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Service Manual for WP6 Diesel Engine

392

Disassembly, Inspection, Maintenance and Assembly of Engine Oil Pump ...
................................................................................................................... 90

393

Disassembly, Inspection, Maintenance and Assembly of Engine Oil Filter ....
................................................................................................................... 91

394

Disassembly, Inspection, Maintenance and Assembly of Engine Oil Cooler ..
................................................................................................................... 92

395

Disassembly, Inspection, Maintenance and Assembly of Main Oil Gallery
Pressure Limiting Valve ............................................................................... 93

396

Disassembly, Inspection, Maintenance and Assembly of Engine Oil Strainer
................................................................................................................... 94

310

Starting System ................................................................................................... 95

3101Disassembly, Inspection, Maintenance and Assembly of Starting System. 95

311

Engine Accessory System .................................................................................. 96

3111 Disassembly and Assembly of Engine Accessory System ......................... 96

3112 Disassembly, Inspection, Maintenance and Assembly of Generator ......... 97

3113 Disassembly, Inspection, Maintenance and Assembly of Air Compressor ...

.................................................................................................................... 103

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Summary of Contents for WP6

Page 1: ...Service Manual for WP6 Mechanical Pump Series Engine Service Manual for WP6 Diesel Engine...

Page 2: ......

Page 3: ...ine oil or diesel oil whose brand must complied with requirements specified in operation and maintenance manual moreover all oil must be filtered with specialized clean filter fuel must be subsided fo...

Page 4: ...cal parameters structural features operation and maintenance methods and overhaul tips of WP6 mechanical pump series diesel engine for users to refer to provided service technologies of diesel engine...

Page 5: ...l Oil Engine oil Coolant and Auxiliary Materials 10 211 Fuel Oil 10 212 Engine Oil 10 213 Lubrication of Tensioning Wheel 11 214 Antifreeze Additive in Engine Cooling System 11 215 Auxiliary Materials...

Page 6: ...on Maintenance and Assembly of Lifting Eyes 37 33 Engine Block Assembly 39 331 Disassembly Inspection Maintenance and Assembly of Engine Block Assembly 39 332 Disassembly Inspection Maintenance and As...

Page 7: ...ion Maintenance and Assembly of Intake Pipe 73 363 Disassembly Inspection Maintenance and Assembly of Exhaust Pipe 74 364 Disassembly Inspection Maintenance and Assembly of Turbocharger System 75 37 F...

Page 8: ...ion Maintenance and Assembly of Main Oil Gallery Pressure Limiting Valve 93 396 Disassembly Inspection Maintenance and Assembly of Engine Oil Strainer 94 310 Starting System 95 3101Disassembly Inspect...

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Page 11: ...Service Manual for WP6 Diesel Engine 1 1 Usage Instructions for Diesel Engine 11 External View of Diesel Engine Fig 1 1 WP6 mechanical pump series diesel engine View 1...

Page 12: ...Service Manual for WP6 Diesel Engine 2 Fig 1 2 WP6 mechanical pump series diesel engine View 2...

Page 13: ...3 WP6 mechanical pump series diesel engine View 3 12 Diesel Engine Model Composition and Significance WP6 G XXX E2 XX Variant code Emission standard Power code Use code Product series code Fig 1 4 Die...

Page 14: ...ocharged Displacement L 6 75 Cylinder diameter Stroke mm 105 130 Number of cylinders 6 Number of air valves for each cylinder 2 Compression ratio 18 1 Ignition order 1 5 3 6 2 4 Fuel injection equipme...

Page 15: ...elled Spray solvent into turbocharger intake and exhaust vent until all seal fuel there is expelled According to the service agreement with customer we are obliged to add specified engine oil to engin...

Page 16: ...st you apply lifting appliance as shown in left hand chart of Fig 1 5 and keep the center line of engine crankshaft horizontal during lifting It is inadvisable to lift the engine triangularly with onl...

Page 17: ...om scale and top scale on oil dipstick add engine oil through oil filling port if necessary 4 Check whether all accessories are reliably connected to the engine and eliminate abnormal phenomenon Check...

Page 18: ...fuel inlet temperature 40 45o C 6 Check the exhaust gas color to determine working quality of injector and load condition if the color is serious bad stop the engine for inspection NOTICE When the eng...

Page 19: ...stored in cold weather for long term be sure to take down the battery and put it in warm environment 6 Stop For shutting down the engine in cold weather you should firstly unload it and run it idly fo...

Page 20: ...gine Oil Diesel engine oil capacity 16L engine oil capacity is subjected to the marks on oil dipstick there might slight differences between different models Selection of engine oil To ensure safety a...

Page 21: ...to note that long acting antifreeze additive should be replaced periodically according to related requirements Calculation of antifreeze additive for reference Coolant amount 40L for an engine with r...

Page 22: ...e oiling agent Dark gray Play lubrication action before lubricating oil pressure is built up For example Apply on intake valve rod Table 2 2 Reference table for grease application of diesel engine Bra...

Page 23: ...ng board Fitting surface between engine oil filter seat and crankcase Water pump rear cover engine block front end face Flywheel connecting board flywheel housing Fitting surface between cylinder bloc...

Page 24: ...vel is between the bottom scale and top scale on oil dipstick Under no circumstances should the engine be started if the oil level is lower than the bottom scale or higher than the top scale Oil level...

Page 25: ...Leakages Check engine appearance for water leakage air leakage and oil leakage 225 Check Fan Visually check whether fan blades are damaged whether plastic fan is deformed whether rivets of iron fan ar...

Page 26: ...ine horizontal and put a container under the engine to recycle engine oil screw off oil drain plug 2 on the bottom of oil sump to drain all engine oil out and then screw on the plug Open the filler ca...

Page 27: ...ine started Fig 2 10 Engine oil filter Check and adjust intake and exhaust valve clearance Follow the steps below to check and adjust intake and exhaust valve clearance 1 Firstly make sure the engine...

Page 28: ...oo large or too small you can loosen locking nut 2 and then turn adjusting screw 3 to change the clearance Keep adjusting screw 3 still and tighten locking nut 2 and then measure the clearance again R...

Page 29: ...ace fuel filter element Follow the steps below to replace fuel filter element Remove the old fuel filter element if the water collector that installed on coarse filter can be reused please the take co...

Page 30: ...ced according to the regulations of manufacturer NOTICE By no means should an engine without air filter be running Otherwise infiltration of dust and impurities will lead to premature wear of engine F...

Page 31: ...on intake pipe end face and inject slushing oil into the pipe with pressure nozzle During the injecting you should rotate the crankshaft with hand to open air valve so that slushing oil can get to com...

Page 32: ...rld recognized danger sign In this manual this sign is used to emphasize the importance of following information Make sure you are well aware of the consequence that the danger can bring and know how...

Page 33: ...ine 312 Safety Signs Signs Wear protective gloves Information Wear protective ear covers Wear protective googles Wear protective hat Wear protective shoes Wear protective mask Wear protective suit No...

Page 34: ...process of disassembling 1 Avoid exposing to used engine oil long time repeatedly 2 Please wear protective suit and gloves if possible 3 Do not put oil stained rag in your pocket 4 Avoid dirtying you...

Page 35: ...use maintenance and repair accidents are caused by failing to comply with safety regulations and basic notes So you should be able to realize the danger ahead and take relevant preventive measures to...

Page 36: ...linder cover shield gasket Cylinder cover bolt Cylinder cover Injector Cylinder cover gasket Fig 3 1 Exploded view of cylinder cover assembly 3212 Steps to Disassemble Cylinder Cover Assembly 1 Remove...

Page 37: ...for details 9 Remove rocker assembly and pushrod refer to disassembly of valve mechanism for details 10 Remove lubricating pipe of cylinder cover 11 Remove cylinder cover assembly and take down the ga...

Page 38: ...Fig 3 2 Exploded view of cylinder cover shield 3222 Steps to Disassemble Cylinder Cover Shield 1 Screw off cylinder cover shield bolts orderly 2 Pull the shield vertically up to take it and its gaske...

Page 39: ...rocker and valve contacting area between rocker and pushrod and the area between them 3 Assemble cylinder cover shield gaskets keep graphitic end upwards 4 Place cylinder cover shield 5 Adjust the ga...

Page 40: ...ust valve Intake valve Cylinder cover gasket Valve rod seal cartridge Fig 3 3 Exploded view of cylinder cover 3232 Steps to Disassemble Cylinder Cover 1 Remove cylinder cover shield refer to disassemb...

Page 41: ...le refer to disassembly of valve mechanism for details 8 Remove valve rod seal carriage 3233 Inspection and Maintenance of Cylinder Cover Check the cylinder cover for water leakage oil leakage air lea...

Page 42: ...ide micrometer as shown in Fig 3 5 Outer diameter of valve rod can be measured with an outside micrometer Both allowed ranges for clearance between intake valve rod and its guide pipe exhaust valve ro...

Page 43: ...Service Manual for WP6 Diesel Engine 33 120 4 and 120 4 again 6 Refer to Fig 3 6 for pre tightening and tightening order Fig 3 6 cylinder cover bolts tightening order...

Page 44: ...er Outlet Pipe 3241 Exploded View of Cylinder Cover Thermostat Pipe joint fitting Cooling water pipe module outlet Pipe adapter hose Water pump belt pulley water pump assembly Fan terminal pad Water p...

Page 45: ...d be analyzed and corroded pipe should be replaced WP6 engine water outlet pipe is of integral type welded structure the whole pipe should be replaced even if only one pipe joint is damaged or leaking...

Page 46: ...n all clamps 2 Disconnect oil connecting hose 3 Remove fixing bolts of oil gas separator 4 Remove oil gas separator and its support take the spring out 5 Disconnect the hose that used to connect oil g...

Page 47: ...joint if so 3254 Steps to Assemble Oil Gas Separator Assembling steps are contrary to disassembling ones 326 Disassembly Inspection Maintenance and Assembly of Lifting Eyes 3261 Exploded View of Lift...

Page 48: ...arts that used to cover lifting eye screw screw off the screw 3263 Inspection and Maintenance of Lifting Eye Check whether there is crack on lifting eye screw and the threaded hole replace the cracked...

Page 49: ...r WP6 Diesel Engine 39 33 Engine Block Assembly 331 Disassembly Inspection Maintenance and Assembly of Engine Block Assembly 3311 Exploded View of Engine Block Assembly Fig 3 10 Exploded view of engin...

Page 50: ...ort 8 Seal gasket 22 Camshaft sleeve 36 Gasket 9 Hexagon head plug 23 Camshaft sleeve 37 2 type hexagon nut 10 Sleeve 24 Camshaft sleeve 38 Lifting eye screw 11 Bowl shape plug 25 Cylindrical pin 39 S...

Page 51: ...is no suitable four axis tightening machine then tighten the bolts with a torque wrench according to the following procedures a Pre tighten each bolt to 30Nm b Tighten for 120 4 c 120 4 again Refer t...

Page 52: ...s on the sleeve and engine block and then assemble the sleeve knock it to the right place evenly with nylon rod Key point 4 Disassembling Use dedicated tool to disassemble the camshaft sleeve and try...

Page 53: ...Steps to Disassemble Engine Block Module 1 Remove main bearing bolts key pint 1 2 Remove main bearing caps key pint 2 3323 Inspection and Maintenance of Engine Block Module Key point 1 Inspection Chec...

Page 54: ...tly pre tighten each bolt to 70Nm and tighten the bolts for further 90 4 Fig 3 13 Main bearing bolts tightening order Key point 2 Assembling Install the thrust bearing cap on rear end of engine block...

Page 55: ...ate Hexagon bolt Hexagon bolt Hexagon bolt Hexagon bolt Fig 3 14 Exploded view of engine front cover 3332 Steps to Disassemble Engine Front Cover 1 Remove breather 2 Remove cover plate 3 Remove the pl...

Page 56: ...enly distributed and no discontinuity Fig 3 16 Sealant application of engine front cover 3 Place engine front cover and align pins and pin holes knock the cover edge gently with nylon rod so that the...

Page 57: ...d 10 in Fig 3 18 are for installation of generator support the bolt specification should be M8 90 Specification of bolt 11 is M8 25 specification of bolt 18 is M8 35 specification of bolt 16 and 17 is...

Page 58: ...Remove fixing bolts of flywheel housing key point 1 2 Remove fixing bolts of monitoring window cap on flywheel housing take down the cap 3 Remove flywheel housing 3343 Inspection and Maintenance of Fl...

Page 59: ...e M12 bolts according to the marked order 1 2 3 4 5 6 tighten torque for M12 bolts is 140 145Nm Fig 3 20 Tightening order of flywheel housing bolts NOTICE For the strengthening bolts listed above the...

Page 60: ...eps to Disassemble Oil Sump 1 Turn over the engine to keep oil sump upward key point 1 2 Remove oil sump fastening bolts key point 2 3 Take down oil sump and sealing gaskets 4 Remove the combination g...

Page 61: ...careful and avoid crashing the fitting surface 3 Place bolts and gaskets and tighten the bolts with pneumatic impact wrench to 20 355Nm 3354 Steps to Assemble Oil Sump Assembling steps are contrary to...

Page 62: ...and pressing plate 2 Place the pressing plate in nozzle end face groove 3 Bolts tightening Set TOKU pneumatic impact wrench to gear II Key point 2 Inspection Check O shape seal ring for damage make su...

Page 63: ...ed in pairs and the side with oil groove should be outward during assembling Put the anti misloading lug in corresponding groove of thrust bearing cap 3374 Steps to Assemble Thrust Plates Assembling s...

Page 64: ...s should be checked before assembling make sure there is no damage Check whether rear oil seal cover is clean and whether its finished surface is free of obvious scratch Assembling Apply sealant on th...

Page 65: ...eck tightening torque of connecting rod bolts Tilt and lay the engine on its side rotate the flywheel until the to be removed piston is in BDC remove connecting rod bolts and cap Rotate the flywheel u...

Page 66: ...ankshaft Engine block module Fig 3 26 Schematic diagram of piston rod assembly Connecting rod body Piston pin Piston pin circlip Elastic locating pin Connecting rod cap Connecting rod bolt First compr...

Page 67: ...r throat fillet and piston pin boss Check piston skirt and piston head for cylinder scoring phenomenon Check wear condition of piston pin hole 2 Check wear condition of piston ring outer edge Check we...

Page 68: ...compression ring and opening direction of oil ring should be 120 to both that of first compression ring and second compression ring also should be perpendicular to piston pin center line As shown in F...

Page 69: ...lace the crankshaft on bracket for long time storage the crankshaft should be placed vertical 3 Classify the removed parts according to the requirements 3433 Inspection and Maintenance of Crankshaft 1...

Page 70: ...ock properly 6 Lift up crankshaft and clean up oil holes with compressed air wipe out main journal and connecting rod journal with a towel and then drop the crankshaft into cylinder body slowly preven...

Page 71: ...ance of Flywheel and Ring Gear 1 Check whether there is failure like thread damage on flywheel bolts 2 Check flywheel surface for conquassation 3 Check whether flywheel ring gear is damaged 3444 Steps...

Page 72: ...take down pulley and damper orderly 3453 Inspection and Maintenance of Torque Vibration Damper Crankshaft Pulley and Hub 1 Check crankshaft pulley for bump damage and distortion 2 Check whether cranks...

Page 73: ...rresponded with holes on engine block and crankcase 3463 Inspection and Maintenance of Crankshaft Bearing Shell 1 Clean the bearing shells and check their wear condition 2 Check and ensure there is no...

Page 74: ...ing gear Hexagon socket cap screw Flange Sector plate Hexagon flange bearing surface toothed bolt Hexagon flange bearing surface toothed bolt Fig 3 34 Exploded view of valve mechanism 3512 Steps to Di...

Page 75: ...whether there is wear trace on cam face that contacting tappet check main journal for seizure and abrasion 2 Check whether timing gear and hexagon bolts are distorted check whether there is misengage...

Page 76: ...e the crankshaft until 0 tick on timing gear is closest to camshaft firstly install fuel injection pump driven gear on the camshaft and then install camshaft timing gear make sure 0 tick of timing gea...

Page 77: ...and check the change of valve clearance 3 If the rocker is not flexible or too big valve clearance loosen hexagon screw and then take down rocker seat circlip for shaft butterfly spring washer rocker...

Page 78: ...plate observe and make sure 0 tick of crankshaft timing gear is engaged with 0 tick of camshaft gear Then adjust valve clearance of No 1 2 3 6 7 10 rocker count from the front end intake valve adjust...

Page 79: ...d rocker shafts directly take out pushrod place them orderly 2 After removing camshaft directly take out valve tappet place them orderly 3543 Inspection and Maintenance of Valve Tappet and Pushrod 1 C...

Page 80: ...ate freely in the hole Install camshaft refer to assembly of camshaft for details 4 Loose fit rocker seat on cylinder cover check whether pushrod is clean and whether its welding area is intact 5 Appl...

Page 81: ...e with severe wear or carbon deposit or sintering should be replaced 1 Apply molybdenum disulfide cream on intake and exhaust valve rod and then install intake and exhaust valve into cylinder cover en...

Page 82: ...d Exhaust System 1 Loosen air filter fixing bolts and hose clamps take down air filter and hoses 2 Loosen clamps of air circuit connecting hose take down turbocharger compressor outlet hose 3 Remove f...

Page 83: ...xploded View of Intake Pipe Intake pipe Intake pipe gasket Fig 3 40 Exploded view of intake pipe 3622 Steps to Disassemble Intake Pipe 1 Remove intake pipe fixing bolts take down the pipe and gaskets...

Page 84: ...Exhaust Pipe 1 Check whether there is crack on exhaust pipe whether the flange is deformed replace the pipe if necessary 2 Check whether there is air leakage on exhaust pipe flange replace the gasket...

Page 85: ...r finger it is normal if the impeller can rotate for more than one round if the impeller stopped soon then it means the bearing is abnormally worn or there is clash or jamming problem between rotating...

Page 86: ...8mm if exceeds this range then check the bearing and eliminate the fault NOTICE Ensure the turbocharger is cold when performing the measurement Fig 3 44 Compressor impeller radial clearance measuring...

Page 87: ...l return pipe fixing bolts to 22 29Nm 4 Place a gasket on exhaust adapter flange and fix them on turbocharger assembly loose fit 2 type all metal hexagon lock nuts and tighten them 5 Pour proper amoun...

Page 88: ...xploded view of fuel system 3712 Steps to Disassemble Fuel System 1 Disconnect all external pipes and wiring harnesses of fuel system 2 Remove low pressure fuel pipe module refer to disassembly of low...

Page 89: ...ure fuel pipe Injection pump Coarse fuel filter Coarse fuel filter support Smoke limiter Low pressure fuel pipe Injection pump gear Engine front cover plate Injection pump lubricating pipe Fig 3 46 Ex...

Page 90: ...leakage if so replace the pipe or bolt gaskets 3724 Steps to Assemble Fuel Injection Pump Assembling steps are contrary to disassembling ones But note that when assembling fuel injection pump gear the...

Page 91: ...s that connecting each injector and injector oil return pipe 2 Remove fastening bolts of injector pressing plate take down the plate 3 Remove the injector with dedicated tool 3743 Inspection and Maint...

Page 92: ...f the air bleed screw on filter seat operate the hand pump on injection pump to bleed the filter 3754 Steps to Assemble Fuel Filters Assembling steps are contrary to disassembling ones But note that w...

Page 93: ...l pipe appearance for crack and oil leakage if so replace the pipe or feedback the problem to the manufacturer 2 Check the two joints of low pressure fuel pipe for oil leakage replace hollow bolt seal...

Page 94: ...ork at proper temperature Forced circulation cooling offers the best guarantee to keep the engine in normal operating temperature mainly consists of water pump fan expansion water tank water tank and...

Page 95: ...emove fan and connecting plate refer to disassembly of fan for details 2 Remove the tensioning wheel 3 Remove the belt 4 Remove generator generator support crankshaft pulley and damper 5 Remove thermo...

Page 96: ...of fan 3822 Steps to Disassemble Fan As shown in Fig 3 49 1 Remove the screws and gaskets that connecting fan and connecting plate take down the fan 2 Remove the screws and gaskets that connecting the...

Page 97: ...water pump pulley 2 Remove water pump inlet pipe thermostat connecting hose and clamps 3 Remove the hexagon bolts spring washers take down the pump 4 Remove water pump gasket and middle cushion block...

Page 98: ...h connecting cooling water pipe and thermostat 2 Remove clamp of lower rubber hose which connecting water pump and thermostat 3 Remove thermostat 4 Remove the two coolant rubber hoses 3843 Inspection...

Page 99: ...ssembly Fig 3 52 Exploded view of lubricating system 3912 Steps to Disassemble Lubricating System 1 Remove oil sump refer to disassembly of oil sump for details 2 Remove crankshaft pulley damper and t...

Page 100: ...shown in Fig 3 53 3923 Inspection and Maintenance of Engine Oil Pump 1 Check the engine oil pump for crack damage check whether its inner cavity is smooth replace it if necessary 2 Check whether engi...

Page 101: ...mble Engine Oil Filter Remove the filter with dedicated tool as shown in Fig 3 54 3933 Inspection and Maintenance of Engine Oil Filter Check the engine oil filter assembly for damage replace it if nec...

Page 102: ...and clamp that connected to engine oil cooler water return pipe disconnect engine oil cooler water inlet pipe and take down the cooler as shown in Fig 3 55 3943 Inspection and Maintenance of Engine Oi...

Page 103: ...lery Pressure Limiting Valve Screw off main oil gallery pressure limiting valve as shown in Fig 3 56 3953 Inspection and Maintenance of Main Oil Gallery Pressure Limiting Valve 1 Check service conditi...

Page 104: ...f the 1 type hexagon nuts and two self locking nuts on the bended plate take down the oil strainer as shown in Fig 3 57 3963 Inspection and Maintenance of Engine Oil Strainer Check the strainer for cr...

Page 105: ...xagon bolt 4 Starter motor Fig 3 58 Exploded view of starting system 31012 Steps to Disassemble Starting System 1 Remove hexagon bolt 3 and spring washer 2 2 Hold the starter motor firmly and pull it...

Page 106: ...or Hexagon bolt Gasket Generator Generator support Air compressor support Belt Gasket Sleeve Hexagon socket cap screw Fig 3 59 Exploded view of engine accessory system 31112 Steps to Disassemble Engin...

Page 107: ...olt pad Generator Generator support Gasket Sleeve Hexagon socket cap screw Fig 3 60 Exploded view of generator 31122 Steps to Disassemble Generator 1 Remove generator draw in nut and connecting bolt a...

Page 108: ...machine power switch and connect test lamp to generator B terminal and E negative terminal Is the test lamp on It means there is no voltage in B terminal the wire to battery positive is in failure NO...

Page 109: ...3V b Check whether generator output end B to ground voltage is about 24V battery voltage a If voltage of generator indicator end is very small then it means rated power of indicator lamp is small or t...

Page 110: ...ioning situation of generator belt and relevant pulley belts d Check generator pulley e Check whether electric wires are reasonably connected measure the voltage of generator and battery f Check wheth...

Page 111: ...tage reading on voltmeter a Check whether voltmeter is damaged b Check whether wires connectors and bolts in charging system are loose and producing too much heat check whether there is short circuit...

Page 112: ...ectors in charging circuit c Clean the dirt or replace the brush and brush spring d Replace the regulator e Generator produces abnormal sound Fault 5 Generator produces abnormal sound Phenomenon Fault...

Page 113: ...32 Steps to Disassemble Air Compressor 1 Remove air compressor belt 2 Remove the four bolts and gaskets that used to fix air compressor on support 3 Take down air compressor and remove air compressor...

Page 114: ...g to air leakage 5 Severe wear of air compressor cylinder sleeve piston and piston ring that leading to air leakage Troubleshooting 1 Observe air pressure gauge if it indicates insufficient air pressu...

Page 115: ...sufficient cooling of air compressor 5 Too much unclean matter in gasholder 6 Long running of air compressor 7 High pressure in engine crankcase 8 High engine oil pressure 9 Deteriorated engine oil 10...

Page 116: ...ine is running If refrigerant flow rate is small check whether cooling pipe and accessories are rusted or twisted 5 Check and ensure water temperature is under 93o C check the air valve on gasholder a...

Page 117: ...thumb it is suitable if the belt is depressed about 10mm 3 Check engine oil pressure air compressor oil inlet port check whether engine oil pipe is damaged or blocked adjust clean or replace the inval...

Page 118: ...s too tight which results in wear of main bearing shell 5 Casting or manufacturing deficiency Troubleshooting 1 Oil seal Check whether oil seal is fractured whether its inner lip is cracked or turnup...

Page 119: ...air brake system which caused the compressor fail to take a break 3 Insufficient oil supply to the running parts or scuffing Troubleshooting 1 Check relief valve module when unloading intake clean th...

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