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Service Manual for WP6 Diesel Engine

31123

Inspection and Maintenance of Generator

(1)

Generator fault diagnosis flow

When a failure happens to the engine, firstly you should check whether it is generator failure.

Instrument: test lamp. Flow chart is shown in Fig. 3-61

Turn on the 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.

Connect one end of test lamp to

generator D+ terminal instead of E

terminal.

YES

Start the engine

YES

Is the test lamp on?

Generator is fine

Generator failure

YES

Circuit in generator D+

terminal is in failure

Fig. 3-61 Generator fault diagnosis flow chart

Содержание WP6

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

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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