cylinder Head Group
4.2.10.1 Exploded View for Assembly of Cylinder Head Group
The cylinder head is located on the upper portion of the cylinder block and works with piston head
to form the combustion chamber. The parts connected with the cylinder head include intake pipe,
exhaust pipe, water outlet pipe, fuel injector, cylinder head cover, oil-gas separator, cylinder head
gasket, and some parts of valve mechanism. See Figure 4-17.
51
Cylinder head coverCylinder
gasket head cover
Install the rocker arm seat, rocker arm and valve spring.
Nut
Clamping block Rear lifting plate
Cylinder cover main bolt
Fuel injector
Front lifting plate

Water outlet pipe
Intake pipe
Exhaust pipe
Valve stem seal
Cylinder head gasket Cylinder head
Auxiliary bolt, cylinder head

Oil-gas separator
Cylinder block
Valve
Figure 4-17 Exploded View for Assembly of cylinder head group
4.2.10.2 Cylinder Head GroupDisassembly Procedures
The Disassembly Procedures are indicated in turn:

(1) Remove the exhaust pipe. For details, see the instructions for Disassembly of intake and
exhaust system .
(2) Remove the intake pipe. For details, see the instructions for Disassembly of intake and exhaust
system .
(3) Remove the oil-gas separator;
(4) Remove the water outlet pipe;
(5) Remove the front and rear lifting plates;
(6) Remove the fuel pipe;
(7) Remove the fuel injector harness. Remove the fuel return pipe of fuel injector and the high
pressure fuel pipe. For details, see the instructions for Disassembly of fuel system .
(8) Removal the fuel injector. For details , see the instructions for Disassembly of fuel system;
(9) Remove the cylinder head cover and the cylinder head cover gasket.
(10)Remove the rocker arm assembly and push rod. For details, see the instructions for
Disassembly of valve mechanism.
(11) Remove the cylinder head subassembly and the cylinder head gasket.
52
The sequence for tightening the bolts is shown in Figure 4-18.
1) Tighten the main bolts to the torque of 2000N·m (MF). Then make marks on the bolts.
2) Tighten the nuts of auxiliary bolts in the specified sequence by 90º. Then make marks on the
nuts.
3) Tighten the main bolts in the specified sequence by 90º. Then make marks on the bolts.
4) Tighten the nuts of auxiliary bolts in the specified sequence by another 90º to the torque of
(120~160)N·m.
5) Tighten the main bolts in the specified sequence by another 90º to the torque of (240~340)N·m.
Figure 4-18 Sequence for tightening the main bolts

(12)Remove the inner and outer springs of valves, spring upper and lower seats of intake and
exhaust valves, valve collets, and valves. For details, see the instructions for Disassembly of valve
mechanism.
(13)Remove the valve stem seal.
4.2.10.3 Cylinder Head Group Assembly procedures
Assembly of cylinder head group is in the reverse order of disassembly.
4.2.11 Disassembly and Assembly of Cylinder Head Cover
4.2.11.1 Exploded View for Assembly of Cylinder Head Cover
The cylinder head cover subgroup consists mainly of the cylinder head cover, gasket, and fixing
bolts. See Figure 4-19.
53
Figure 4-19 Exploded View for Assembly of Cylinder Head Cover
1- Cylinder head cover gasket; 2- Cylinder head cover; 3- Hexagon flange bolt
4.2.11.2 Cylinder Head CoverDisassembly Procedures
Tools: Socket wrench or pneumatic wrench.

Preparation before Disassembly: Fix the engine. Remove the parts above the cylinder head.
(1) Using a wrench, loosen the bolts of cylinder head cover, and the supporting block. Remove the
bracket.
(2) Vertically pull up the cylinder head cover and cylinder head cover gasket.
(3) Put the cylinder head cover and cylinder head cover gasket at an appropriate location for
inspection.
4.2.11.3 Inspection and Maintenance of Cylinder Head Cover
(1) Observe the cylinder head cover for presence of cracking and serious wear. Upon detection of
cracking, replace with new cylinder head cover.
(2) In the case of oil leakage from the cylinder head cover gasket, check for cylinder head gasket
failure, and excessive wear of the upper plane of cylinder head and the underside of cylinder head
cover. Replace the cylinder head cover gasket with a new one, and then check whether oil leakage
still occurs.
4.2.11.4 Cylinder Head CoverAssembly Procedures
(1) The cylinder head cover gaskets can be used only once. Replace with new ones in event of
repair. Before installing cylinder head cover gaskets, check and ensure that new cylinder head cover
gaskets are free of manufacturing and operation defects and damages;
(2) Wipe clean the top face of cylinder head and assemble cylinder head gaskets correctly in turn;
54
(3) Clean the cylinder head cover, and accurately install it onto the cylinder head cover in turn.
(4) Install the cylinder head cover bolts, and then tighten them.
4.2.12 Disassembly and Assembly of Oil-gas Separator
4.2.12.1 Exploded View for Assembly of Oil-gas Separator
The oil-gas separation subgroup consists mainly of the oil-gas separator, gas inlet pipe, gas outlet
pipe, oil return pipe, bolts, washers, pipe clamps, and clamps. See Figure 4-20.
Figure 4-20 Exploded View for Assembly of oil-gas separator

2- Gas inlet pipe joint of oil- 3- Blot; 4- Oil-gas 5- Oil-gas separator
gas separator; separator; outlet pipe;
6- Clamp; 7- Oil-gas-separator return 8- Pipe clamp; 9- Clamp;
fuel pipe;
4.2.12.2 Oil-gas SeparatorDisassembly Procedures
Tools: Socket wrench or pneumatic wrench and open-end wrench.

(1) Remove the two bolts used for fixing the gas inlet pipe joint of oil-gas separator to the cylinder
block.
(2) Remove the bolt used for fixing the oil-gas separator to the lifting ring clamping block.
(3) Remove the bolts used for fixing the gas outlet pipe clamps and return oil pipe clamps of oil-
gas separator. Remove the gas outlet pipe. Remove the clamps for the return oil hose and return oil
pipe. Remove the return oil hose.
(4) If the return oil pipe that extends into the oil pan shall be removed for inspection, loosen the
return oil pipe using a wrench then take it out.
55
4.2.12.3 Inspection and Maintenance of Oil-gas Separator
(1) Check the parts for damage including cracks. Check the hose for failure such as hardening and
brittleness. If any, replace the faulty part.
(2) Feed air to the gas inlet pipe of the oil-gas separator to check for obstruction. In the case of
obstruction, feed pressurized air to the nipples of oil-gas separator to remove foreign matters such
as oil sludge. If obstruction is still there, replace the oil-gas separator with a new one.
(3) If oil leakage occurs where the gas inlet nipple is connected to the engine body, check the O-
ring for damage. Replace the damaged O-ring.
(4) Ensure the hoses are securely connected to the correct nipples, without twisting. The
arrangement of the hoses shall be meet the diesel engine requirements.
4.2.12.4 Oil-gas Separator Assembly Procedures
(1) Install the oil-gas separator. Tighten the two bolts used for fixing the gas inlet pipe joint of oil-
gas separator.
(2) Install the bolt used for fixing the oil-gas separator to the front lifting plate.
(3) If the connecting pipe at the end of return oil pipe of oil-gas separator is removed, insert the
connecting pipe into the crankcase correctly. Tighten the sleeve.
(4) Install the clamps and clamps for the gas outlet pipe and return oil pipe of the oil-gas separator,
and those for the return oil pipe of the oil pan.
4.2.13 Disassembly and Assembly of Engine Lifting Plate
4.2.13.1 Exploded View for Assembly of Engine Lifting Plate
The engine lifting plate subgroup consists mainly of the front and rear lifting plates, bolts, and
washers. See Figure 4-21.
56
Hexagon bolt
Rear lifting plate
Hexagon bolt
Front lifting plate
Figure 4-21 Exploded View for Assembly of Lifting Plate
4.2.13.2 Engine Lifting PlateDisassembly Procedures
Used for lifting the engine, the lifting plates are fixed to the main bolts of cylinder head. Remove
the parts fixed on the lifting plate (such as oil-gas separator, etc.), loosen the hexagon bolts of the
engine lifting plate in turn, and take out the lifting plate.
4.2.13.3 Inspection and Maintenance of Engine Lifting Plate
Remove the front and rear lifting plates and check them for failures, such as cracks and serious
deformation. Check the hexagon bolts for failure. In the case of failure, replace the failed part with a
new one to prevent possible accident.
4.2.13.4 Engine Lifting PlateAssembly Procedures
Distinguish the front lifting plate from the rear one. The front lifting plate is installed in the front of
the engine (on the side of fan). The rear lifting plate is installed in the rear of engine (on the side of
flywheel). Tighten the M12 bolts all the way to the torque of (100~125)N·m.
4.2.14 Disassembly and Assembly of Cylinder Head
4.2.14.1 Exploded View for Assembly of cylinder head
The cylinder head subgroup consists mainly of the cylinder head, cylinder head gasket, main and
auxiliary bolts, and clamping blocks. See Figure 4-22.
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Figure 4-22 Exploded View for Assembly of cylinder head
1- Cylinder block; 2- Auxiliary bolt, 3- Cylinder head 4- Cylinder head; 5- Valve stem seal;
cylinder head; gasket;

6- Lifting ring 7- Clamping block; 8- Lifting ring joint 9- Nut; 10- Lifting ring
clamping block; block; screw;

11- Cylinder cover 12- Clamping block; 13- Clamping block;
main bolt;
4.2.14.2 Cylinder Head Disassembly Procedures
Tools: Socket wrench or pneumatic wrench, torque spanner, and open-end wrench.
Preparation before disassembly: Disassemble the cylinder head cover, lifting plates, intake and
exhaust pipes, water outlet pipe, high-pressure fuel pipe, and other parts possibly fixed to the
cylinder head.
(1) Loosen and remove the fixing screws and joint blocks of lifting rings.
(2) Loosen the nuts of auxiliary bolts of cylinder head. Remove the clamping blocks. In terms of
installation location, four designs are provided for the clamping blocks. (1) the clamping blocks
have a cylinder shape, installed between two cylinder heads and to one auxiliary bolt; (2) the
clamping blocks have a rectangular solid shape, installed to two auxiliary bolts; (3) the clamping
bolts are installed at both ends of the engine, on only a cylinder head, and to two auxiliary bolts;
joint blocks of lifting rings may be installed to the clamping blocks; (4) the clamping blocks are
installed at both ends of the engine, on only a cylinder head, and to one auxiliary bolt.
58
(3) Loosen the main bolts of cylinder head. Remove the main bolts and put them at a proper
location.
(4) Remove the fuel injectors. Since the fuel injector heads normally project beyond the cylinder
head underside, make sure that the fuel injectors have been removed before removing the cylinder
head. Otherwise, damage is probably caused to the fuel injector heads when the cylinder head
removed is put at a location.
(5) Remove the cylinder head and place the removed cylinder head on a paper board, in order to
prevent wearing the top surface of combustion chamber and other sealing surfaces. If the
Disassembly of multiple cylinder heads is required, mark the cylinder heads with cylinder numbers
to ease the problem analysis.
(6) Remove the cylinder head gasket. If the Disassembly of multiple cylinder head gaskets is
required, mark the cylinder numbers on the cylinder head gaskets to ease the problem analysis.
(7) If the replacement or checking is required for the cylinder head auxiliary bolts, remove the
cylinder head auxiliary bolts.
(8) Remove the parts of the Valve Mechanism, such as rocker arm seats, and intake and exhaust
valves (see the section of Valve Mechanism).
(9) If the valve stem seal shall be checked or replaced, remove it using a special tool. The valve
stem seal may also be removed using a pair of pliers. Clamp the outer surface of the valve stem seal
using the pliers. Rotate the pliers up and down, to take out the valve stem seal. The removed seal
may not be reused.
4.2.14.3 Inspection and Maintenance of Cylinder Head
(1) Before removing the cylinder head, check the interface between cylinder head and engine body
for signs of water, air, oil, and fuel leakage, and other abnormal signs. In the case of leakage,
replace the cylinder head gasket with a new one. Check whether the leakage occurs. Refer to this
section for the Disassembly and installation of cylinder head gasket.
(2) Check appearance of cylinder head. Check discoloration and crack of the cylinder head
carefully, and in case of crack, carry out penetrant inspection.
(3) Before removing the Valve Mechanism, measure the valve sink, which is the vertical distance
between valve underside and cylinder head underside. The difference between measured and
required valve sinks reflects indirectly the degrees of wear of valve and valve seat. It is possible to
59
use depth micrometer to measure the valve sink as shown in Figure 4-23.
Figure 4-23 Measuring valve sink using a depth micrometer

For the required valve sinks, refer to Table 4-1. If measured valve sink is outside the specified
range, check the degrees of wear of the valve and valve seat. To check the degree of wear of the
valve seat, a new valve may be used to measure the valve sink.
If the valve sink is still outside the specified range, the cylinder head shall be replaced to ensure the
reliability of diesel engine operation.
If the valve sink does not exceed the permissible value, remove the valve for checking and then
check the sealing surface of the valve seat ring. Check whether there is apparent wear and abnormal
damage to the valve and the sealing surface of the valve seat ring.
Table 4-1 Required Valve of Valve sink
Item Required Valve sink Values (mm)

Intake valve 0.85~1.05
Exhaust valve 1.08~1.48
(4) With the Valve Mechanism removed, check the intake and exhaust ducts in the cylinder head
for sign of water leakage. If any, clean the cylinder head. Using the paint impression method,
identify the cause for leakage. If necessary, replace the cylinder head with a new one.
(5) Clean the cylinder head, and clean the surfaces of the combustion chamber, valve seat, intake
and exhaust valves, intake and exhaust ports, and remove the carbon deposit and varnish, as well as
inspect surface conditions.
(6) Check inside diameter of valve guide. The inside diameter of the valve guide is the contact
surface between the valve guide and the valve, and if the inside diameter of the valve guide exceeds
the permissible value due to wear, it will result in influence on guiding effect of the valve, reducing
reliability of the diesel engine operation.
The inside diameter of the valve guide can be measured by use of an inside micrometer, as shown in
60
Figure 4-24.
Specified range for inside diameter of valve guide is (11~11.018)mm. If measured value is outside
the specified range, the cylinder head shall be replaced to ensure the reliability of diesel engine
operation.
Figure 4-24 Measuring the inside diameter of valve guide with an inside micrometer
(7) Removing cylinder head gasket, and check whether there is visible damage to the cylinder head
gasket and analyze the cause. Regardless of problems at the cylinder head gasket, it should be
replaced with a new one after being removed.
(8) Before removing the valve stem seal, check the spring for failure. Anyway, replace the valve
stem seal with a new one.
4.2.14.4 Cylinder Head Assembly procedures
(1) Install the auxiliary bolts of cylinder head as shown in Figure 4-25.
Figure 4-25 Auxiliary bolt, cylinder head

1) Auxiliary bolts of cylinder head may be reused once. If the cylinder head is installed for the
third time, these bolts must be replaced with new ones.
2) Apply anaerobic thread locker 262 to the screw-in ends (with shorter threaded section length)
of auxiliary bolts of cylinder head in the first row on the side of the engine oil cooler cover
assembly. Apply pre-applied adhesive to the other auxiliary bolts.
3) Clean the threaded holes in the cylinder block.
4) Tighten the bolts to the torque of (76~102)N·m.
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(2) Install the cylinder head gasket as shown in Figure 4-26.
Figure 4-26 Cylinder head gasket

1) The cylinder head gasket can be used once only, and in case that it is returned for repairing, it
must be replaced with a new one.
2) Wipe clean the inner wall of the cylinder liner and apply some clean lubricating oil; wipe clean
the top plane of cylinder block and place the cylinder head gasket as per the corresponding pin
holes.
3) Check that the holes of the cylinder head gasket align with the corresponding holes in the
cylinder head, to ensure correct installation.
(3) Install the valve stem seal and valve stem seal as shown in Figures 4-27 and 4-28, respectively.
Spring
Figure 4-27 Valve stem seal

1) The valve stem seal can be only used once. Make sure to replace with new one in event of
repair.
2) Check the valve stem seal for presence of defect and check valve stem seal spring for
intactness.
3) Install valve stem seal on valve guide pipe.
4) Apply lubricating oil to the lips of valve stem seal.
5) Use valve stem seal assembling tool and rubber hammer to install the valve stem seal.
Valve stem seal installer
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Valve stem seal
Valve Guide
Cylinder head
Figure 4-28 Assembly of Valve Stem Seal

(4) Cylinder head assembly:
1) Wipe clean the cylinder head carefully and ensure that there is not dust, debris, sand and other
contaminants, and then further wipe clean the bottom surface of the cylinder head.
2) Check the air ducts and coolant passages in the cylinder head for foreign matters. Check the
cylinders, cylinder head gasket, and cylinder head underside for foreign matters.
3) Before the bolts of cylinder head are tightened, the cylinder head is located with the locating
pins.
4) Cylinder head assembly.
(5) Install the clamping blocks.
1) Wipe clean the clamping blocks.
2) Apply clean lubricating oil to the working faces of the clamping blocks. Install the clamping
blocks to the cylinder head. Do not apply too much lubricating oil; otherwise lubricating oil may
overflow into the gap between the cylinder heads.
3) The clamping block shall be installed so that its groove is in the same direction as the gap
between the cylinder heads.
4) Manually tighten the nuts of the auxiliary bolts of cylinder head.
(6) Install the bolts of cylinder head, main bolts of cylinder head, and main bolts of cylinder head
used for fixing the lifting plates, as shown in Figure 4-29.
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Figure 4-29 Main bolt of cylinder head (left), and main bolt of cylinder head used for fixing the lifting plate
(right)
1) Main bolts of cylinder head may be reused twice.

2) Align the cylinder head with the cylinder block. Apply a proper amount of clean lubricating
oil to the threads and pressure-bearing surfaces of shoulders of the main bolts of cylinder head, and
the shouldered nuts. Install the main bolts to the cylinder head. Install the nuts to the auxiliary bolts
of cylinder head, and clamping blocks.
Notice:
Two types of main bolts of cylinder head are used for the diesel engine equipped with lifting plates:
a. Ordinary cylinder cover main bolts;
b. The main bolts of cylinder head used for fixing the lifting plates are installed on both sides of
the diesel engine. See Figure 4-29.
3) Using a torque wrench, tighten the main bolts and nuts of auxiliary bolts of cylinder head to
the torque of (30~50)N·m.
4) Tap the clamping blocks so that they descend in place.
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Figure 4-30 Assembly of auxiliary bolts of cylinder head and clamping blocks
Flywheel side Fan side
Figure 4-31 Tightening the M12 auxiliary bolts of cylinder head (stud bolts) numbered 1 to 7
5) Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence to the
torque of 100N.m. Make marks on the nuts. Shown in Figure 4-31 is the sequence for tightening the
auxiliary bolts of cylinder head.
6) Using a torque wrench, tighten the main bolts in the specified sequence to the torque of
200N.m. Then make marks on the bolts.
7) Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by 90º.
Then make marks on the nuts.
Figure 4-32 Assembly of main bolts of cylinder head
Flywheel side Fan side
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Figure 4-33 Tightening the M16 main bolts of cylinder head (screws) numbered 22 to 45
8) Using a torque wrench, tighten the main bolts in the specified sequence by 90º. Then make
marks on the bolts. See Figure 4-33.
9) Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by another
90º to the torque of (120~160)N·m.
10) Using a torque wrench, tighten the main bolts in the specified sequence by another 90º to the
torque of (240~340)N·m.
4.3 Crank Connecting Rod Mechanism
4.3.1 Disassembly and Assembly of Crank Connecting Rod Mechanism
4.3.1.1 Exploded View of Crank Connecting Rod Mechanism
The crank connecting rod mechanism is generally divided into the crankshaft-flywheel group and
the piston connecting rod group. The crankshaft-flywheel group consists mainly of the crankshaft,
main bearing shells, main bearing bolts, timing gear, vibration damper, flywheel, and flywheel gear
ring. The piston connecting rod group consists mainly of the piston, piston rings, piston pin, retainer
rings, connecting rod big end, connecting rod small end, connecting rod bearing shells, and
connecting rod bolts. Main parts of the crank connecting rod mechanism are shown in Figure 4-34.
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Main bearing bolt
Main bearing shell
Crankcase
Crankshaft
Connecting rod cap
Crankshaft timing gear
Flywheel gear ring
Vibration damper
Flywheel
Pulley
Flywheel bolt
Bearing
Flange
Pulley bolt Flywheel cover
Engine block
Piston connecting rod group
Figure 4-34 Exploded View of Crank Connecting Rod Mechanism
4.3.1.2 Crank Connecting Rod MechanismDisassembly Procedures
(1) Check before disassembly. Check axial backlash of the connecting rod and tightening torque
of the connecting rod bolt; put the slant side of the engine against the ground, turn the piston to the
bottom dead center, and remove the connecting rod bolt and connecting rod cap; turn the piston to
the top dead center, and tap out the piston with a wood hammer. Care should be taken to protect the
big end of the connecting rod from being seized in the cylinder block. Remove the remaining
pistons by the same method, and put them in sequence.
(2) Unscrew the bolts of front pulley. Remove the pulley, and vibration damper.
(3) Screw out the flywheel bolts, and remove the flywheel assembly, bearings and other parts.
4.3.1.3 Crank Connecting Rod Mechanism Assembly procedures
Assembly of the crank connecting rod mechanism is in the reverse order of disassembly.
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4.3.2 Disassembly and Assembly of Piston Connecting Rod Group
4.3.2.1 Exploded View for Assembly of Piston Connecting Rod Group
The piston connecting rod group consists mainly of the piston, piston rings, piston pin, retainer
rings, connecting rod big end, connecting rod small end, connecting rod bearing shells, and
connecting rod bolts. Assembly of the connecting rod of piston connecting rod group and
crankshaft. See Figure 4-35.
The 1st compression ring

The 2nd compression ring
Piston pin Oil ring
Piston
Piston pin retainer
Connecting rod shank
Connecting rod caps

Connecting rod bearing shell
Connecting rod bolts
Figure 4-35 Exploded View of piston Connecting rod group
4.3.2.2 Piston Connecting Rod Group Disassembly Procedures
(1) Use a pair of internal circlip pliers to dismantle the circlips on both sides of the piston
carefully, and push out the piston pin to remove the connecting rod shank. Assign numbers to the
piston pin and connecting rod shank, and put them in numerical sequence.
(2) Use a pair of piston ring pliers to dismantle the 1st & 2nd gas rings and oil ring respectively,
and mark them.
4.3.2.3 Inspection and Maintenance of Piston Connecting Rod Group
(1) Check whether the combustion chamber throat fillet of piston and piston pin seat have cracks;
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check whether the piston skirt and head have scuffing phenomenon; and check whether the wearing
of piston pin hole is normal;
(2) Check the outer surfaces of piston rings for excessive wear. Check the upper and lower sides
of piston rings for excessive wear.
(3) Check the outer surface of piston pin for excessive wear.
(4) Check the connecting rod big end pre-formed hole, connecting rod shank, and connecting rod
small end lubricating oil hole for cracks. Check the connecting rod bearing shells for excessive wear
or peeling-off of alloy layer. Check the flanks of connecting rod for excessive wear. Check the
connecting rod shank for bending.
(5) Check the connecting rod bearing shell for excessive wear, discoloration, peeling-off, and
sliding of alloy layer.
4.3.2.4 Piston Connecting Rod Group Assembly procedures
(1) Use a pair of internal circlip pliers to install one circlip onto the piston circlip groove, and turn
the circlip to have it inserted completely. The rough side of the circlip should be inward. The open
end of the piston pin circlip should be upward.
(2) Insert the connecting rod small end into the inner cavity of the piston, and enable the small
end to align with the piston pin hole, and then mount the piston pin, and eventually mount the piston
pin circlip on other side. Note that the connecting rod oblique split plane in the opposite direction as
the piston cooling oil passage. Apply a proper amount of lubricating oil to the connecting rod small
end and piston before installation.
(3) Put the assembled parts of the piston connecting rod aside in sequence of the cylinder
numbers, and use a pair of piston ring pliers to mount the oil ring, 2nd and 1st gas rings into the
piston ring groove in sequence. The “TOP” end of the piston ring should be upward, and the ring
should be turned flexibly in the ring groove.
(4) Wipe clean the inner wall of the cylinder, crankshaft crank arm and piston connecting rod
parts, and apply some clean lubricating oil at individual kinematic pair positions.
(5) Adjust direction of opening end of rings: the first ring is installed in such a manner that its
opening end is deflected from the centerline of the piston pin by 30°, and the second ring is installed
in such a manner that its opening end is staggered from the opening end of the first ring by 120°,
and the oil ring is installed in such a manner that its opening end is staggered from the opening end
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of the first ring and the second ring by 120°, respectively, and is at position where the perpendicular
bisector of the piston pin centerline is placed. See Figure 4-36.
1st gas ring 2nd gas ring
Horizontal direction of piston pin
Oil ring
Figure 4-36 Piston ring gap arrangement

(6) Manually rotate the flywheel until the pistons in the 1st and 6thcylinders reach approximately
their respective bottom dead centers. Install the piston connecting rod subassemblies of the 1st and
6th cylinders. Slightly tighten the connecting rod bolts. The split plane of connecting rod shall face
the left of cylinder block (i.e. the side of engine oil cooler). The cylinder sequential number marked
on the piston shall be consistent with that marked on the corresponding cylinder. The connecting
rod cap shall be used together with the corresponding connecting rod shank. Before installing the
connecting rod bolts, apply clean lubricating oil to them.
(7) Connecting rod bolts: First slightly screw them in. Then symmetrically tighten them to the
torque of 120N.m. Finally tighten them by 90°±5° to the torque of 170N·m~250N·m. In the same
manner, install the pistons and connecting rods of the remaining cylinders.
4.3.3 Disassembly and Assembly of Crankshaft-flywheel Group
4.3.3.1 Exploded View for Assembly of Crankshaft-flywheel Group
The crankshaft-flywheel group consists mainly of the crankshaft, main bearing shells, main bearing
bolts, timing gear, vibration damper, flywheel, and flywheel gear ring. See Figure 4-37.
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Main bearing bolt
Main bearing shell
Crankcase
Crankshaft
Connecting rod cap
Crankshaft timing gear Flywheel gear ring
Vibration damper
Flywheel
Pulley
Flywheel bolt
Flange Bearing
Pulley bolt Flywheel cover
Engine block
Piston pin and connecting rod subassembly
Figure 4-37 Exploded View for Assembly of Crankshaft-Flywheel Group
4.3.3.2 Crankshaft Disassembly Procedures
(1) Enable the engine crankcase upward, remove the main bearing bolts, and put them on the
ground in sequence.
(2) Remove the crankshaft and flywheel, front and rear thrust halfrings, and flywheel end
bearing. Remove the oil seal; put the crankshaft on the bracket (If the crankshaft is put on the
bracket too long, the crankshaft should be put vertically).
(3) All parts removed should be put by category as required.
4.3.3.3 Inspection and Maintenance of Crankshaft
(1) Check whether the main journal of crankshaft and the fillet part of connecting rod neck have
cracks; in the combination part of crankshaft and bearing shell, check the dredging pipeline for
cracks and other abnormalities.
(2) Check wear of the main bearing journal and connecting rod journal, and whether there are
linear cracks and metal peelings.
(3) Check wear condition of the front and rear oil seals.
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(4) Check whether the main bearing bolts are subject to thread damage and other failures.
(5) Check whether the crankshaft flange bolt holes are cracked.
(6) Check the wear status of crankshaft journal and check crankshaft for presence of bending and
distortion.
4.3.3.4 Crankshaft Assembly Procedures
(1) Wipe clean the bottom hole of cylinder block.

(2) Clean the pre-formed hole in cylinder block for the upper bearing shell. Remove foreign
matters from the bearing shell.
1) Before the upper bearing shell is pressed in the bottom hole, it is required to strictly check
whether it is collided, and if collided, it cannot be repaired for use.
2) After being pressed in, the upper bearing shell should be aligned with oil hole and oil groove
on the cylinder block, and cannot be assembled if the upper bearing shell is misaligned with the oil
hole by more than 1/5-1/4 of the oil hole; the upper bearing shell should be completely against the
bottom hole of cylinder block.
(3) Apply appropriate quantity of clean lubricating oil onto the inner surface of the upper bearing
shell.
(4) Deoil and wipe clean the lower surface of cylinder block and ensure that the lower surface of
cylinder block is free of oil.
(5) Apply a line of sealant to the lower surface of cylinder block and ensure the uniform and
continuous sealant by a sealant roller.
(6) Lift the crankshaft, and purge the oil port with compressed air, and wipe clean the main
bearing journal and connecting rod journal with a towel, and then lightly lower them into the
cylinder block. In this process, it is required that the crankshaft be free from collision.
(7) Wipe clean the upper thrust halfring and press it into the cylinder block. The oil groove of the
upper thrust halfring should be outward (toward the crankshaft).
(8) On the precondition of guaranteeing the level oil seals without distortion or deformation,
place the oil seals levelly into the seal grooves on the lower surface of cylinder block by special
tooling.
(9) Press the lower main bearing shell and lower thrust halfring into the crankcase (with the oil
groove facing towards crankshaft side) and assemble the crankcase.
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(10) Apply clean lubricating oil to the bolt-supporting plane of the crankcase and the threads of the
main bearing bolts. Slightly tighten the main bearing bolts. Pre-tighten all the main bearing bolts in
the sequence as shown in Figure 4-38.
Figure 4-38 Tightening Sequence of Main Bearing Bolts

(11) Tightening the bolts for the first time is performed using a low-torque pneumatic wrench.
Tightening the bolts for the second and third times attains the torque of 80N.m and (250~280)N·m,
respectively. Complete assembling of the crankshaft.
4.3.4 Disassembly and Assembly of Flywheel and Gear ring
4.3.4.1 Exploded View for Assembly of Flywheel
The flywheel subgroup consists mainly of the flywheel, flywheel gear ring, locating pin, and fixing
bolts. See Figure 4-39.
Flywheel
Flywheel gear ring
Hexagon bolt
Crankshaft Bearing
Flywheel bolt
Retainer ring
Locating pin Stud bolt
Figure 4-39 Exploded View for Assembly of flywheel
4.3.4.2 Flywheel and Gear Ring Disassembly Procedures
Disassembly of the flywheel and gear ring is in the reverse order of installation
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4.3.4.3 Inspection and Maintenance of Flywheel and Gear Ring
(1) Check whether the flywheel is subject to thread damage and other failures.
(2) Check the flywheel surface for damage.
(3) Check whether the flywheel gear ring is damaged.
4.3.4.4 Flywheel and Gear RingAssembly Procedures
(1) Fix the flywheel gear ring to the flywheel using the bolts.
(2) Knock in the parallel pin to the rear end of crankshaft and make sure to knock in the parallel
pin to the end.
(3) After inserting the flywheel guide bar in the threaded hole of the crankshaft, mount the
flywheel parts and pre-tighten the flywheel bolts in a diagonal manner.
1) Apply lubricating oil to the threads and pressure-bearing surface of the flywheel bolts.
2) Flywheel bolt M14×1.5 (9 pieces);
Fasten with hands; after the thread and bearing surfaces are lubricated, the flywheel bolt shall be
installed into threaded hole to screw them diagonally, with the tightening torque 60+20 0N·m; and
then turn by two 90°±5° angles, and the torque shall reach (230～280)N·m at the same time.
Replace the bolts for which the required torque can’t be met at the specified torsion angle. The bolts
can be re-used for 2 times.
Tighten with auto-wrench; after the thread and bearing surfaces are lubricated, the flywheel bolt
shall be installed into threaded hole to screw them diagonally, with the tightening torque 60N·m;
and then turn by 160°+5°, and the torque shall reach (230～300)N·m at the same time. Replace the
bolts for which the required torque can’t be met at the specified torsion angle. The bolts can be re-
used for 2 times.
(4) Tighten the flywheel bolt:
1) Apply lubricating oil to the threads and pressure-bearing surfaces of the flywheel bolts.
Tighten diagonally the bolts to the torque of (60~ 80) N.m. Then tighten them by 90°±5° twice to
the torque of (230~280)N·m. Replace the bolts that fail to meet the torque requirements. A bolt may
be reused twice. The flywheel installation is then completed.
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4.3.5 Disassembly and Assembly of Vibration Damper and Crankshaft Pulley
4.3.5.1 Exploded View for Assembly of Vibration Damper and Crankshaft Pulley
The vibration damper and crankshaft pulley subgroup consists mainly of the vibration damper,
pulley, flange, and fixing bolts. See Figure 4-40.
Crankshaft timing gear
Flange Crankshaft
Vibration damper
Pulley
Pulley bolt
Figure 4-40 Exploded View for Assembly of vibration damper and crankshaft pulley
4.3.5.2 Vibration Damper and Crankshaft Pulley Disassembly Procedures
Remove the pulley bolts. Remove the pulley and vibration damper.
4.3.5.3 Inspection and Maintenance of Vibration Damper and Crankshaft Pulley
(1) Check the vibration damper for deformation and collision damage.
(2) Check whether the pulley is damaged, and bolts are crushed.
(3) Check the pulley bolts for damage.
4.3.5.4 Vibration Damper and Crankshaft PulleyAssembly Procedures
With the timing gear chamber installed, fix the vibration damper and pulley to the crankshaft flange
using the pulley bolts.
4.3.6 Disassembly and Assembly of Crankshaft Bearing Shell
4.3.6.1 Exploded View for Assembly of Crankshaft Bearing Shell
Crankshaft bearing shells include the upper and lower main bearing shells. See Figure 4-41.
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Main bearing shell (upper)
Crankshaft
Main bearing shell (lower)
Figure 4-41 Exploded View for Assembly of Crankshaft Bearing Shell
4.3.6.2 Crankshaft Bearing Shell Disassembly Procedures
Push out the bearing shell from its side by hand, and mark the bearing shell dismantled,
corresponding to saddle bores of the engine block and crankcase.
4.3.6.3 Inspection and Maintenance of c Crankshaft Bearing Shell
(1) Clean the bearing shell, and check wear condition of the bearing shell.
(2) Check whether the bearing shell is subject to metal peeling, damage to the locating lip and
transversal cracks.
4.3.6.4 Crankshaft Bearing ShellAssembly Procedures
(1) First, clean main bearing shell and assembling holes, and wipe them clean.
(2) If the bearing shell is not replaced with a new one, mount the upper bearing shell into the
engine block and the lower bearing shell into the crankcase in dismantling sequence. Pay attention
to differentiate the upper and lower bearing shells. The bearing shell with oil groove is the upper
one. If the bearing shell is replaced with a new one, it is directly installed.
Notice: During installation, pay attention that the lips should be aligned, and applied with a small
amount of oil.
4.4 Valve Mechanism
4.4.1 Disassembly and Assembly of Valve Mechanism
4.4.1.1 Exploded View for Assembly of Valve Mechanism
Generally the Valve Mechanism consists of the valve group and valve driver group. The valve
group includes mainly the valves, valve springs, valve seats, and valve collets. The valve drive
group includes mainly the camshaft, tappets, push rods, rocker arms, and rocker arm shafts. See
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Figure 4-42.
Adjusting nut
Hexagon bolt
Intake rocker arm
Supporting arm
Adjusting screw
Adjusting bolt assembly
Adjusting nut Valve collet
Rocker arm shaft Upper seat of valve spring
Inner valve spring
Exhaust rocker arm
Outer valve spring
Adjusting screw
Lower seat of valve spring
Valve cap Valve
Push rod Camshaft
Locating pin
Tappet
Camshaft timing gear
Cup plug
Hexagon bolt
Hexagon bolt
Thrust halfring
Figure 4-42 Exploded View for Assembly of valve mechanism
4.4.1.2 Valve MechanismDisassembly Procedures
(1) Disassemble the rocker arm and rocker arm shaft. For details, see the Disassembly
Procedures.
(2) Disassemble the intake and exhaust valves. For details, see the valve Disassembly Procedures;
(3) Disassemble the tappet and push rod. For details, see the tappet and push rod Disassembly
Procedures;
(4) Disassemble the camshaft and camshaft timing gear. For details, see the Disassembly
Procedures.
(5) Disassemble the intermediate gear. For details, see the Disassembly Procedures.
4.4.1.3 Valve Mechanism Assembly procedures
(1) Assemble the intermediate gear. For details, see the intermediate gear assembly procedures;
(2) Assemble the camshaft and camshaft timing gear. For details, see the camshaft and camshaft
timing gear assembly procedures.

(3) Assemble the tappet and push rod. For details, see the tappet and push rod assembly
procedures;
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(4) Assemble the intake and exhaust valves. For details, see the intake and exhaust valves
assembly procedures;
(5) Assemble the rocker arm and rocker arm shaft. For details, see the assembly procedures.
4.4.2 Disassembly and Assembly of Camshaft
4.4.2.1 Exploded View for Assembly of Camshaft
The camshaft subgroup consists mainly of the camshaft, camshaft timing gear, thrust halfrings,
camshaft bearing shells, and locating pin. See Figure 4-43.
Camshaft
Thrust halfring
Camshaft bearing shell
Camshaft timing gear
Locating pin
Hexagon screw
Hexagon bolt
Hexagon bolt for thrust halfring
Figure 4-43 Exploded View for Assembly of Camshaft
4.4.2.2 Camshaft Disassembly Procedures
(1) Turn the camshaft, and check whether the camshaft and timing gear are flexible, without
blockage;
(2) Check visually for axial play of the camshaft. Compare the axial play with the specification of
0.1mm~0.4mm.
(3) Check the timing gear backlash.
(4) On the working bench for installation and Disassembly of the engine, turn the crankshaft to
enable the camshaft timing gear to be at the top dead center of the 1st cylinder. Remove the
hexagon bolts of camshaft timing gear. Remove the timing gear and locating pin.
(5) Remove the hexagon bolts for camshaft thrust halfrings. Remove the thrust halfrings.
(6) Remove the camshaft.
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4.4.2.3 Inspection and Maintenance of Camshaft
(1) Check whether the cam surface in contact with the tappet is worn or not, and whether the
main bearing journal is seized or worn;
(2) Measure the circular run-out of the camshaft main journals. See Table 4-2.
Table 4-2 Permissible circular run-outs of camshaft main journals
Cam Permissible circular run- Measure valve

out (max)
2nd main journal (between 1st and 2nd cylinders) 0.04
3rd main journal (between 2nd and 3rd cylinders) 0.05
4th main journal (between 3rd and 4th cylinders) 0.06
5th main journal (between 4th and 5th cylinders) 0.05
6th main journal (between 5th and 6th cylinders) 0.04
(3) Measure the maximum lift of tappet (distance between the nose and the basic circle of intake
or exhaust cam), as shown in Table 4-3.
Table 4-3 Measuring maximum lift of tappet
Cam Standard value Measure valve

Maximum lift of intake tappet 7.0743mm
Maximum lift of exhaust tappet 8.3183mm
(4) Check the timing gear for tooth interference or serious wear of tooth surface.
4.4.2.4 Camshaft Assembly Procedures
With the camshaft and timing gear removed, check them for excessive wear or deviation from
parameter specifications. If any, repair the camshaft and timing gear, or replace them with new
ones.
(1) Using a towel, clean the camshaft holes. Check the hole for collision damage. Using a
lubricator, apply lubrication oil to the camshaft bushings. The camshaft hole with collision damage
(if any) removed is not permitted.
(2) Put the guide tool and lubrication sleeve of camshaft in the camshaft hole. Clean the camshaft
then check it for collision damage. Insert the camshaft through the camshaft hole. With the
installation completed, remove the guide tool and lubrication sleeve. While inserting the camshaft
through the camshaft hole, be careful not to cause damage to the camshaft bushing.
(3) Install the camshaft thrust halfrings. Slightly tighten the hexagon bolts to which adhesive is
preapplied. Torque specification: (29 ~35)N·m
(4) Apply Loctite 277 adhesive continuously to the outer front end of the camshaft hole cup plug.
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Drive the cup plug in the camshaft hole at the free end in the cylinder block. Ensure the cup plug is
not skewed. Remove surplus adhesive from around the cup plug.
(5) Manually rotate the flywheel counterclockwise (seen from the timing gear chamber) until the
pistons in the 1st and 6th cylinders reach their respective top dead centers so that piston top is flush
with the cylinder block top.
(6) For alignment purpose, draw a line on both the flywheel cover and the flywheel. Install the dial.
Adjust the dial so that its 0º scale aligns with the line on the flywheel cover. Install the timing gear.
(7) Align the scale of timing gear with the “OT” scale on the timing gear chamber.
(8) Tighten symmetrically the hexagon bolts, to which adhesive is preapplied, to the torque of (32
~36)N·m. Make a white mark on any bolt. Check the backlash between the mating teeth of timing
gear and intermediate gear. The number of teeth used in backlash checking shall meet the
requirement. Record the backlash values.
(9) The backlash between the mating teeth of timing gear and intermediate gear shall be
0.015~0.33mm. Drive a parallel pin in the backlash.
4.4.3 Disassembly and Assembly of Rocker Arm and Rocker Arm Shaft
4.4.3.1 Exploded View for Assembly of Rocker Arm and Rocker Arm Shaft
The rocker arm and rocker arm shaft subgroup consists mainly of the intake rocker arm assembly,
exhaust rocker arm assembly, rocker arm shaft, adjusting nut, and supporting arm. See Figure 4-44.
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Hexagon bolt
Adjusting nut
Supporting arm
Adjusting bolt assembly
Intake rocker arm assembly Exhaust rocker arm assembly
Rocker arm shaft
Figure 4-44 Exploded View for Assembly of Rocker Arm and Rocker Arm Shaft
4.4.3.2 Rocker Arm and Rocker Arm ShaftDisassembly Procedures
(1) Turn the crankshaft, and observe whether the rocker arm is turned flexibly.
(2) Measure clearance of individual valves, and check change in clearance of the valves.
(3) In the case of rocker arm rotation sticking or excessive valve clearance variation, loosen the
hexagon screw. Carefully remove the bracket, rocker arm shaft, and intake and exhaust rocker arm
assemblies. Make marks on the rocker arms, to prevent confusion.
4.4.3.3 Inspection and Maintenance of Rocker Arm and Rocker Arm Shaft
(1) Clean the rockers and observe the appearances of rockers for presence of defects (such as
cracking).
(2) Check whether the rocker arm hole is worn or abraded, and measure its diameter;
(3) Check the ball pin and the curved face of rocker arm for wear.
(4) Check the all oil-ways for presence of obstruction.
(5) Measure the diameters of rocker arm hole and rocker arm shaft. Ensure the required play after
installation. See Figure 4-4.
Table 4-4 Measure diameters of the rocker arm hole and rocker arm shaft
Model Checking items Standard value (mm) Actual value

WP10 Diameter of the rocker φ23.972~φ23.993
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arm hole
Diameter of the rocker φ23.927~φ23.960
arm shaft
4.4.3.4 Rocker Arm and Rocker Arm ShaftAssembly Procedures
(1) Apply a little lubricating oil to the rocker arm seats. Place the intake and exhaust valve rocker
arm assemblies on the rocker arm seats. Slightly tighten the hexagon bolts. Ensure the required
clearance between the rocker arm and rocker arm seat and that the rocker arms can rotate smoothly.
(2) Rotate the crankshaft, to check whether the rocker arms can rotate smoothly.
4.4.3.5 Check and Adjust the Clearances of Intake and Exhaust Valves
(1) Manually rotate the flywheel until the piston in the 1st cylinder reaches top dead center, that
is, the scale on the flywheel aligns with that on the flywheel cover.
(2) This method is used to check whether the piston in the 1st cylinder reaches the top dead center
at the compression stroke. Adjust the intake valve clearance of the 1st, 2nd, and 4th cylinders,
which shall be (0.3±0.03)mm. Adjust the exhaust valve clearance of the 1st, 3rd, and 5th cylinders,
which shall be (0.4±0.03)mm. The adjusting nuts of intake and exhaust valves shall be tightened to
the torque of (30~40)N·m.
Adjusting the exhaust valve clearance:
1) See Figure 4-45. Loosen the No.2 adjusting bolt assembly. Without pressing the rocker arm
oil sealing plane, rotate the No.10 valve clearance adjusting screw at the push rod end, to adjust the
exhaust valve clearance to 0.4mm. Tighten the lock nut. Notice: Rotate the valve clearance
adjusting screw to press the feeler gauge. The No.5 valve rocker arm piston is hence pressed to the
lowest point, no clearance existing between it and the underside of piston hole in the exhaust valve
rocker arm.
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11 Hexagon bolt 12 Supporting arm
1 Adjusting nut
2 Adjusting bolt
3 Valve rocker arm assembly
4 Steel ball
10 Push rod
5 Valve rocker arm piston
6 Rocker arm piston spring
9 Rocker arm seat 7 Needle

8 Ball valve spring
Figure 4-45 Exhaust valve construction

2) Place a 0.25mm feeler gauge between the No.5 valve rocker arm piston and exhaust valve. By
adjusting the No.2 adjusting bolt assembly, adjust the valve end clearance to 0.25mm. Tighten the
lock nut. Notice: Rotate the No.2 adjusting bolt assembly to press the feeler gauge. The No.5 valve
rocker arm piston is hence pressed to the lowest point, no clearance existing between it and the
underside of piston hole in the exhaust valve rocker arm.
(3) Manually rotate the flywheel by 360º, with the piston in the 6th cylinder moving to top dead
center. Adjust the intake valve clearances of the 6th, 5th, and 3rd cylinders, and the exhaust valve
clearances of the 6th, 4th, and 2nd cylinders.
(4) With the engine at cold state, check the valve timing of the 1st cylinder. Intake valve opens at
18°~23° before top dead center; exhaust valve opens at 20°~25° before top dead center
4.4.4 Disassembly and Assembly of Tappet and Push Rod
4.4.4.1 Exploded View for Assembly of Tappet and Push Rod
Tappet and push rod subgroup consists mainly of the tappets and push rods. See Figure 4-46.
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Push rod
Cylinder head
Engine block
Tappet
Figure 4-46 Exploded View for Assembly of Tappet and Push rod
4.4.4.2 Tappet and Push Rod Disassembly Procedures
(1) After the rocker arm and rocker arm shaft have been dismantled, directly remove the push
rod, and put it aside in order;
(2) After removing load off cylinder head (for details, see the Disassembly Procedures), take out
the tappets and place them in order.
4.4.4.3 Inspection and Maintenance of Tappet and Push Rod
(1) Clean the push rods and tappets;

(2) Check the oil passages of the tappets and push rods for obstruction;
(3) Check the push rods for bending and excessive wear;
(4) Check the ball ends of the push rods for excessive wear;
(5) Check the cylindrical surfaces and undersides of the tappets for excessive wear;
(6) Check the mating sockets of the tappets for excessive wear.
4.4.4.4 Tappet and Push Rod Assembly Procedures
(1) Check whether the tappet and push rod have a problem, and if a problem occurs, replace them
with a new one, respectively. Before installation of the tappet, must purge it with compressed air,
and check whether the oil hole is unobstructed;
(2) Apply lubricating oil to the tappets.
(3) Place the tappets in the tappet holes.
(4) With the installation of cylinder head completed, clean the push rods using compressed air.
Check whether the oil holes are clogged.
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(5) Apply clean lubricating oil to the push rods. Ensure that the push rod ends are sufficiently lubricated.
(6) Install the push rods and put the push rods in place.
4.4.5 Disassembly and Assembly of Valve
4.4.5.1 Exploded View for Assembly of Valve
The valve subgroup consists mainly of the valves, valve seats, springs, valve collets, and shielding
caps. See Figure 4-47.
Valve cap
Valve collet
Upper seat of valve spring
Inner valve spring
Outer valve spring
Lower seat of valve spring
Valve
Figure 4-47 Exploded View for Assembly of Valve
4.4.5.2 Valve Disassembly Procedures
(1) Using the valve spring compressor or an overhead-valve spring pincer or another equivalent
tool, compress squarely the valve springs. Remove the valve collets. Remove the upper retainers for
the valve springs, and the inner and outer valve springs;
(2) Remove the valve from the valve seat.
4.4.5.3 Inspection and Maintenance of Valve
(1) Check whether the valve stem and valve stem end surface are worn;
(2) Check whether the valve cone is worn or damaged;
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(3) Check the valve faces for carbon deposit.
(4) Check valve heads for carbon deposit and sintering.
4.4.5.4 Valve Assembly Procedures
If the valve is worn or seriously carbon-deposited or has other bad phenomena, it is required to
change the used valve with a new one.
(1) Apply some molybdenum disulfide paste on the intake and exhaust valve stems evenly, and
assemble the intake and exhaust valves into the cylinder head, ensuring that the intake and exhaust
valves slide in the guide, without blockage;
(2) Apply evenly thread locker to the underside of lower seat of exhaust valve spring. Install the
lower seat to the cylinder head. Check whether the lower seat is in place. If necessary, replace or
repair it. Do not rudely drive it in place.
(3) Install the lower seat of intake valve spring. Put the protective sleeves in the valve guides.
Install the valve stem seal.
Notice:
Before assembling, must check whether the internal spring in the sealing bush of the valve stem is
kept intact.
(4) Install the inner valve spring then the outer valve spring, ensuring the inner spring is wound in
the opposite direction of the outer spring.
(5) Install the upper retainer for the valve spring. Press the valve spring in place. Install the valve
collet.
(6) After installation of the valve collets, tap the intake and exhaust valves using a rubber
hammer so that the valve collets come in close contact with the upper retainers for the valve
springs. If the valve collets fail to come in contact with the upper retainers for the valve springs,
identify then remove the causes.
4.4.6 Disassembly and Assembly of Intermediate Gear
4.4.6.1 Exploded View for Assembly of Intermediate Gear
The intermediate gear subgroup consists mainly of the intermediate gear, intermediate gear shaft,
bushing, bolt and washer. See Figure 4-48.
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Bushing
Intermediate gear shaft
Gasket Blot
Intermediate gear
Figure 4-48 Exploded View for Assembly of Intermediate Gear
4.4.6.2 Intermediate GearDisassembly Procedures
(1) Remove the air compressor. For details, see the instructions for Disassembly of accessory
system.
(2) Remove the fuel injection pump. For details, see the instructions for Disassembly of fuel
system.
(3) Remove the camshaft timing gear. For details, see the instructions for Disassembly of valve
system.
(4) Check the mark on the fixing bolt of the intermediate gear and confirm whether the bolt turns
or not. Remove the four M10 hexagon bolts used for fixing the intermediate gear. Remove the
washer. Tighten an M8 bolt through the gear hole to the shaft. Be careful to prevent gear falling;
(5) Remove the intermediate gear assembly along with the gear chamber. Take the gear out of
gear chamber.
4.4.6.3 Inspection and Maintenance of Intermediate Gear
(1) Check whether the threads of the fixing bolts are in good condition;
(2) Check whether individual gears are subject to spalling of tooth surface or tooth flank
breakage, and the load bearing surface of the bolt is crushed, and the tapped holes or through holes
on the gear are deformed;
(3) Check whether there is abnormal wear between the intermediate gear shaft and the
intermediate gear bushing. Check whether the oil holes are clogged by contaminants or foreign
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matters.
4.4.6.4 Intermediate GearAssembly Procedures
(1) Install the engine oil pump, crankshaft, and engine oil pump intermediate gear subassembly;
(2) Install the gear chamber. Before installing the gear chamber, put the intermediate gear shaft in
the intermediate gear assembly (which includes the intermediate gear and bushing). The
intermediate gear side with a letter V shall be oriented outwards (so that the letter V is not visually
covered by the intermediate shaft). Put the intermediate gear assembly and the intermediate gear
shaft in the corresponding position in the gear chamber. Before doing so, the diesel engine shall be
placed upside down; otherwise the intermediate gear assembly and intermediate gear shaft could
fall to the ground.
4.5 Intake and Exhaust System
4.5.1 Disassembly and Assembly of Intake and Exhaust System
4.5.1.1 Exploded View for Assembly of Intake and Exhaust System
The intake and exhaust system consists mainly of the intake pipe, exhaust pipe, turbocharger, inter-
cooler intake pipe, intake connecting pipe, exhaust connecting pipe, bolts, and washers. See Figure
4-49.
Intake pipe
Exhaust pipe
Intake connecting pipe;
Turbocharger
Intake connecting pipe

Inter-cooler intake pipe
Figure 4-49 Exploded View for Assembly of Intake and Exhaust System
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4.5.1.2 Intake and Exhaust System Disassembly Procedures
(1) Loosen the fixing bolts and the pipe clamps of the air filter. Remove the air filter and its hose;
(2) Loosen the intercooler pipe clamp. Remove the connecting pipes from the outlet of
compressor of turbocharger, and from the inlet of the intake pipe.
(3) Loosen the inlet and outlet oil pipes fixing bolts of the turbocharger. Remove the inlet and
outlet oil pipes and their washers;
(4) Loosen the exhaust tailpipe fixing bolts and the turbocharger fixing bolts. Remove the
turbocharger;
(5) Remove the cable of the intake heater. Loosen the intake pipe fixing bolts. Remove the intake
pipe. For details, see section 4.5.2 “Disassembly, inspection, repair, and Assembly of intake pipe”.
(6) Remove the heat shield bolts and heat shield. Loosen the exhaust pipe fixing bolts. Remove
the exhaust pipe. For details, see section 4.5.3 “Disassembly, inspection, repair, and Assembly of
exhaust pipe”.
4.5.1.3 Intake and Exhaust System Assembly Procedures
Assembly of the intake and exhaust system is in the reverse order of Disassembly.
4.5.2 Disassembly and Assembly of Intake Pipe
4.5.2.1 Exploded View for Assembly of Intake Pipe
The intake pipe subgroup consists mainly of the intake pipe, intake connecting pipe, intake heater,
bolts, gaskets, washers, and nuts. See Figure 4-50.
1- Intake Pipe 2- Stud bolt 3- Heater 4- Gasket 5- Intake
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gasket connecting pipe;
6- Washer 7- Nut 8- Intake pipe 9- Intake pipe
bolts
Figure 4-50 Exploded View for Assembly of Intake Pipe
4.5.2.2 Intake Pipe Disassembly Procedures
(1) Loosen the intake pipe bolts in sequence, and remove the intake pipe and its gasket.
(2) Loosen the fixing nuts of the intake pipe, and remove the intake connecting pipe, intake heater
and heater gasket.
(3) Loosen the intake pipe end cover fixing nuts. Remove the intake pipe end over and gasket.
4.5.2.3 Inspection and Maintenance ofIntake Pipe
(1) Check whether the intake pipe is cracked, deformed or damaged, and if any, it is required to
replace the pipe with a new one.
(2) Check whether the intake pipe gasket and end cover are deformed, torn or damaged, and if
any, it is required to replace them.
(3) Check whether the intake heater is burned out and shorted, and if any, it is required to replace
it.
4.5.2.4 Intake PipeAssembly Procedures
Assembly of the intake pipe is in the reverse order of Disassembly. The bolts should be tightened to
the torque of 23N·m.
4.5.3 Disassembly and Assembly of Exhaust Pipe
4.5.3.1 Exploded View for Assembly of Exhaust Pipe
The exhaust pipe subgroup consists mainly of the front and rear exhaust pipes, exhaust pipe heat
shield, exhaust pipe seal rings, bolts, and gaskets. See Figure 4-51.
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1- S 2- Exha 3- Exhaust pipe seal 4- Exhaust 5-
eal ring ust pipe washer pipe bolts
Figure 4-51 Exploded View for Assembly of Exhaust Pipe
4.5.3.2 Exhaust Pipe Disassembly Procedures
(1) Loosen the exhaust pipe fixing bolts. Remove the exhaust pipes and their washers;
(2) Separate the exhaust pipes from each other. Remove the seal ring of exhaust pipe.
4.5.3.3 Inspection and Maintenance of Exhaust Pipe
(1) Check whether the exhaust pipe is cracked or damaged, and the flange is deformed, and if
any, it is required to replace the use exhaust pipe with a new one.
(2) Check whether the exhaust pipe flange is subject to gas leakage, and if any, it is required to
replace the used exhaust pipe gasket with a new one.
(3) Check the washer of exhaust pipe for deformation, tear and absence. If necessary, replace it
with a new one.
(4) Check the seal ring for sintering, rust, and carbon deposit. If any, replace it with new one.
4.5.3.4 Exhaust Pipe Assembly Procedures
Assembly of the exhaust pipes is in the reverse order of Disassembly. Attention shall be given to the
following:
(1) While installing the exhaust pipe seal rings, be careful not to cause damage to the exhaust
pipe joint surface. The four seal rings shall be installed with their gaps being staggered by 90º from
each other.
(2) The exhaust pipe bolt is applied with anti-seize sealant (molybdenum disulfide), and tightened
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to a torque within 65 N·m -80 N·m, and can be re-used twice at most.
4.5.4 Disassembly and Assembly of Turbocharger System
4.5.4.1 Exploded View for Assembly of Turbocharger System
The turbocharger system consists mainly of the turbocharger, turbocharger gaskets, stud bolts, and nuts. See
Figure 4-52.
Stud bolt
Lock nut
Turbocharger Type 2 all-metal hexagon lock nut
Stud bolt
Turbocharger gasket
Figure 4-52 Exploded View for Assembly of Inner-cooling Turbocharger System
4.5.4.2 Inner-cooling Turbocharger System Disassembly Procedures
Disassembly of the turbocharger system is in the reverse order of assembly.
4.5.4.3 Inspection and Maintenance of Turbocharger System
(1) Check the running status of rotor

By lightly turning the air compressor impeller with hand, rotation of the impeller by more than 1
turn indicates that it is in normal condition. If the impeller stops immediately, it indicates that the
bearing is worn abnormally or collision or jamming between the rotating part and the stationary part
occurs, it is required to analyze cause and carry out troubleshooting.
(2) Check the run-out of rotor
Enable the dial indicator probe to be against the air compressor end, and push and pull the rotator
shaft, and measure and record difference indicated on the dial indicator, as shown in Figure 4-53.
The rotor displacement should be within 0.088mm~0.118mm, and in case of exceeding this range, it
indicates that the thrust bearing plate or thrust halfring and bearing body are worn, and it is required
to analyze cause and eliminate the problem.
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Figure 4-53 Measuring axial clearance of rotor
(3) Check the radial clearance of air compressor impeller
Press the air compressor impeller by hand in axial direction, and use a plug gauge to measure the
minimum and maximum clearance between the air compressor impeller and air compressor scroll,
as shown in Figure 4-54. This value should be within 0.4mm~0.8mm, and in case of exceeding this
range, it is required to check the bearing, and eliminate the problem.
Notice: The measurement should be carried out in cold state of the turbocharger.
Figure 4-54 Measuring radial and axial clearances of impeller of air compressor
Daily Maintenance:
(1) Check whether the connecting pipe between the turbocharger and the engine is loosened or
not, and if any, eliminate the problem.
(2) Check whether the turbocharger is subject to air leakage or oil leakage, and if any, it is
required to timely eliminate the problem in time.
(3) Check whether the fastening screws of the turbocharger are loosened or not, and if any, it is
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required to eliminate the problem in time.
(4) Check the air filter, and if the air filter is dusted heavily, it required to clean it in time.
4.5.4.4 Turbocharger System Assembly procedures
(1) Screw one end of the turbocharger oil inlet pipe in the screw plug in the rear screw plug of the
Main oil-way in the cylinder block. Adjust the position of the oil inlet pipe for easy connection to
the turbocharger.
(2) Assemble the turbocharger gasket onto the exhaust pipe flange.
(3) Mount the return pipe of the turbocharger and stud bolt onto the turbocharger assembly, and
apply 0# molybdenum disulfide and clean lubricating oil onto the stud bolt. Tighten the return pipe
bolt to a torque within 22 N.m -29 N.m.
(4) Place a turbocharger gasket between the exhaust pipe flange and the turbocharger assembly,
and mount the type 2 fully-metallic hexagon locknut in a loose fit manner, and then tighten it.
(5) Inject proper amount of clean lubricating oil into the turbocharger oil inlet, and wipe away the
spilled lubricating oil.
(6) Install the turbocharger oil inlet pipe and washer. Slightly tighten the hex socket head cap bolt
and self-lock washer. Tighten the oil inlet pipe bolt to a torque within 22 N.m -29 N.m. Rotate the
turbocharger impeller to determine whether it rotates freely without jamming.
(7) Install the oil return bent pipe. Apply Loctite 271 thread locker to the outer surface of mating
end of the oil return bent pipe;
(8) Assemble the return pipe and pipe clamp of the turbocharger, and tighten them. Note that the
two pipe clamps shall be in the same direction and adjust the position of return oil pipe;
(9) All washers may be used once. Replace them with new ones when the turbocharger system is
repaired.
4.6 Fuel system
4.6.1 Disassembly and Assembly of Fuel System
4.6.1.1 Exploded View for Assembly of Fuel System
The fuel system consists mainly of the fuel injection pump, fuel injectors, fuel filter, and high and
low pressure fuel pipes. See Figure 4-55.
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Fuel
喷油器 injectorHigh-pressure fuel pipe
高压油管
Fuel
喷油泵 injection pump
燃油滤清器
Fuel filter
低压油管
Low-pressure fuel pipe
Figure 4-55 Exploded View for Assembly of Fuel System
4.6.1.2 Fuel System Disassembly Procedures
(1) Remove the low-pressure fuel pipe;

(2) Remove the high-pressure fuel pipe
(3) Remove the fuel injector
(4) Remove the fuel filter
(5) Remove the fuel injection pump.
4.6.1.3 Fuel System Assembly Procedures
Assembly of the fuel system is in the reverse order of disassembly.
4.6.2 Disassembly and Assembly of Fuel Injection Pump
4.6.2.1 Exploded View for Assembly of Fuel Injection Pump
The fuel injection pump consists mainly of the fuel injection pump, coupling, flange, gear, and
lubricating pipe. See Figure 4-56.
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Fuel injection pump flange
喷油泵法兰
密封圈
Seal 喷油泵齿轮
ring
Fuel injection pump gear
Fuel injection
喷油泵pump
润滑油管油泵支架
Lubricating oil
总成 pipe assembly Oil pump bracket
油泵托架
Bracket and support
Figure 4-56 Exploded View for Assembly of Fuel Injection Pump
4.6.2.2 Fuel Injection PumpDisassembly Procedures
a) Remove the hexagon nuts used for fixing the fuel injection pump flange to the gear chamber.
b) Remove the fuel injection pump and gear subassembly from the engine;
c) Remove the locking nut of the fuel injection pump;
d) Remove the hexagon bolts used for fixing the fuel injection pump to the flange.
e) Remove the fuel injection pump flange.
4.6.2.3 Inspection and Maintenance of Fuel Injection Pump
Check the fuel supply starting point:

(1) Manually rotate the flywheel to 30°~40° before the top dead center in the compression stroke
of the 1st cylinder;
(2) Remove the high-pressure fuel pipe from fuel injection pump to the 1st cylinder. Clockwise
rotate the flywheel until the fuel level at the joint of high-pressure fuel pipe to the 1st cylinder
slightly increases. Read the fuel injection advance angle from the flywheel.
Adjusting fuel supply starting point:
Manually rotate the flywheel (in the normal direction, not the opposite direction) to the specified
fuel advance angle before the top dead center in the compression stroke of the 1st cylinder. Remove
the high-pressure fuel pipe to the 1st cylinder. Set the throttle at the maximum opening. Bleed air
out of the fuel pipe. Manually slowly rotate the flywheel (in the normal direction, not the opposite
direction) until fuel just comes out of the delivery valve of the 1st cylinder. Record the position of
flywheel at the moment. Without operating the pump, tighten the pump fixing bolt. Observe the fuel
injection advance angle. If the angle does not comply with the requirement, adjust it by loosening
the pump fixing bolt, and manually rotating the pump.
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4.6.2.4 Fuel Injection Pump Assembly Procedures
a) Manually rotate the flywheel until the piston in the 1stcylinder reaches 21CA before top dead
center. Slightly fix the fuel injection pump to the flange (the stud bolt is in the middle of the fuel
injection pump kidney-shape slot). Install the fuel injection pump gear and flange, with their scales
aligning with each other. During the installation, check the position of the scale of fuel injection
pump gear (see the figure below, the piston in the 1st cylinder is 21º before the top dead center in
the compression stroke, and the scale deviates by 2.41º from the vertical line), or check the position
of the timing pin.
b) Finally, achieve the specified fuel injection advance angle by adjusting the fuel injection
pump kidney-shape slot.
c) Tighten the hexagon nuts for fixing the fuel injection pump to the gear chamber.
Scale on the gear
Figure 4-1 Position of scale on the fuel injection pump
4.6.3 Disassembly and Assembly of High-pressure Fuel Pipe
4.6.3.1 Exploded View for Assembly of High-pressure Fuel Pipe
The high-pressure fuel pipe subgroup consists mainly of the high-pressure fuel pipe from the fuel
injection pump to the common rail, the high-pressure fuel pipe from the common rail to the fuel
injection pump, brackets, and pipe clamps. See Figure 4-57.
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Figure 4-57 Exploded View for Assembly of High-pressure Fuel Pipe
4.6.3.2 High-pressure Fuel PipeDisassembly Procedures
(1) Remove high-pressure fuel pipe bracket;

(2) Remove high-pressure fuel pipe
4.6.3.3 High-pressure Fuel PipeAssembly Procedures
Assembly of high-pressure fuel pipe is in the reverse order of Disassembly.

Notice:
Torque for high-pressure fuel pipe fixing bolts: (30~40)N·m at the ends connecting the fuel injector,
fuel rail, and fuel pump.
4.6.4 Disassembly and Assembly of Fuel Injector
4.6.4.1 Exploded View for Assembly of Fuel Injector
The fuel injector subgroup consists mainly of the fuel injector assembly, pad, and clamping block.
See Figure 4-58.
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Fuel injector pad
Hexagon bolt
Fuel injector clamping block
Fuel injector assembly
Figure 4-58 Exploded View for Assembly of Fuel Injector
4.6.4.2 Fuel Injector Disassembly Procedures
(1) Remove the 2 hexagon bolts used for fixing the fuel injector clamping block.
(2) Remove the fuel injector clamping block.
(3) Take the fuel injector assembly from the cylinder head.
4.6.4.3 Inspection and Maintenance of Fuel Injector
Replacement of nozzle of fuel injector must be done by Bosch authorized service station. The part
numbers of fuel injector assembly are shown in Table 4-5. An example of real fuel injector
assembly is shown in Figure 4-59.
Fuel injector impression identification:
Location: On solenoid valve of fuel injector;
Specification:
Line 1: Fuel injector model, for example, WPCRIN2;
Line 2: Weichai part number, for example, 612640080031;
Line 3: Bosch part number, for example, 0445120343;
Notice:
Fuel injectors with different part numbers may not be exchanged. Fuel injectors used in the engines
meeting the national emission standard at stage III and those used in the engines meeting the
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national emission standard at state IV may not be exchanged.
Figure 4-59 Example of fuel injector assembly identification
4.6.4.4 Fuel InjectorAssembly Procedures
Assembly of fuel injector is in the reverse order of Disassembly.

Notice:
The two M8 bolts (different in length) for fixing fuel injector shall be alternatively tightened to the
torque of (20~25)N·m, with the same lateral clearance.
4.7 Cooling System
4.7.1 Disassembly and Assembly of Cooling System
4.7.1.1 Exploded View for Assembly of Cooling System
The cooling system consists mainly of the fan, water pump, thermostat, and water outlet pipe. See
Figure 4-60.
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Figure 4-60 Exploded View for Assembly of Cooling System
2- Fan connecting 3- Water
1- Fan; 4- Alternator;
plate; pump;
5- Crankshaft pulley and vibration
6- Water pipe joint; 7- Thermostat;
damper
4.7.1.2 Cooling System Disassembly Procedures
Cooling system Disassembly Procedures. See Figure 4-60.

(1) Remove the fan connecting plate. For details, see the instructions for Disassembly of fan.
(2) Remove the tensioner
(3) Remove the belt
(4) Remove the alternator, alternator bracket, crankshaft pulley and vibration damper
(5) Remove the alternator and the alternator bracket
(6) Remove the thermostat. For details, see the instructions for Disassembly of thermostat.
（8） Remove the water pump and water pipe joint. For details, see the instructions for
Disassembly of water pump.
4.7.1.3 Cooling System Assembly procedures
Assembly of the cooling system is in the reverse order of disassembly.
4.7.2 Disassembly and Assembly of Fan
4.7.2.1 Exploded View for Assembly of Fan
The fan subgroup consists mainly of the fan, fan clutch, fan connecting plate, and bolts. See Figure
101
4-61.
Figure 4-61 Exploded View for Assembly of Fan

2- Fan
1- Blot; 3- Nut; 4- Stud bolt; 5- Fan connecting plate 6- Water pump
;
4.7.2.2 Fan Disassembly Procedures
Fan dismantling procedures is shown in Figure 4-61.

(1) Remove the bolts used for fixing the fan to the connecting plate. Remove the fan;
(2) Remove the fan connecting plate;
(3) Remove the pulley.
4.7.2.3 Inspection and Maintenance of Fan
Check the fan, fan connecting plate, and pulley for cracks.
4.7.2.4 Fan Assembly Procedures
(1) Before installation, check the fan, fan connecting plate, and hexagon head flanged bolts for
defects in manufacturing or application, and damage.
(2) Assembly of the fan is in the reverse order of Disassembly.
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4.7.3 Disassembly and Assembly of Water Pump
4.7.3.1 Exploded View for Assembly of Water Pump
The water pump subgroup consists mainly of the water pump, water pump gasket, bolts, and
washers. See Figure 4-62.
Water pump gasket Water pump
Stud bolt
Pipe joint washer
Figure 4-62 Exploded View for Assembly of Water Pump
4.7.3.2 Water Pump Disassembly Procedures
Disassembly of water pump is shown in Figure 4-62.

(1) Remove the pipe joint subassembly.
(2) Remove the supporting block and hexagon bolts. Remove the flexible corrugated gasket.
(3) Remove the water pipe joint and washer.
(4) Remove the hexagon head flanged nuts from the water pump.
(5) Remove the stud bolts
(6) Remove the water pump. Remove the water pump gasket.
4.7.3.3 Inspection and Maintenance of Water Pump
(1) Check the pipe joint and pipe joint subassembly for blockage, cracks. If any, replace them
with new ones.
(2) Check the pipe joint gasket and water pump gasket for breakage. If any, replace them with
new ones.
(3) Check the bolts, stud bolts, and nuts for scratches. If any, replace them with new ones.
(4) Check the water pump for cracks. If any, replace it with a new one.
4.7.3.4 Water Pump Assembly Procedures
(1) Before the installation, check the pipe joint, pipe joint subassembly, hexagon bolts, flexible
corrugated gasket, supporting block, nuts, stud bolts, pipe joint gasket, water pump gasket, and
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water pump for defects in manufacturing and application, and damage.
(2) Clean the inner cavity of gear chamber that links the water pump.
(3) Assembly is in the reverse order of Disassembly.
4.7.4 Disassembly and Assembly of Thermostat
4.7.4.1 Exploded View for Assembly of Thermostat
The thermostat subgroup consists mainly of the thermostat, coolant hose, and clamps. See Figure 4-
63.
Clamp
Coolant connecting hose Coolant connecting hose
Clamp
Thermostat
Figure 4-63 Exploded View for Assembly of Thermostat
4.7.4.2 Thermostat Disassembly Procedures
Disassembly of the thermostat is shown in Figure 4-63.

(1) Remove the two clamps used for connecting the upper coolant hose to the water outlet pipe and
thermostat.
(2) Remove the two clamps used for connecting the lower coolant hose to the water outlet pipe of
water pump and the thermostat.
(3) Remove the thermostat;
(4) Remove the two coolant hoses.
4.7.4.3 Inspection and Maintenance of Thermostat
(1) Check the four clamps for failure. If any, replace them with new ones.
(2) Check the coolant hoses for cracks. If any, replace them with new ones.
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(3) Check the thermostat for breakage. If any, replace it with a new one.
4.7.4.4 Thermostat Assembly Procedures
(1) Before installation, check the clamps, hoses, thermostat, and thermostat cover for defects in
manufacturing or application, and damage.
(2) Clean the water outlet pipe of water pump. Ensure no ingress of foreign matters in the water
outlet pipe.
(3) Assembly of the thermostat is in the reverse order of Disassembly.
Thermostat opening temperature:
SN. Initial opening Full opening temperature
temperature
1 (71±2)℃ 82℃
4.7.5 Disassembly and Assembly of Water Outlet Pipe
4.7.5.1 Exploded View for Assembly of Water Outlet Pipe
The water outlet pipe subgroup includes mainly the water outlet pipe, gasket, and bolt. See Figure
4-64.
Figure 4-64 Exploded View for Assembly of Water Outlet Pipe

1- Intake Pipe gasket; 2- Water outlet pipe; 3- Water outlet pipe bolt; 4- Hose
5- Thermostat; 6- Hose 7- Clamp;
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4.7.5.2 Water Outlet PipeDisassembly Procedures
Tools: Socket wrench or pneumatic wrench, open-end wrench;

Preparation before disassembly: Disassemble the intake pipe, and the high-pressure fuel pipe clamp
fixing bolts.
(1) Separate the sensor harness off the water outlet pipe;
(2) Before removing the water outlet pipe, the intake pipe must be removed. For details, refer to
section 4.5 “intake and exhaust system”;
(3) Loosen the high-pressure fuel pipe clamp fixing bolts;
(4) Loosen the water outlet pipe fixing bolts. Remove the water outlet pipe.
(5) For WP10 engines with two valves per cylinder, the water outlet pipe gasket is integrated with
the intake pipe gasket. The gasket can be removed after the Disassembly of the water outlet
pipe. See Figure 4-64.
4.7.5.3 Inspection and Maintenance of Water Outlet Pipe
(1) Before Disassembly, check the water outlet pipe for cracks, excessive wear, corrosion, and sign
of leakage. If any cracks, replace the pipe. In the case of serious corrosion that could affect
reliability, analyze the cause and replace the pipe.
(2) In the case of water leakage at pipe joint, replace the joint with a new one, and then check for
sign of leakage again. In the case of damaged threads of water outlet pipe, replace the pipe with
a new one.
(3) Check the thermostat for abnormality. In the case of excessively high engine coolant
temperature, locate the cause, and replace the thermostat with a new one.
4.7.5.4 Water Outlet PipeAssembly Procedures
(1) Install the thermostat, O-ring, thermostat cover gasket, thermostat cover and flange one by one
to the water outlet pipe, and then tighten the bolt.
(2) Recommendation is that the intake pipe gasket should be used only once. Replace it with a new
one in the servicing of intake pipe.
(3) Clean the water outlet pipe mating face. Then connect the pipe to the cylinder head and insert
the fixing bolts.
(4) Tighten the fixing bolts.
106
(5) Tighten the high-pressure fuel pipe clamp fixing bolts.
(6) Fix the sensor harness to the water outlet pipe.
4.8 Lubrication System
4.8.1 Disassembly and Assembly of Lubrication System
4.8.1.1 Exploded View for Assembly of Lubrication System
The lubrication system consists mainly of the engine oil suction filter, engine oil filter, oil pump and
engine oil cooler. See Figure 4-65.
Oil suction filter

Oil cooler
Engine oil intermediate gear subassembly
Main oil-way pressure control valve

Oil pump
Oil cooler cover
Oil pan
Engine oil cooler bypass valve
Engine oil filter
Figure 4-65 Exploded View for Assembly of Lubrication System
4.8.1.2 Lubrication System Disassembly Procedures
(1) Remove the oil pan. For details, see the instructions for Disassembly of engine body group.
(2) Remove the engine oil suction filter
(3) Remove the crankshaft pulley, vibration damper, and the hexagon screw hexagon screw plug of
the gear chamber. For details, see the instructions for Disassembly of crank connecting rod
mechanism.
(4) Remove the engine oil pump intermediate gear subassembly.
(5) Remove the oil pump
(6) Remove the Main oil-way pressure control valve
(7) Remove the engine oil filter
(8) Loosen the hollow bolt on the engine oil cooler cover and used for the air compressor, and the
hexagon bolt used for fixing the oil dipstick subassembly. Remove the engine oil cooler cover.
(9) Remove the oil cooler
(10)Remove the engine oil cooler bypass valve.
107
4.8.1.3 Lubrication system Assembly Procedures
Assembly of the lubrication system is in the reverse order of disassembly.
4.8.2 Disassembly and Assembly of Oil Pump
4.8.2.1 Exploded View for Assembly of Oil Pump
The engine oil pump subgroup consists mainly of the engine oil pump, engine oil pump gasket,
bolts and washers. See Figure 4-66.
Oil pump
Oil pump
gasket
gasket
Oil pump
Oil pump
Hex head
Hextooth-flanged
head tooth-flanged
bolt bolt
Hex head
Hextooth-flanged
head tooth-flanged
bolt bolt
Figure 4-66 Exploded View for Assembly of Oil Pump
4.8.2.2 Oil Pump Disassembly Procedures
Loosen the two hexagon head flanged bolts on the engine oil pump. Remove the engine oil pump
and gasket. See figure 4-66.
4.8.2.3 Inspection and Maintenance of Oil Pump
(1) Check the engine oil pump for cracks. Check whether the inner cavity of the pump is smooth. If
necessary, remove the pump.
(2) Check the engine oil pump gasket for leakage. If any, analyze the cause and replace the gasket
with a new one.
4.8.2.4 Oil pump Assembly Procedures
(1) Before installation, check the engine oil pump and gasket for defects in manufacturing or
application, and damage. They shall be in good conditions.
(2) Clean the mating faces of the engine oil pump and crankcase;
(3) Install the engine oil gasket, and;
(4) Install the engine oil pump;
108
(5) Install the two hexagon head flanged bolts, and then tighten them.
4.8.3 Disassembly and Assembly of Engine Oil Intermediate Gear Assembly
4.8.3.1 Exploded View for Assembly of Engine Oil Intermediate Gear Assembly
The engine oil pump intermediate gear subassembly subgroup includes mainly the engine oil pump
intermediate gear subassembly and intermediate gear shaft. See Figure 4-67.
Engine oil intermediate gear subassembly

Intermediate gear shaft
Seal ring
Hexagon bolt
Figure 4-67 Exploded View for Assembly of Engine Oil Intermediate Gear Assembly
4.8.3.2 Engine Oil Intermediate Gear Assembly Disassembly Procedures
(1) Loosen and remove the hexagon bolt.

(2) Using a special tool, remove the intermediate gear shaft. Then remove the engine oil pump
intermediate gear subassembly.
4.8.3.3 Inspection and Maintenance of Engine Oil Intermediate Gear Assembly
(1) Check the engine oil pump intermediate gear and intermediate gear shaft for cracks. If any,
replace them with new ones.
(2) Check the seal ring for breakage. If any, replace it with a new one.
4.8.3.4 Engine Oil Intermediate Gear AssemblyAssembly Procedures
(1) Before installation, check the engine oil pump intermediate gear subassembly, intermediate
gear shaft, hexagon bolts, and seal ring for defects in manufacturing or application, and
damage.
(2) Clean the mating faces of crankcase and engine oil pump intermediate gear subassembly, and
the engine oil pump intermediate gear subassembly.
109
(3) Install the seal ring to the intermediate gear.
(4) Install the engine oil pump intermediate gear, with its raised side facing inward.
(5) Install the intermediate gear shaft
(6) Install the hexagon bolts, and then tighten it.
4.8.4 Disassembly and Assembly of Engine Oil Filter
4.8.4.1 Exploded View for Assembly of Engine Oil Filter
The engine oil filter subgroup consists mainly of the engine oil filter assembly, engine oil filter
holder gasket, bolts, and washers. See Figure 4-68.
1- Hexagon bolt 2- Washer 3- Engine oil filter 4- Engine oil filter
assembly; holder gasket

Figure 4-68 Exploded View for Assembly of Engine oil filter
4.8.4.2 Engine Oil filter Disassembly Procedures
Loosen the 4 bolts used for fixing the engine oil filter. Remove the engine oil filter assembly and
engine oil filter holder gasket. See Figure 4-72.
4.8.4.3 Inspection and Maintenance of Engine Oil Filter
(1) Check the engine oil filter assembly for damage. If any, replace it with a new one.
(2) Check the engine oil filter holder gasket for damage. If any, replace it with a new one.
4.8.4.4 Engine Oil FilterAssembly Procedures
(1) Before installation, check the engine oil filter holder gasket and engine oil filter assembly for
defects in manufacturing or application, and damage. They shall be in good conditions.
110
(2) Clean the mating faces of the engine oil filter assembly and engine body.
(3) Install the engine oil filter holder gasket and engine oil filter assembly.
(4) Install the flexible corrugated gasket and bolt, and then tighten them.
4.8.5 Disassembly and Assembly of Oil Cooler Cover
4.8.5.1 Exploded View for Assembly of Oil Cooler Cover
The engine oil cooler cover subgroup consists mainly of the engine oil cooler cover, engine oil
cooler cover gasket, some supporting blocks, and bolts. See Figure 4-69.
Supporting block
Hexagon flange bolt
Seal washer
Hexagonal screwSupporting
plug block
Supporting block
Engine oil cooler cover washer
Hexagon flange bolt Oil cooler cover
Figure 4-69 Exploded View for Assembly of Oil Cooler Cover
4.8.5.2 Oil Cooler CoverDisassembly Procedures
Before removal, drain coolant from the engine. Loosen the bolts of engine oil cooler cover. Remove
the engine oil cooler cover and gasket. See Figure 4-69.
4.8.5.3 Inspection and Maintenance of Oil Cooler Cover
(1) Observe the oil cooler cover for presence of cracking and other damage. Upon detection of
cracking, replace with new oil cooler cover.
(2) Check the engine oil cooler cover gasket for sign of leakage. If any, identify the cause and
replace the gasket with a new one.
111
4.8.5.4 Oil Cooler CoverAssembly Procedures
(1) Before installing the engine oil cooler cover gasket, check it and the engine oil cooler cover for
defects in manufacturing or application, and damage. They shall be in good conditions.
(2) Clean the mating faces of the engine oil cooler cover and engine body. Install the engine oil
cooler cover gasket.
(3) Install the bolts of the engine oil cooler cover, and then tighten it.
4.8.6 Disassembly and Assembly of Oil Cooler
Exploded View for Assembly of Oil Cooler
The engine oil cooler subgroup consists mainly of the engine oil cooler, bolts and washers. See
Figure 4-70.
Seal ring
Oil cooler
Flexible corrugated gasket
Hex socket-head cap screw
Figure 4-70 Exploded View for Assembly of Oil Cooler
4.8.6.2 Oil Cooler Disassembly Procedures
Loosen the 4 bolts of the engine oil cooler. Remove the engine oil cooler and seal ring as shown in
Figure 4-70.
4.8.6.3 Inspection and Maintenance of Oil Cooler
Check the engine oil cooler for cracks. If any, replace it with a new one.
4.8.6.4 Oil cooler Assembly Procedures
(1) Before installation, check the engine oil cooler for defects in manufacturing or application, and
112
damage. They shall be in good conditions.
(2) Clean the mating faces of the engine oil cooler and engine body.
(3) Install the seal ring and engine oil coolers.
(4) Install the flexible corrugated gasket and bolt, and then tighten it.
4.8.7 Disassembly and Assembly of Main oil-wayPressure Control Valve
4.8.7.1 Disassembly and Assembly of Main oil-way Pressure Control Valve
Assembly of the Main oil-way pressure control valve is shown in Figure 4-71.
Main oil-way pressure control valve
Figure 4-71 Disassembly and Assembly of Main oil-way pressure control valve
4.8.7.2 Main oil-way Pressure Control ValveDisassembly Procedures
Loosen and remove the Main oil-way pressure control valve, as shown in Figure 4-71.
4.8.7.3 Inspection and Maintenance of Main oil-way Pressure Control Valve
Check the Main oil-way pressure control valve for failure. If any, replace it with a new one.
Check the Main oil-way pressure control valve for cracks. If any, replace it with a new one.
4.8.7.4 Main oil-way Pressure Control ValveAssembly Procedures
(1) Before the assembly, check that Main oil-way pressure control valve are free of manufacturing
and functional defects including damage;
(2) Clean the hole in engine body for the Main oil-way pressure control valve, and the pressure
control valve.
(3) Apply sealant to the threads of the Main oil-way pressure control valve.
(4) Install the Main oil-way pressure control valve, and then tighten it.
113
4.8.8 Disassembly and Assembly of Engine Oil Cooler Bypass Valve
4.8.8.1 Exploded View for assembly of Engine Oil Cooler Bypass Valve
The engine oil cooler bypass valve consists mainly of the relief valve, relief valve spring, hexagon
head screw plug, and washer. See Figure 4-72.
Hexagon screw plug;
Combination washer
Relief valve spring
Safety valve
Figure 4-72 Exploded View for assembly of engine oil cooler bypass valve
4.8.8.2 Engine Oil Cooler Bypass ValveDisassembly Procedures
Loosen and remove the hexagon head screw plug. Remove the combination washer, relief valve
spring, and relief valve. See Figure 4-72.
4.8.8.3 Inspection and Maintenance of Engine Oil Cooler Bypass Valve
(1) Check the relief valve spring for lack of flexibility. If any, replace the spring with a new one.
(2) Check the relief valve, hexagon head screw plug, and combination washer for cracks. If any,
replace them with new ones.
4.8.8.4 Engine Oil Cooler Bypass ValveAssembly Procedures
(1) Before installation, check the relief valve, relief valve spring, combination washer, and hexagon
head screw plug for defects in manufacturing or application, and damage. They shall be in good
conditions.
(2) Clean the engine oil cooler bypass valve and the hole in engine body for the engine oil cooler
bypass valve.
114
(3) Install the relief valve, relief valve spring, and combination washer.
(4) Install the hexagon head screw plug, and then tighten it.
4.8.9 Disassembly and Assembly of Engine Oil Suction Filter
4.8.9.1 Exploded View for Assembly of Engine Oil Suction Filter
The location of engine oil suction filter is shown in Figure 4-73.
Gasket
Hexagon bolt Flat washer
Engine oil suction filter
Figure 4-73 Exploded View for Assembly of Engine oil suction filter
4.8.9.2 Engine oil suction filter Disassembly Procedures
Loosen the two hexagon bolts of the engine oil suction filter. Remove the filter and gasket. See
Figure 4-73.
4.8.9.3 Inspection and Maintenance of engine oil suction filter
Check the engine oil suction filter and gasket for cracks. If any, replace them with new ones.
4.8.9.4 Engine oil suction filter Assembly Procedures
(1) Before installation, check the engine oil suction filter and gasket for defects in manufacturing
or application, and damage. They shall be in good conditions.
(2) Clean the mating faces of the engine oil suction filter and engine oil pump, and the inner cavity
of the engine oil suction filter;
115
(3) Install the gasket and engine oil suction filter;
(4) Install the hexagon bolts, and then tighten it.
4.9 Starting System
4.9.1 Disassembly and Assembly of Starting System
4.9.1.1 Exploded View of Starting System
The starting system consists mainly of the starter, and the stud bolts and nuts used for fixing the
starter. See Figure 4-74.
4 Gear ring
2 Stud bolt
1 Starter 3 Hexagon nut
Figure 4-74 Exploded View of Starting System
4.9.1.2 Starting System Disassembly Procedures
(1) Remove the starting system

(2) Remove the gear ring. See section 4.4.5.
4.9.1.3 Starting system Assembly Procedures
Assembly of the starting system is in the reverse order of disassembly.
4.9.2 Disassembly and Assembly of Starter
4.9.2.1 Exploded View for Assembly of Starter
Exploded View for assembly of starting system. See Figure 4-74.
116
4.9.2.2 Starter Disassembly Procedures
(1) Remove the hexagon nut (3).

(2) Holding the starter (1) with both hands, pull it off horizontally.
(3) Remove the stud bolts (2).
4.9.2.3 Inspection and Maintenance of Starter
Check the gear teeth of the starter for damage. If any, replace the starter.
4.9.2.4 Starter Assembly Procedures
Assembly of the starter is in the reverse order of Disassembly.
4.10 Electrical system
4.10.1 Disassembly and Assembly of Alternator
4.10.1.1 Exploded View for Assembly of Alternator
The alternator subgroup consists mainly of the alternator, and V-belt. See Figure 4-76.
Figure 4-75 Exploded View for Assembly of alternator

1- Ribbed belt; 2- Alternator; 3- Hexagon 4- Corrugated 5- Sleeve; 6- Hexagon
bolt; gasket; bolt;
7- Nut; 8- Alternator 9- Supporting 10- Hexagon 11- Corrugated
bracket; block; bolt; gasket;
117
4.10.1.2 Alternator Disassembly and Assembly Procedures
(1) Alternator installation location

(2) Loosen the air conditioning compressor V-belt tensioning bolt. Remove the V-belt (see the
section “Disassembly and Assembly of air conditioning compressor”).
(3) Loosen and remove the M10 nut used for tensioning the alternator V-belt
(4) Remove the tensioning block fixing bolt and the tensioning block.
(5) Remove the M10 stud bolts used for fixing the alternator.
(6) Assembly of the alternator is in the reverse order of Disassembly.
Notice:
The alternator must be dismantled and repaired by a professional. During installation, check all
insulation gaskets and sleeves for intactness and ensure to replace any damaged one. The positive
terminal of alternator can’t be short circuited with the housing, otherwise it’s prohibited to install
the alternator onto the vehicle to prevent causing serious vehicle accidents.
4.10.1.3 Malfunction Diagnosis and Maintenance of Alternator
4.10.1.3.1 Procedure for judgment of Alternator Malfunction
During the warranty service for the user, firstly test on the vehicle to judge whether the alternator is
malfunctioned. Tool: Test lamp. The procedure is shown in Figure4-77.
118
Turn on the power switch of the vehicle and connect the test lamp to the terminal B+ and E (negative) of the alternator.
It indicates that there is no voltage at terminal B+ of alternator and the wire to the positive pole of battery is m
No
Is test lamp ON?
Yes
Connect the wire from terminal E to terminal D+ of alternator
No
It indicates that the internal electric circuit at terminal D+ of alternator is malfunctioned.
Is test lamp ON?
Yes
Start the engine
Yes
Is test lamp ON? Alternator malfunction
No
Alternator is not malfunctioned
Figure 4-76 Flowchart for judgment of alternator malfunction
4.10.1.3.2 Malfunction diagnosis and troubleshooting of charging system
(1) Charging failure

Malfunction 1: Charging failure
Vehicle symptom Fault Detection Solution
(1) The charging a. Check charging 1 Check alternator indicator lamp for
indicator lamp fails to indicator lamp. presence of voltage to ground. If not, replace
turn on after turn-on of b. Check the excitation indicator lamp or check circuit.
key switch. circuit for presence of 2 If yes, it indicates that the alternator
open-circuit. regulator or rotor is malfunctioned. Repair or
replace alternator.
(2) The charging a. Low power of 1 Use recommended 2~6W lamp bulb or
indicator lamp fails to indicator lamp or loose repair circuit.
turn off during idling parallel excitation resistor. 2 Adjust idling speed of the engine.
of engine and turns off b. Low idling speed of
during high-speed engine.
running of engine.
(3) The charging a. Check whether the 1 If the alternator indicator lamp terminal
119
indicator lamp fails to voltage to ground of the voltage is really low, it indicates low power
turn off while the alternator exciting of excitation line indicator lamp or loose
engine is running. terminal is within 1~3V. connection in circuit. Adjust the indicator
lamp power or check the circuit connectors
and connection points.
2 If the alternator indicator lamp terminal
voltage is zero, it indicate the presence of
short-circuit to ground at the excitation circuit
alternator terminal. In such case, check the
circuit.
3 If the alternator indicator lamp terminal
voltage is the battery voltage, it indicates the
presence of malfunction in vehicle excitation
circuit and that the alternator regulator and
excitation tube may be damaged. In such
case, make sure to correct the excitation
circuit and then repair the alternator.
b. Check whether the 1 If the B+ voltage to ground is zero, check
voltage to ground of the whether both the positive and negative wires
alternator output terminal between alternator and battery are under
B+ equals to battery continuity status.
voltage of approximately 2 If the B+ voltage to ground is
24V. significantly below the battery voltage, check
the connecting points of positive and negative
wires between alternator and battery for
presence of looseness or check the battery for
damage.
Recommended measurement method: Jumper
connect one 2W indicator lamp between
alternator output terminal B+ and excitation
terminal D+/L and observe the working status
of indicator lamp.
Solution:
1 The lighting intensity of indicator lamp is
normal, the indicator lamp turns off after the
engine is started, and the alternator output
voltage is 27~28.5V. The vehicle excitation
circuit is malfunctioned and needs checking
and repair.
normal, the indicator lamp turns on
constantly after the engine is started, and the
alternator output voltage is 27~28.5V. The
alternator regulator is malfunctioned and
needs to be replaced.
120
normal, the indicator lamp turns on
constantly after the engine is started, and the
alternator output voltage is the battery
voltage. The alternator regulator, rectifier
bridge, stator, or internal connection may be
malfunctioned and need repair or
replacement.
(2) Low charging voltage
Malfunction 2: Low charging voltage
Vehicle Fault Detection Solution
symptom
The battery is Understand whether The measurement of alternator terminal B+ voltage shall
frequently the alternator output be at 27.8~28.4V. If the voltage is normal, it indicates
charged power is reasonably that the voltmeter or voltmeter sampling point is
insufficiently, matched with the malfunctioned and needs to be repaired or replaced.
with low electric devices of
charging vehicle.
voltage, and its a. Check voltmeter 1 It’s recommended that the no-load idling speed of
voltage drops for damage. alternator is higher than 1600RPM.
significantly b. Check the 2 When the alternator is working under high power
when being alternator speed. load condition (for instance, the air conditioner is
loaded. switched on), the alternator speed shall be ≥2000rpm or
the voltage shall be approximately 27V.
c. Check the drive 1 Check the quality of belts for alternator and relevant
belt quality and pulley systems and replace any burnt, ruptured, distorted
tension for alternator belt or the belt with tooth breakage or the belt dropping
and related gear to the bottom of groove.
system. 2 Re-tension the alternator and relevant pulley
systems.
Notice:
For the systems with double drive belt, replace both
belts in event of replacement.
d. Check alternator Tighten if loosened.
pulley.
e. Check wires for 1 If the voltage difference is higher than 1V (high
reasonable use and voltage drop due to thin wires) under heavy-load
measure voltages at condition, replace the wires.
alternator andS≥6mm2 within 35A S≥12mm2 within 70A
battery terminals. S≥20mm2 within 100A S≥25mm2 within 150A
2 If the wire or connector has clear temperature rise
under heavy-load working condition, replace the wire or
connector.
f. Check for 1 Grind the wire lugs with oxidized surfaces and the
presence of high housing surface for installation of grounding bolt and
121
temperature due to reinstall.
looseness, oxidation, 2 Retighten any loose nut and wire lug and re-insert
or loose connection the connectors.
at the joint between Notice:
wire and bolt of Run the reinstalled or re-tightened portions for 3~5min
charging system. when the alternator is under heavy-load and then check
for the presence of high temperature.
g. Check the phase If there is high difference between phase terminal
output voltage of (W/R/AC) output voltage and normal output, the
alternator (This alternator rectifier bridge or stator is malfunction and
voltage shall be the checking and replacement shall be considered.
approximately one
half of B+ output
voltage.)
h. Check the The charging current shall drop to approximately 10A
battery for normal after 10min charging. If the charging current is at
charging. 30~90A constantly, the battery is damaged and needs
repair or replacement.
(3) High charging voltage
Malfunction 3: High charging voltage
symptom
The voltmeter a. Check voltmeter The measurement of alternator B+ terminal voltage
indicates high for damage. generally shall be at 27~28.4V. If the voltage is normal,
voltage it indicates that the calibration error of voltmeter is high
and the voltmeter needs to be repaired or replaced.
b. Check the wires 1 In event of poor contact or loose connection,
and connections of retighten or re-insert the connectors.
the charging system, 2 In event of short-circuit, re-connect the wires.
check the connection

bolts for presence of
looseness, loose
connection, and high
temperature, and
check for presence
of short-circuit
between wires and
122
alternator housing.
c. Check battery 1 Observe during the charging of battery whether the
for normal working charging current varies greatly within a short period
status. (from 50A to below 10A). If not, the replacement of
battery as soon as possible shall be considered.
2 Observe the battery surfaces for cleanliness and
dryness and check whether the wiring terminals and
clamps are in good fit. Replace as soon as possible in
event of any damage.
d. Check the phase If there is high difference between phase terminal (W/R/AC)
output voltage of output voltage and normal output and the voltage drop is high
alternator (This when the alternator is loaded, the alternator rectifier bridge or
voltage shall be stator is malfunctioned and the checking and replacement shall
approximately one be considered.
half of B+ output
voltage.)
e. The malfunction Replace alternator regulator, rotor, or whole alternator.
symptom is not
solved after above
checking.
(4) Unstable charging voltage
Malfunction 4: Unstable charging voltage
symptom
The voltmeter a. Loose belt or Tension belts for alternator and related pulley systems.
indicates the belt run-out for
charging during alternator or related
normal running pulley systems.
b. Looseness or Check and tighten connections of charging circuit
of engine, but
poor contact at
the pointer
connections of
fluctuates and
charging circuit
the reading
c. Contamination Remove contaminants or replace electric brush or electric
123
can’t be read (or of collector ring, brush spring
the charging excessive wear of
indicator lamp electric brush, or
turns off softening or
occasionally). breakage of electric
brush spring
d. Damage of Replace the regulator.
regulator
(5) Alternator noise
Malfunction 4: Unstable charging voltage
symptom
There is an a. The fixing bracket of alternator is Improve strength of fixing bracket
abnormal noise deformed or is too close to other and adjust installation status.
during running external housings.
b. Looseness or slip of alternator belt Replace engine belt.
of alternator.
c. Loose alternator pulley Tighten pulley.
d. Oil shortage or damage of Replace alternator bearing
alternator bearings
e. Low noise within alternator The stator coil is short circuited.
Replace it.
f. Speed-dependent squealing within This is the noise generated by the
alternator vibration of stator iron core. If
necessary, replace stator subassembly.
124
Appendix A Fit Clearances for Main Parts of Diesel Engine
(reference value)
SN. Item Theoretical value (mm)

1 Main bearing clearance 0.095～0.171
2 Connecting rod bearing clearance 0.059～0.135
3 Crankshaft endplay 0.102～0.305
4 Axial clearance of connecting rod plane 0.15～0.35
Clearance between connecting rod small end and 0.04～0.061
5
piston pin
6 Clearance between piston pin boss 0.005～0.018
Working clearance of piston ring opening in cold state
1st ring 0.35～0.60

7
2nd ring 0.4～0.6
Oil ring 0.35～0.55

End clearance of piston ring in cold state
1st ring
8
2nd ring 0.07～0.115
Oil ring 0.04～0.075

9 Clearance between intake valve stem and valve guide 0.02～0.048
10 Clearance between exhaust valve stem and valve guide 0.025～0.053
Valve bottom sink in cylinder head
11
Exhaust / Intake 1.08～1.48/0.85～1.05
12 Protrusion of cylinder liner top above engine body top 0.05～0.10
13 Camshaft axial clearance 0.1～0.4
14 Camshaft bearing clearance 0.04～0.12
15 Clearance between tappet and tappet hole 0.025～0.089
Interference or clearance between cylinder liner －0.02～0.023
16
outside diameter and cylinder liner hole in engine body
17 Clearance between rocker arm and rocker arm shaft 0.012～0.066
Backlash between mating teeth of timing gear and 0.015～0.33
18
intermediate gear
125
Appendix B Wear Evaluation References for Main Friction Pairs in Diesel
Engine
(reference value)
Wear limit Clearance limit
mm mm
Closed gap of the 1st piston ring 1.70 -
Height of the 1st piston ring 0.10 -
Closed gap of the 2nd piston ring 1.50 -
Height of the 2nd piston ring 0.10 -
Closed gap of oil ring 1.50 -
Height of oil ring 0.15 -
Outside diameter of piston skirt 0.25
0.60
Inside diameter of cylinder liner 0.50
Outside diameter of piston pin 0.04
Inside diameter of piston pin hole 0.08
Inside diameter of bushing at connecting rod small 0.10
0.08
end
Outside diameter of main journal of camshaft 0.06
0.10
Inside diameter of camshaft bushing 0.06
Height of cam nose relative to basic circle 2.00 -
Outside diameter of basic circle of cam 0.05 -
Outside diameter of crankshaft journal for
0.12
connecting rod 0.15
Inside diameter of connecting rod bearing 0.10
Outside diameter of crankshaft main journal 0.08
0.15
Inside diameter of main bearing 0.10
Thickness of thrust bearing 0.40 -
Intake valve sink 0.04*d(1)
Intake valve seal ring 0.75
Intake valve seat 0.75
Exhaust valve sink 0.04*d(1)
Exhaust valve seal ring 0.85
Exhaust valve seat 0.85
Inside diameter of intake valve guide 0.06
0.1
Outside diameter of intake valve stem 0.06
Inside diameter of exhaust valve guide 0.06
0.1
Outside diameter of exhaust valve stem 0.06
Inside diameter of bushing of rocker arm shaft 0.10 0.12
126
Outside diameter of rocker arm shaft 0.05
127

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Service Manual For WP10 Two-Valve Stage-II Series Diesel Engine

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Service Manual for WP10 Two-valve Stage-II Series Land-use Diesel Engine for Power Generation

Service Manual for WP10 Two-valve Stage-II Series

Weichai Power Co., Ltd.

1.1 Exterior View of Diesel Engine....................................................................................................1

1.2 Model Meaning of Diesel Engine................................................................................................2

1.3 Main Technical Specification of Diesel Engine...........................................................................2

1.4 Unsealing of Diesel Engine..........................................................................................................3

1.5 Hoisting of Diesel Engine............................................................................................................4

1.6 Installation of Diesel Engine........................................................................................................4

1.7 Pre-start Preparations of Diesel Engine.......................................................................................4

1.8 Start of Diesel Engine...................................................................................................................5

1.9 Running of Diesel Engine............................................................................................................6

Chapter II Maintenance Guide.......................................................................................................................8

2.1.1 Fuel Oil.................................................................................................................................8

2.1.2 Lubricating Oil.....................................................................................................................8

2.1.4 Auxiliary Materials.............................................................................................................10

2.2 Routine Maintenance..................................................................................................................11

2.3 Periodic Maintenance.................................................................................................................14

2.3.1 Replace Engine Oil.............................................................................................................14

2.3.2 Replace Engine Oil Filter...................................................................................................14

2.3.4 Replace Fuel Filter Element...............................................................................................15

2.3.5 Check the Intake and Exhaust System...............................................................................18

2.3.6 Check the Air Filter Element..............................................................................................18

2.4 Maintenance for Long-term Storage..........................................................................................20

2.4.3 Oil Seal...............................................................................................................................20

Chapter III Typical Faults and Solutions......................................................................................................22

3.1 Diagnostic Method.....................................................................................................................22

3.2 Common Faults and Troubleshooting........................................................................................23

3.2.2 Stop of Engine Shortly after Start......................................................................................23

3.2.3 Low Power..........................................................................................................................24

3.2.4 Excessive Fuel Consumption.............................................................................................25

3.2.5 Black Exhaust Gas..............................................................................................................25

3.2.6 White or Blue Exhaust Gas................................................................................................26

3.2.8 Unstable Speed...................................................................................................................26

3.2.9 Engine Oil Pressure Too Low............................................................................................27

3.2.10 High Coolant Temperature.................................................................................................27

3.2.11 Excessive Wear of Parts.....................................................................................................28

3.2.12 Excessive Noise..................................................................................................................28

3.2.13 Working Failure of Starter Motor.......................................................................................29

3.2.14 Weak Starter Motor............................................................................................................29

3.2.15 Generally Cannot Generate Electricity at All....................................................................29

3.2.16 Inadequate Charging Current of Alternator.......................................................................30

3.2.17 Instable Charging Current..................................................................................................30

3.2.18 Excessive Charging Current of Alternator.........................................................................30

3.2.19 Abnormal Sound from Alternator......................................................................................31

Chapter IV Disassembly and Assembly of Engine.......................................................................................32

4.1.1 Danger Sign........................................................................................................................32

4.1.2 Safety Sign..........................................................................................................................33

4.1.4 Precautions for Health Protection......................................................................................34

4.1.5 Precautions for Environment Protection............................................................................35

4.1.6 Precautions on Disassembly and Installation of Engine....................................................35

4.2 Engine Block Group...................................................................................................................37

4.2.1 Disassembly and Assembly of Engine Block Group.........................................................37

4.2.2 Disassembly and Assembly of Cylinder Block Preassembly............................................40

4.2.3 Disassembly and Assembly of Front End Cover...............................................................42

4.2.4 Disassembly and Assembly of Gear Chamber...................................................................43

4.2.5 Disassembly and Assembly of Flywheel Cover.................................................................45

4.2.7 Disassembly and Assembly of Piston Nozzle....................................................................49

4.2.8 Disassembly and Assembly of Thrust Halfring.................................................................50