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1
Usage Instructions for Diesel Engine ..................................................................... 1
11 External View of Diesel Engine ............................................................................. 1
12 Diesel Engine Model Composition and Significance ............................................. 3
13 Diesel Engine Main Technical Parameters ............................................................. 3
14 Unseal of Diesel engine .......................................................................................... 5
15 Lifting of Diesel Engine ......................................................................................... 6
16 Installation of Engine .............................................................................................. 6
17 Preparation before Starting Engine ......................................................................... 6
18 Start the Engine ....................................................................................................... 7
19 Run the Engine ....................................................................................................... 7
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Maintenance Guidelines for Diesel Engine ............................................................ 9
21 Fuel Oil, Engine oil, Coolant and Auxiliary Materials .......................................... 9
211 Fuel Oil ........................................................................................................... 9
212 Engine Oil ....................................................................................................... 9
213 Lubrication of Tensioning Wheel ................................................................. 10
214 Antifreeze Additive in Engine Cooling System ........................................... 10
215 Auxiliary Materials ....................................................................................... 11
22 Daily Maintenance ................................................................................................ 12
221 Check Coolant Level and Temperature ........................................................ 12
222 Check Engine Oil Level ............................................................................... 13
223 Check Fuel Level .......................................................................................... 14
224 Check "Three Leakages" .............................................................................. 14
225 Check Fan ..................................................................................................... 14
226 Check Belt .................................................................................................... 14
227 Check Whether Exhaust Gas Color is Normal ............................................. 14
228 Check Whether Running Sound is Normal .................................................. 15
229 Check Whether Rotating Speed and Vibration are Normal ......................... 15
23 Periodic Maintenance ........................................................................................... 15
24 Maintenance for Long-Term Storage ................................................................... 20
241 Cleaning ........................................................................................................ 20
242 Protection ...................................................................................................... 20
Service Manual for WD10 Diesel Engine
CONTENTS
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Summary of Contents for WEICHAI WD10
- Page 1 Service Manual for WD10 Diesel Engine CONTENTS Usage Instructions for Diesel Engine ..............1 11 External View of Diesel Engine ................1 12 Diesel Engine Model Composition and Significance ..........3 13 Diesel Engine Main Technical Parameters ............. 3 14 Unseal of Diesel engine ..................5 15 Lifting of Diesel Engine ..................
- Page 2 Service Manual for WD10 Diesel Engine Diagnosis and Troubleshooting of Diesel Engine Common Faults ..... 21 31 Diagnostic Methods ....................21 32 Fault Causes and Elimination Methods ..............22 321 Diesel Engine Couldn’t Be Started .............. 22 322 Diesel Engine Stops Soon after Starting ............23 323 Underpower ....................
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Page 3: Table Of Contents
Service Manual for WD10 Diesel Engine 422 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover Shield ......................38 423 Disassembly, Inspection, Maintenance and Assembly of Water Outlet Pipe …………………………………………………………………………...39 424 Disassembly, Inspection, Maintenance and Assembly of Oil-Gas Separator …………………………………………………………………………...41 425 Disassembly, Inspection, Maintenance and Assembly of Hanger Plates ..42 426 Disassembly, Inspection, Maintenance and Assembly of Cylinder Cover .. - Page 4 Service Manual for WD10 Diesel Engine 453 Disassembly, Inspection, Maintenance and Assembly of Rocker and Rocker Shaft ......................79 454 Disassembly, Inspection, Maintenance and Assembly of Valve Tappet and Pushrod ......................82 455 Disassembly, Inspection, Maintenance and Assembly of Valve ....83 456 Disassembly, Inspection, Maintenance and Assembly of Intermediate Gear …………………………………………………………………………...85...
- Page 5 Service Manual for WD10 Diesel Engine 497 Disassembly, Inspection, Maintenance and Assembly of Main Oil Gallery Pressure Limiting Valve ................111 498 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler Bypass Valve ....................112 499 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer ………………………………………………………………………….113...
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Page 6: 43 Engine Block Assembly
Service Manual for WD10 Diesel Engine 43 Engine Block Assembly 431 Disassembly, Inspection, Maintenance and Assembly of Engine Block Assembly 4311 Exploded View of Engine Block Assembly Engine block module Cylinder sleeve Cylinder cover auxiliary bolt Elastic cylindrical pin Pre-glued set screw... -
Page 7: 439 Disassembly, Inspection, Maintenance And Assembly Of Front And Rear Oil Seals
Service Manual for WD10 Diesel Engine side with oil groove should be outward. 4384 Steps to Assemble Thrust Plates (1) Install crankshaft; (2) Install upper thrust plates (without lug); (3) Install lower thrust plates (key point 1). 439 Disassembly, Inspection, Maintenance and Assembly of Front and... -
Page 8: Gear
Service Manual for WD10 Diesel Engine (3) Install valve tappet and pushrod, refer to assembly of valve tappet and pushrod for details; (4) Assemble intake and exhaust valves, refer to assembly of valves for details; (5) Install rocker and rocker shaft, refer to assembly of rocker and rocker shaft for details;... - Page 9 Service Manual for WD10 Diesel Engine (10) Remove engine oil cooler bypass valve. 4913 Steps to Assemble Lubricating System Assembling steps are contrary to disassembling ones. 492 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump 4921 Exploded View of Engine Oil Pump...
- Page 10 Service Manual for WD10 Diesel Engine (4) Install engine oil pump. (5) Install and tighten the two toothed hexagon bolts. 493 Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump Intermediate Gear 4931 Exploded View of Engine Oil Pump Intermediate Gear...
- Page 11 Service Manual for WD10 Diesel Engine (2) Clean up engine oil cooler bypass valve and valve fitting hole on engine block. (3) Install safety valve, safety valve spring and compound gasket orderly. (4) Install the hexagon plug and tighten it.
- Page 12 Service Manual for WD10 Diesel Engine Fig. 4-81 Assembly of A/C compressor (2) Install A/C compressor V-belt. (3) Adjust the location of compressor and tension the V-belt with the draw-in rod, tighten compressor fixing bolts and nuts, as shown in Fig. 4-81.
- Page 13 Service Manual for WD10 Diesel Engine Fault 2: Low charging voltage Phenomenon Fault detection Troubleshooting Measure generator B+ terminal voltage, which should be within 27.8~28.4V, if the voltage is normal, then it means voltmeter failure or voltmeter sampling point is in fault, repair or replace.
- Page 14 Service Manual for WD10 Diesel Engine 3) Check measure wear condition and fitting condition of air compressor cylinder sleeve, piston and piston ring, severely worn parts should be replaced. 4) For compressor air cooling parts, please: Clean up accumulated oil dirt, soot and other dirty materials on cooling fin.
- Page 15 Service Manual for WD10 Diesel Engine surface, and push the pump (with a sealing gasket) into the mounting hole gently, ensure the helical gears are normally engaged and steering pump flange face should be parallel with the fitting surface, loose-fit the pump with two M10 hexagon bolts and wave spring washers, and tighten the bolts diagonally with 16mm open end wrench (or double offset ring spanner) to 50~60Nm, make sure not to damage the sealing gasket in this process.
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